Aspen Capital Cost Estimator V7.3.1 User Guide

Aspen Capital Cost Estimator V7.3.1 User Guide Version Number: V7.3.1 March 2011 Copyright (c) 2001-2011 by Aspen Technology, Inc. All rights reserved. Aspen Capital Cost Estimator, the aspen leaf logo and Plantelligence and Enterprise Optimization are trademarks or registered trademarks of Aspen Technology, Inc., Burlington, MA. All other brand and product names are trademarks or registered trademarks of their respective companies. This document is intended as a guide to using AspenTech's software. This documentation contains AspenTech proprietary and confidential information and may not be disclosed, used, or copied without the prior consent of AspenTech or as set forth in the applicable license agreement. Users are solely responsible for the proper use of the software and the application of the results obtained. Although AspenTech has tested the software and reviewed the documentation, the sole warranty for the software may be found in the applicable license agreement between AspenTech and the user. ASPENTECH MAKES NO WARRANTY OR REPRESENTATION, EITHER EXPRESSED OR IMPLIED, WITH RESPECT TO THIS DOCUMENTATION, ITS QUALITY, PERFORMANCE, MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE. Aspen Technology, Inc. 200 Wheeler Road Burlington, MA 01803-5501 USA Phone: 781 221-6400 Toll Free: 888 996-7100 URL: http://www.aspentech.com Contents Contents ............................................................................................3 Introducing Aspen Capital Cost Estimator .......................................15 Main Features ............................................................................ 15 Detailed EPC Estimates....................................................... 15 CPM Schedules .................................................................. 16 Information Tracking .......................................................... 16 Aspen Capital Cost Estimator Project Workflow .............................. 16 The Guide ................................................................................. 17 Organization ..................................................................... 17 Related Documentation ............................................................... 18 Installation Notes............................................................... 18 Known Issues and Workarounds .......................................... 18 New Features in Aspen Economic Evaluation V7.3 .................. 18 Icarus Reference................................................................ 18 Piping and Instrumentation Drawings ................................... 18 Technical Support ...................................................................... 18 1 Getting Started .............................................................................21 Starting Aspen Capital Cost Estimator........................................... 21 Starting a Project Scenario.................................................. 23 Creating a New Project Scenario .......................................... 23 Importing a Project Scenario ............................................... 29 Opening an Existing Project Scenario ............................................ 31 Palette Shortcut................................................................. 32 Working with Templates.............................................................. 32 Adding a Template. ............................................................ 32 Creating a Project by Importing a Template .......................... 33 Understanding the Icarus Interface .............................................. 33 Project Explorer ................................................................. 34 Main Window..................................................................... 36 Palette.............................................................................. 40 Contents 3 Customizing the Icarus Interface ......................................... 46 Aspen Capital Cost Estimator Toolbar ................................... 48 Run Menu ......................................................................... 50 View Menu ........................................................................ 51 Tools Menu ....................................................................... 52 Window Menu.................................................................... 53 Help Menu ........................................................................ 53 Working with Project Scenarios .................................................... 53 Saving Project Scenarios..................................................... 53 Deleting Project Scenarios .................................................. 54 Salvaging Project Scenarios ................................................ 55 Unlocking Project Scenarios ................................................ 56 Copying Project Directories.......................................................... 57 Preferences ............................................................................... 58 General ............................................................................ 58 Forms............................................................................... 60 Spreadsheet Views............................................................. 60 Backup ............................................................................. 61 Process............................................................................. 62 Locations .......................................................................... 63 Logging ............................................................................ 64 Unit Costs ......................................................................... 64 Logging ............................................................................ 68 Schedule........................................................................... 68 Unzipping Files After Upgrading to Newer Versions of Aspen Capital Cost Estimator ........................................................................... 68 2 Defining the Project Basis ............................................................71 Project Properties....................................................................... 72 General Project Data .................................................................. 73 Basis for Capital Costs ................................................................ 75 Input Units of Measure Customization .................................. 75 Output (Reports) Units of Measure Customization .................. 79 Design Basis ..................................................................... 80 Contingency and Miscellaneous Project Costs ........................ 96 Escalation ......................................................................... 97 Engineering Workforce ....................................................... 99 Construction Workforce .................................................... 107 Code of Accounts ............................................................. 115 Overriding Code of Accounts at the Component Level ........... 120 Choosing between the Icarus Code of Accounts and User Code of Accounts at the Component Level ...................................... 122 Indexing ......................................................................... 122 Equipment Rental ............................................................ 129 4 Contents Systems ......................................................................... 132 Contracts ........................................................................ 140 Importing old Standard basis files .............................................. 151 Merging Projects ...................................................................... 152 Merging Areas Into Projects....................................................... 152 Customer External Files ............................................................ 153 Project Execution Schedule Settings ........................................... 154 Adjusting Schedule and Barcharts ...................................... 155 Setting Delivery Times for Equipment Classes ..................... 156 Scheduling Individual Project Components .......................... 157 Adding Bar Chart Items .................................................... 158 IPS Project Schedule Settings .................................................... 159 Using Aspen Icarus Project Scheduler (IPS) in the Aspen Capital Cost Estimator Environment .............................................. 160 Schedule Appearance Adjustments..................................... 161 Schedule Adjustments by Duration..................................... 167 Schedule Adjustments by Activity and Logic ........................ 172 Primavera Information...................................................... 183 Process Design ........................................................................ 184 Simulator Type and Simulator File Name ............................ 185 Simulator Units of Measure Mapping Specs ......................... 185 Project Component Map Specifications................................ 188 Default Simulator Mapping Specs....................................... 190 Design Criteria ................................................................ 195 Utility Specifications ......................................................... 210 Investment Analysis ................................................................. 214 Investment Parameters .................................................... 214 Operating Unit Costs ........................................................ 219 Raw Material Specifications ............................................... 221 Product Specifications....................................................... 224 Developing Streams ................................................................. 228 Viewing or Modifying an Existing Stream............................. 228 Mixture Specs Dialog Box.................................................. 231 Estimation of Utility Usage and Resulting Costs in Aspen Capital Cost Estimator................................................................. 233 Stream Connectivity......................................................... 234 Creating A New Stream .................................................... 235 Deleting a Stream ............................................................ 238 Specification Libraries ............................................................... 239 Customizing Specification Libraries..................................... 240 Customizing Steel Costs Using an External File .................... 245 Selecting Specification File for Use in a Project .................... 250 Changing File Directory Location ........................................ 251 Instrument Field Hook-Up Customization..................................... 251 Contents 5 Using the Plot Plan Layout Tool .................................................. 256 Workflow for Plot Plan Layout Tool: .................................... 257 3 Loading and Mapping Simulation Data........................................261 Overview................................................................................. 261 Preparing Simulation Reports..................................................... 262 AspenPlus Report Generation ............................................ 262 AspenPlus – Aspen Process Economic Analyzer Simulator link 266 ChemCAD Report Generation............................................. 267 HYSIM Report Generation ................................................. 269 HYSYS Report Generation ................................................. 271 SimSci’s PRO/II with PROVISION Report Generation............. 274 Loading Simulation Data ........................................................... 275 Viewing Data Derived from Simulator ................................. 278 Working with Block Flow Diagrams ............................................. 279 Displaying the Block Flow Diagram..................................... 279 The Drag & Find Feature ................................................... 280 Accessing Commands in the Block Flow Diagram ................. 281 Zooming ......................................................................... 282 BlockFlow Diagram View Menu........................................... 283 Mapping Simulator Items to Icarus Project Components................ 285 Component Status ........................................................... 291 Deleting Mappings ........................................................... 292 Tower Configurations ................................................................ 292 Sizing Selection ....................................................................... 303 Project Sizing Selection............................................................. 303 Specifying Additional Components .............................................. 305 Working with Process Flow Diagrams .......................................... 305 Editing the Layout............................................................ 306 Process Flow Diagram View Menu ...................................... 307 Setting Grid Properties ..................................................... 309 Editing Connectivity ......................................................... 310 Adding a Stream.............................................................. 312 Drawing a Disconnected Stream ........................................ 315 Working with Streams ...................................................... 315 4 Defining Report Groups, Areas, and Project Components ...........317 Adding a Report Group.............................................................. 318 Adding an Area ........................................................................ 319 Copying a Report Area over another Report Area ......................... 320 Defining Area Specifications ...................................................... 320 Method 1: Defining area specifications using Project View ..... 320 Method 2: Defining area specifications using Spreadsheet View324 6 Contents Adding and Defining Pipeline Areas............................................. 325 Adding a Project Component...................................................... 326 Method 1: Dragging a Component from the Palette .............. 326 Method 2: Using the Pop-up Menu ..................................... 328 Entering Component Specifications............................................. 329 Defining Installation Bulks ......................................................... 332 Mat’l/Man-hours Adjustments ............................................ 333 Mat’l/Man-hours Additions................................................. 336 Pipe – General Specs........................................................ 336 Pipe – Item Details........................................................... 337 Duct............................................................................... 340 Civil ............................................................................... 340 Steel .............................................................................. 340 Instrumentation............................................................... 340 Electrical......................................................................... 344 Insulation ....................................................................... 344 Paint .............................................................................. 344 Importing Areas and Components .............................................. 345 Importing an Entire Scenario ..................................................... 346 Copying Components ................................................................ 347 Cut and Paste.................................................................. 348 Drag and Drop................................................................. 348 Modifying Components.............................................................. 348 Copying Areas ......................................................................... 349 Deleting Components................................................................ 350 Re-numbering Components ............................................... 350 Deleting Areas ......................................................................... 351 Re-numbering Areas ........................................................ 351 Using the Custom Model Tool..................................................... 351 Creating a Template ......................................................... 356 Running the Custom Model Tool at Project-Level for Batch Update ........................................................................... 357 5 Sizing Project Components .........................................................359 Overview................................................................................. 359 Sizing for Project Components Mapped from Simulator Items 359 Interactive Sizing Expert................................................... 360 Sizing for Project Components Not Mapped from Simulator Items361 Resizing Project Components............................................. 361 Creating Streams to Connect to Equipment Items ........................ 362 Using the Interactive Sizing Form............................................... 366 Utility Resources .............................................................. 368 Global Sizing Selection.............................................................. 372 Sizing Areas ............................................................................ 375 Contents 7 Sizing Requirements, Calculations, and Defaults .......................... 377 Air Coolers ...................................................................... 377 Agitated Tanks ................................................................ 379 Compressors ................................................................... 380 Crushers......................................................................... 382 Crystallizers .................................................................... 382 Dryers ............................................................................ 383 Dust Collectors ................................................................ 384 Filters............................................................................. 385 Heat Exchangers.............................................................. 385 Pumps ............................................................................ 389 Screens .......................................................................... 391 Towers ........................................................................... 392 Vessels ........................................................................... 407 6 Piping and Instrumentation Models ............................................415 Overview................................................................................. 415 Using the P&ID Editor ............................................................... 415 Features of P&IDs ............................................................ 415 P&ID Modes .................................................................... 416 P&ID Layout and Structure................................................ 416 The Aspen Capital Cost Estimator PID Layout: Radpfs Interface419 Working with Ports........................................................... 422 Editing P&IDs .................................................................. 424 Adding Instrumentation Loops ........................................... 427 Efficient PID Creation ....................................................... 433 Cosmetic Tips .................................................................. 434 Custom Equipment Symbols .............................................. 437 Modifying a system equipment symbol ............................... 438 Importing an equipment symbol ........................................ 439 Creating an equipment symbol from scratch........................ 440 Line sizing Tutorial ........................................................... 440 Using Custom P&ID’s in Aspen Capital Cost Estimator........... 445 Working with Non-Graphic P&ID Data ......................................... 450 Saving Component Information as Non-Graphical P&ID ........ 450 Creating Non-Graphical P&ID Libraries Outside a Project....... 451 Importing External P&ID Data.................................................... 451 Interconnecting Volumetric P&ID Lines........................................ 457 Open a Aspen Capital Cost Estimator project ....................... 457 Run Interconnect Piping Lines ........................................... 457 Connecting Piping Lines .................................................... 459 Disconnecting Piping Lines ................................................ 460 Renaming a Line Tag........................................................ 460 Saving All Connections and (optionally) Updating the Project 461 8 Contents Getting the Connected Line List Report ............................... 461 Mapping Streams to Piping Lines ................................................ 463 Importing 3D Piping and Structure Data Using the SmartPlant 3D– Aspen Icarus Interface .............................................................. 463 Overview ........................................................................ 463 Step 1: Exporting Data from SmartPlant 3D ........................ 464 Step 2: Importing the data to Aspen Icarus......................... 466 Step 3: Loading the Data .................................................. 472 Adding or Updating Codes to this Interface ......................... 472 Known Issues .................................................................. 474 7 Developing and Using Cost Libraries...........................................475 Overview................................................................................. 475 Equipment Model Library (EML) ......................................... 475 Unit Cost Library (UCL)..................................................... 476 Developing and Using an Equipment Model Library (EML) .............. 476 Creating an EML .............................................................. 476 Adding an Item to an EML ................................................. 478 Adding an EML Item as a Project Component....................... 480 Developing and Using a Unit Cost Library (UCL) ........................... 483 Creating a Unit Cost Library .............................................. 484 Adding an Item to a UCL................................................... 485 Adding a UCL Item to a Project.......................................... 488 Creating an Assembly of UCL Items.................................... 490 Working with Cost Libraries ....................................................... 494 Copying a Library Item ..................................................... 494 Deleting a Library Item..................................................... 494 Escalating Library Costs.................................................... 494 Importing a Cost Library ................................................... 495 Duplicating a Cost Library ................................................. 496 Deleting a Cost Library ..................................................... 497 8 Changing Plant Capacity and Location ........................................499 Changing Plant Capacity............................................................ 499 Analyzer Scale-Up Module (ASM) ............................................... 501 How ASM Works .............................................................. 501 Scale-Up Rule Set ............................................................ 502 Scale-Up for Configuration Analysis .................................... 504 Analyzer Relocation Module (ARM) ............................................. 504 Relocation Terminology .................................................... 504 Workflow ........................................................................ 505 How the Analyzer Plant Relocation Module (ARM) Works ....... 506 Relocating the Project....................................................... 509 Contents 9 ARM Knowledge Base ....................................................... 509 9 Aspen Utility Modules .................................................................521 Introduction ............................................................................ 521 Analyzer Utility Modules (AUM) – Design and Scope Generators for Utility Systems ........................................................... 522 AUM_CW: Cooling Water Utility Selection, Sizing, and Design Module ........................................................................... 522 AUM_Air: Instrument and Plant Air Utility Selection, Sizing, and Design Module ................................................................. 523 Analyzer Utility Module (AUM) Cooling Water (AUM_Water) ........... 524 Introduction to Analyzer Utility Module (AUM) Cooling Water . 524 1. Overview ................................................................... 526 2. Working with the Cooling Water Model ........................... 528 3. Working with the Cooling Water Model Worksheets.......... 535 4. Basis for the Cooling Water Design Model....................... 545 Notes to Analyzer Utility Model (AUM) Users: ...................... 558 AUM_Air.................................................................................. 558 Utility Design and Scope Generator for Instrument and Plant Air558 Overview................................................................................. 558 Project areas and their project components......................... 559 Benefits:......................................................................... 559 How AUM_Air Works......................................................... 560 General AUM_Air Workflow ........................................................ 560 Using AUM_Air ......................................................................... 561 Accessing AUM_Air........................................................... 561 The Initial Design............................................................. 563 Modifying Air – Instrument, Plant Data ............................... 565 Guide for the Air Utility Model (AUM) .......................................... 568 SPECS Organization Chart................................................. 568 About this SPECS Book ..................................................... 568 About an Air Plant Unit ..................................................... 570 About Distribution Piping for an APU................................... 570 Schematic....................................................................... 571 Configuration of Air Utility Project Components ............................ 572 Project Components ......................................................... 572 An “Air Plant Unit” - APU................................................... 573 Schematic of an Air Plant Unit ........................................... 574 General Layout ................................................................ 575 Multiple Air Plant Units for Multiple Areas ............................ 575 Compressor Redundancy: Multiple, Stand-by, Start-up ......... 576 Design Considerations .............................................................. 576 Units of Measure.............................................................. 576 Air Utility Area ................................................................. 577 10 Contents Air Utility Project Components ........................................... 577 Instrument Air (IA) Requirements: Air Flow Rate ................. 578 Plant Air (PA) Requirements: Air Flow Rate ......................... 578 Compressor Model Selection Method .................................. 579 Interactive Specs ..................................................................... 582 User Preferences.............................................................. 583 Equipment Redundancy .................................................... 583 Equipment Configurations ................................................. 584 Basis for Design: Preferences - 1 ...................................... 584 Configuration Layout Method and Distribution...................... 587 Example layout – group of areas served by APU “A” ............. 588 Circuit Preferences: Configuration of APUs ......................... 588 Sample Layouts: One APU................................................ 589 Sample Layouts: Multiple APUs ......................................... 589 Design Methods ....................................................................... 589 Basis for Sizing Air Distribution Piping ................................ 590 Sample AUM_Air Worksheets ..................................................... 591 List of AUM_Air Worksheets............................................... 592 Welcome Worksheet......................................................... 592 Control Center Worksheet ................................................. 593 Guide Worksheet ............................................................. 593 Status Worksheet ............................................................ 598 Preferences Worksheet ..................................................... 600 Configuration Part 1: Assignment of Plant Air to Areas Not Requiring Instrument Air .................................................. 602 Configuration Part 2: Assignment of Areas to an APU ........... 602 Report – Equipment Component Stats ................................ 603 Report – Pipe Stats .......................................................... 605 10 Evaluating the Project ..............................................................607 Running a Project Evaluation ..................................................... 607 Reviewing Results in Icarus Editor .............................................. 609 Accessing........................................................................ 609 Printing a Single Section ................................................... 610 Icarus Editor Toolbar ........................................................ 610 Report Sections ............................................................... 611 Project Schedule .............................................................. 614 Reviewing Results in Aspen Icarus Reporter................................. 619 Accessing Aspen Icarus Reporter ....................................... 619 Aspen Icarus Reporter Menu Bar............................................. 623 Which Report Mode?......................................................... 624 Standard Reports............................................................. 624 HTML Reports.................................................................. 635 Management Reports ....................................................... 637 Contents 11 Excel Reports .................................................................. 640 Update on Demand Reports............................................... 645 Data Trending ................................................................. 645 Importing Data into Aspen Icarus Reporter ......................... 649 Creating a User Database ................................................. 650 Splitting Very Large CCP Reports ....................................... 652 Reviewing Investment Analysis .................................................. 653 Viewing Investment Analysis ............................................. 653 Equipment Summary........................................................ 654 Project Summary ............................................................. 655 Cashflow......................................................................... 662 Executive Summary ......................................................... 670 Using the Reporting Assistant ............................................ 674 Item Evaluation ....................................................................... 678 11 Introducing IPS ........................................................................683 12 Getting Started With IPS ..........................................................685 Installing Icarus Project Scheduler (IPS) ..................................... 685 Installation Steps and Sequence ........................................ 685 System Requirements for the Integration............................ 693 Primavera Enterprise Client and Server............................... 693 Starting Icarus Project Scheduler ............................................... 694 Starting a Project Scenario ........................................................ 695 Creating a New Project Scenario ........................................ 695 Opening an Existing Project Scenario .......................................... 697 Understanding the Icarus Interface ............................................ 704 13 IPS Project Schedule Settings ..................................................705 IPS Project Schedule Settings .................................................... 705 Schedule Appearance Adjustments..................................... 706 Schedule Adjustments by Duration..................................... 711 Schedule Adjustments by Activity and Logic ........................ 716 Primavera Information...................................................... 727 IPS Appendix A: Engineering and Procurement Activity Numbers .729 Numbering Convention ............................................................. 729 Appendix B: Site Development and Construction Activity Numbers771 Numbering Conventions ............................................................ 771 List of Activity Numbers ............................................................ 773 12 Contents Appendix C: Equipment Class Definitions ......................................779 Appendix D: Equipment Codes .......................................................781 Appendix E: Tutorial ......................................................................785 Index.............................................................................................791 Contents 13 14 Contents Introducing Aspen Capital Cost Estimator Aspen Capital Cost Estimator, formerly known as Aspen Kbase, is a fully integrated, design, estimating, and scheduling system designed to help you evaluate the capital cost of process plants worldwide. Main Features Detailed EPC Estimates Aspen Capital Cost Estimator uses the equipment models contained in the Icarus Evaluation Engine (IEE) – a knowledge base of design, cost, and scheduling data, methods, and models – to generate preliminary equipment designs and simulate vendor-costing procedures to develop detailed EngineeringProcurement-Construction (EPC) estimates. Volumetric models generate a costed, quantity takeoff for the bulk materials without using factors or user input. The volumetric models also produce the quantities of pipe, valves, concrete, steel, and instruments identified by the associated equipment or area. Components of each line of pipe and instrument loop are quantified and costed, enabling you to view and adjust construction tasks. The Aspen Capital Cost Estimator Work Item Models produce the required man-hours by craft and task needed to install Aspen Capital Cost Estimator-generated bulks, as well as the equipment Aspen Capital Cost Estimator designed, by simulating detailed design construction tasks. Finally, the Engineering Models in Aspen Capital Cost Estimator produce man-hours by discipline and engineering work product. Introducing Aspen Capital Cost Estimator 15 CPM Schedules Aspen Capital Cost Estimator has a built-in activity network generator to automatically prepare Critical Path Method (CPM) schedules. The EPC estimate and the planning schedule are in tune with one another, each having been prepared from the same project scope. Information Tracking Aspen Capital Cost Estimator provides tree diagrams that allow you to view, track and revise information such as power distribution, process control networks, tiered contracts, areas and their equipment specs, and installation procedures. Aspen Capital Cost Estimator Project Workflow Before using Aspen Capital Cost Estimator, it may be helpful to review the recommended project workflow: Note: Early in the life of a project, when limited mechanical design detail is available, you need only enter a rough outline of scope to produce the initial estimate of cost and schedule. As more information becomes available, the details of the project can be entered and new reports can be generated and analyzed. 1 Create project scenario and define properties like country base, units of measure, and currency. 2 Define design basis (general mechanical design rules), wage rates and productivities, code of account definition and allocation, material and man-hour indexing, equipment rental, and project execution schedule settings. 3 Define the Power Distribution system (if desired). 4 Define the Process Control system (if desired) and link to areas and substations. 5 Add contractors and redefine responsibilities (if desired) and link to areas and substations. 6 Run an item evaluation to produce direct costs for an individual component or run a project evaluation to produce design and cost results needed to prepare project reports. 7 View and/or print reports. 16 Introducing Aspen Capital Cost Estimator The Guide Organization This guide contains the following: Introducing Aspen Capital Cost Estimator an overview of Aspen Capital Cost Estimator and the user's guide, as well as a list of related documentation and information on technical support. Chapter 1  Getting Started  instructions on how to start Aspen Capital Cost Estimator, open a project, enter project specifications, and work with the Icarus Interface. Chapter 2  Defining the Project Basis  instructions on defining specifications: units of measure, standard basis, component map, design criteria, investment analysis, raw material, product, operating unit costs, and utility. Chapter 3  Loading and Mapping Simulation Data  instructions on preparing different kinds of simulator reports for use in Aspen Capital Cost Estimator, loading simulator data, mapping simulator models to Icarus project components, adding additional components to simulator models, and viewing and defining simulator models in Block Flow Diagram (BFD) and Process Flow Diagram (PFD) view. Chapter 4  Defining Areas, Report Groups, and Project Components  instructions on how to define areas and report groups and then populate them with project components, which are the pieces of the process plant that, when linked together, complete a process. Chapter 5  Sizing Project Components  instructions on sizing project components. Chapter 6 – Piping and Instrumentation Models  instructions on accessing the P&ID Editor and creating and selecting custom P&ID’s. Chapter 7 – Developing and Using Cost Libraries  instructions on developing cost libraries and adding library items as project components. Chapter 8 – Changing Plant Capacity and Location  instructions on using the plant scale-up and relocation modules available if you are licensed to use Aspen Decision Analyzer. Introducing Aspen Capital Cost Estimator 17 Chapter 9 - Analyzer Utility Modules – instructions on using Analyzer Utility Modules for cooling water and air. Chapter 10  Evaluating the Project  instructions on running a project and item evaluations and reviewing capital costs, operating costs, and investment analysis reports. Related Documentation In addition to this document, a number of other documents are provided to help users learn and use Aspen Capital Cost Estimator. The documentation set consists of the following: Installation Notes Aspen Economic Evaluation and Exchanger Design and Rating V7.3 Installation Guide Known Issues and Workarounds Aspen Economic Evaluation V7.3 Release Notes New Features in Aspen Economic Evaluation V7.3 Aspen Economic Evaluation V7.3 Release Notes Icarus Reference Aspen Icarus Reference Guide, for Icarus Evaluation Engine (IEE) Piping and Instrumentation Drawings Piping and Instrumentation Drawings, 3rd edition Technical Support AspenTech customers with a valid license and software maintenance agreement can register to access the online AspenTech Support Center at: http://support.aspentech.com H H This Web support site lets you: 18 Introducing Aspen Capital Cost Estimator         Access current product documentation Search for tech tips, solutions and frequently asked questions (FAQs) Search for and download application examples Search for and download service packs and product updates Submit and track technical issues Send suggestions Report product defects Review lists of known deficiencies and defects Registered users can also subscribe to our Technical Support eBulletins. These e-Bulletins are used to alert users to important technical support information such as:  Technical advisories  Product updates and releases Customer support is also available by phone, fax, and email. The most up-to-date contact information is available at the AspenTech Support Center at http://support.aspentech.com. H Introducing Aspen Capital Cost Estimator H 19 20 Introducing Aspen Capital Cost Estimator 1 Getting Started Starting Aspen Capital Cost Estimator After completing the installation, you can start Aspen Capital Cost Estimator. To start Aspen Capital Cost Estimator: 1 Click the Windows Start button. 2 Point to Programs | AspenTech. 3 Point to Economic Evaluation 7.3; then click Aspen Capital Cost Estimator. Aspen Capital Cost Estimator starts. The Main window, empty because no project is open, appears on the left. The Palette appears in the upper-right and the Properties Window appears in the lower-right. 1 Getting Started 21 Note: You can change the position of the Main Window, Palette, and Properties Window, as explained under Customizing the Interface Arrangement on page 46. X X If you are also licensed to use Aspen Process Economic Analyzer, Aspen Capital Cost Estimator displays at startup the Options dialog box, in which you can choose to use Aspen Process Economic Analyzer in the Aspen Capital Cost Estimator environment. If you are licensed to use Aspen Icarus Project Scheduler (IPS), you can also select to use IPS with any of these options. 22 1 Getting Started Your selection makes certain features of the selected product available in Aspen Capital Cost Estimator. Starting a Project Scenario Note: Viewing the sample project scenario provided with Aspen Capital Cost Estimator before creating a new one will allow you to familiarize yourself with Aspen Capital Cost Estimator without having to fill out specifications. To open the sample project, follow the instructions under “Opening an Existing Project Scenario” on page 31. X X Creating a New Project Scenario To create a new project scenario: 1 Do one of the following:  On the File menu, click New. -or-  Click on the toolbar. The Create New Project dialog box appears. 1 Getting Started 23 Note: Under Preferences, you can create scenarios in project directories other than the default one provided by Aspen Capital Cost Estimator. See page 63 for instructions on adding project directories. 3 Either select an existing project in which to start a new scenario, or enter a new Project Name. Long filenames are accepted, including spaces. However, punctuation marks, such as question marks (?), exclamation points (!), tildes (~), and asterisks (*), are not allowed. 4 Enter the Scenario Name. X X This is the name of the scenario within the project. As with the Project Name, long filenames are accepted, including spaces, while punctuation marks, such as question marks (?), exclamation points (!), tildes (~), and asterisks (*) are not allowed. If you do not enter a Scenario Name, Aspen Capital Cost Estimator uses “BaseCase” as the default. 5 Click OK. 24 1 Getting Started The Project Properties dialog box appears. 6 Enter a Project Description. The description can be up to 500 characters in length and can be comprised of letters, numbers, and punctuation. You can enter or revise the description later on the Project Properties form accessed from the Project Basis view (see page 72). X X In the Units of Measure section, you can keep the default basis of Inch-Pound (IP) or select Metric. The Units of Measure selection cannot be changed after creating the project scenario. 7 If desired, enter more details about the project scenario in the Remarks field. Remarks can be up to 6,000 characters in length and can be comprised of letters, numbers, and punctuation. You can enter and revise remarks later on the Project Properties form accessed from the Project Basis view (see page 72). 8 Click OK. X X Aspen Capital Cost Estimator displays the Input Units of Measure Specifications dialog box, which lets you customize the units of measure that appear on specification forms. 1 Getting Started 25 For example, if you want to use CM/H (centimeters per hour) instead of M/H (meters per hour) to specify conveyor belt speed in your metric-basis project, do the following: A Select Velocity and Flow Rate and click Modify. B On the Velocity and Flow Rate Units form, enter “CM/H” as the new unit name for M/H. Then enter the conversion factor between the two units in the Conversion field. In this example, the conversion factor between the two units is 100 because: 100 CM/H = 1 M/H. C Click OK to accept the modifications and return to the previous dialog box. 26 1 Getting Started Note: You can also customize input units of measure after creating a project scenario, through the Basis for Capital Costs library (see page 75 for instructions). 9 When finished modifying input units of measure, click Close. Aspen Capital Cost Estimator displays the General Project Data form. X X Most specifications on this form can be entered later by selecting General Project Data in the Project Basis view (see page 73). However, country base, currency description and symbol, and allowing pipeline areas can only be selected at this time. X X Selecting Country Base and Currency The default country base is US and the default currency is Dollars (USD). Changing the country base to UK, EU, or JP automatically changes the currency to Pounds (PS), Euros, or 1 Getting Started 27 K-Yen (KY), respectively. You can, however, enter a currency different than that of the country base. Just be sure to also enter a currency conversion rate, which is the number of currency units per one country base currency unit. Allowing Pipeline Areas 2 If this is to be a pipeline project, select P in the Allow Pipeline Areas box. In a pipeline project, items marked with a double-asterisk in Project Explorer’s Project Basis view (see page 71) are not applicable. X X A pipeline project has no multiple contractors. A pipeline project will have both main (process) and pipeline areas. Process equipment may be defined in the main (process) area(s), but not in the pipeline areas. Suppressing Default Equipment/Area/Project Bulks 3 If you want to suppress equipment volumetric model bulks and most of the system developed area and project bulks, click the M option in the Suppress Default Equipment/Area/Project field on the General Project Data dialog box. If you select the M option: • Engineering and Construction (crew mixes, craft names) Workforces, Power Distribution, Process control, Panel Board, Contracts, and Project Execution Schedule will be ignored • All area design basis options to develop estimate and reports will be ignored • Only Interactive Reports (for example, Reporter) are available.No standard Aspen Capital Cost Estimator evaluation report (CCP) is developed. 4 Click OK when finished entering General Project Data. The Main Window now displays Project Explorer and the List view. See “Understanding the Icarus Interface” on page 32 for instructions on working with these and other features now available on the interface. X 28 X 1 Getting Started Importing a Project Scenario Aspen Capital Cost Estimator provides an Import feature so that you can import Analyzer 2.0B, Icarus 2000 9.0, Aspen Process Economic Analyzer 5.0/5.1, IPM 5.0, or Questimate 14.0 project scenarios into Aspen Capital Cost Estimator. To import a project scenario: 1 Do one of the following:  On the File menu, click New. -or-  Click on the toolbar. The Create New Project dialog box appears. Note: You can create scenarios in project directories other than the default one provided by Aspen Capital Cost Estimator. See “Preferences,” particularly the “Locations” subsection on page 63, for instructions. 2 Either select an existing project in which to start a new scenario, or enter a new Project Name. Long filenames are accepted, including spaces. However, punctuation marks, such as question marks (?), exclamation points (!), tildes (~), and asterisks (*), are not allowed. 3 Enter the Scenario Name. X X Again, long filenames are accepted, including spaces, while punctuation marks, such as question marks (?), exclamation points (!), tildes (~), and asterisks (*) are not allowed. After making an entry in the Scenario Name field, the Import button becomes active. 1 Getting Started 29 4 Click Import. The Select Import Type dialog box appears. 5 Select the project type you wish to import and click OK. The Browse for Folder dialog box appears. 2 Select the project scenario folder and click OK. The project scenario’s settings will be imported into the new project scenario. 30 1 Getting Started Opening an Existing Project Scenario To open an existing project scenario: 1 Do one of the following:  On the File menu, click Open. -or On the toolbar, click . The Open Existing Project dialog box appears. In the pictured dialog box, the project named Expansion has been expanded on the tree structure to show the scenario named Asp_Eng01. The tree structure on the left side of the dialog box displays the projects in the default project folder: ...\AspenTech\Economic Evaluation V7.3\Data\Archives_Aspen Capital Cost Estimator Clicking + next to a project expands the view to display the scenarios under that project. Selecting a scenario displays the following scenario information in the pane on the right: Version of Aspen Capital Cost Estimator in which the scenario was created  Name of the user who created the scenario  Name of the computer on which the scenario was created  Units of measure used in the scenario 3 Select a scenario and click OK. 1 Getting Started 31 The project scenario opens. The Main window now displays Project Explorer and the List view. See “Understanding the Icarus Interface” on page 32 for instructions on working with these and other features now available on the interface. X X Palette Shortcut You can also open a project from the Palette, which appears to the right of the Main Window in the default interface arrangement (it can also be floated in the Main Window or dragged onto the Main Window and re-sized, as shown below). 1 In the Projects tab view, right-click on a scenario. 2 On the menu that appears, click Open. This opens the selected scenario. Working with Templates Adding a Template. To add a new template: 1 Click File | New Template. The Create New Template dialog box appears. 32 1 Getting Started 2 On the Create New Template dialog box type the Scenario name. 3 Click OK. The Project Properties dialog box appears. 4 On the Project Properties dialog box, enter: o the project description o the units of measure (IP or Metric) o any (optional) remarks 5 Click OK. The project is created. Note that the Title Bar indicates Templates (name you entered for the scenario). Creating a Project by Importing a Template You can create a new project based on an existing template. To do this: 1 Launch the Aspen Economic Evaluation application. 2 Click File | New. 3 On the Create New Project dialog box that appears, specify the project and scenario name. 4 Click the Template button on the right of the dialog box. The Import Template dialog box appears showing h all available templates. 5 Click the template you want to import; then click OK. The Project Properties dialog box appears, on which you can continue to enter information for the new project. Note: When opening a project from a template, or opening a template itself, not all of the buttons on the Aspen Capital Cost Estimator Toolbar are available. Understanding the Icarus Interface The Icarus interface lets you see multiple windows and documents. You can customize the interface arrangement. The following is the default interface arrangement, with a specifications form open in the Main Window. 1 Getting Started 33 The Icarus interface includes the following features: This feature Does this Title Bar Displays the project file name and current Main Window view. Menu Bar Displays menu options. Toolbar Allows access to Aspen Capital Cost Estimator functions. See page 48. Main Window Provides workspace for all Aspen Capital Cost Estimator documents, List view, specification forms, and other views. See page 36. Project Explorer Organizes project items in tree format. See page 34. Palette Allows access to libraries, projects, components, and templates. See page 40. Status Bar Displays Aspen Capital Cost Estimator system status. Properties Window Describes the field selected on specifications form. See page 44. X X X X X X X X X X Project Explorer Project Explorer is a graphical representation of the project. It has three views: Project Basis view, Process view, and Project view. Each view organizes items in a tree format. Switch views by selecting the appropriate tab at the bottom of Project Explorer. (Stretching the width of the Project Explorer will display the full names on the tabs.) The different views are described on page 35. X 34 X 1 Getting Started To expand a tree level:  Click the PLUS SIGN (+) next to the condensed level. To condense a tree level:  Click the MINUS SIGN ( -) next to the expanded level. Project Explorer Views Project Basis View displays project basis specifications. Double-click on a specification to view and/or modify it. A red arrow on an icon in this view indicates that you can right click on the icon for options. Level Icon Description 2 Specifications folder 3 Specification Process View displays simulator data information. In this view, simulator items can be mapped to Icarus project components. Mapped items can then be sized, modified, and/or deleted. Note: Simulation data can only be used in Aspen Capital Cost Estimator if you are licensed to use Icarus Process Evaluator (Aspen Process Economic Analyzer) or Analyzer. As in a process simulator, like AspenPlus or HYSYS, blocks represent different operations within the process. A block is sometimes referred to as a unit operation. Level Icon Description 2 Main Project, containing a group of simulator areas 3 Process simulator area 4 Unmapped simulator block (yellow) Mapped simulator block (green) 1 Getting Started 35 Project View displays project data information. In this view, mapped items can be sized, modified, and/or deleted. In addition, new areas and Icarus project components can be defined. Level Icon Description 1 Main Project, containing the default Main Area and any user-added areas 2 Report Group, displayed only if Show Report Group in Aspen Capital Cost Estimator is selected in Preferences (see page 60 for instructions) X 3 Area 4 Project component X Main Window The Main Window is located to the right of Project Explorer by default. The Main Window is a workspace for all Aspen Capital Cost Estimator documents, the List view, and other views. You can adjust the relative size of each window by clicking on the division bar and dragging it to the desired location. Note: Here, the Main Window in Workbook Mode displays several tabs because a component specifications form (component A1) and a project specifications form (Escalation Specs) have been opened. 36 1 Getting Started By default, the Main Window is in Workbook Mode. In this mode, tabs are placed at the bottom of the window. These tabs represent all windows open in the Main Window. Clicking on a tab brings the associated window to the foreground. Clicking Tile or Cascade on the Window menu displays all windows open in the Main Window. Regardless of the window arrangement, the tabs are still at the bottom of the Main Window when in Workbook Mode. Clicking the maximize button ( ) on a window returns all windows to full tab view. Clicking the condense button ( ) on the menu bar displays all windows open in the Main Window as they were when last condensed. This is how the Main Window appears when in Workbook Mode with Cascade selected as the condensed window arrangement. Aspen Capital Cost Estimator lets you float Project Explorer, the Palette, and the Properties Window in the Main window. When in this state, these windows behave just like other windows that are part of the Main Window. See “Customizing the Icarus Interface” on page 46 for details. X X You can turn off Workbook Mode by unmarking Workbook Mode on the View menu. When Workbook Mode is off, no tabs are displayed; to bring a window to the front, you must click on the desired window or select the desired window from the Window menu. 1 Getting Started 37 List View The List view in the Main Window displays details on items selected in Project Explorer. For example, when you click on an area in Project Explorer’s Project view, the List view displays a list of all components in the area. This is referred to as the “area-level” list (shown below), in which the components are displayed in rows with component details in columns. When you click on a component in Project Explorer’s Project view, the List provides information only on the selected component, with component details listed in rows. This is referred to as the “component-level” list. Note: In the interface arrangement pictured here, the Palette and the Properties Window have been hidden to make room for the Main Window. Press ALT+1 to hide or display the Palette and press ALT+2 to hide or display the Properties Window. Press ALT+0 to hide or display Project Explorer. Filtering Mechanism You can limit area-level lists to a single category of component. To do so, click the drop-down arrow on the toolbar and click on a category. 38 1 Getting Started For example, if you click ? Incomplete Items the list will only include components that still have specifications that need to be entered in order for the component to be included in an evaluation. Column Settings You can select which columns appear on the area-level list and in which order. To change column settings on the area-level list: 1 Right-click on any of the column headings. A pop-up menu lists all of the columns. Columns currently displayed are checked. 2 To simply hide/unhide a column, you can click it on the menu. 2 To change the order, click Settings on the menu. 1 Getting Started 39 The Settings dialog box appears. 3 To move a column to the right on the List View, click Move Down. To move a column to the left, click Move Up. The Reset button returns to columns to the default setting (shown above). 4 Click OK to save the settings. When you restart Aspen Capital Cost Estimator, all columns will be displayed in the default order unless Save Window States is selected in Preferences (by default, Save Window States is selected). See “Saving Window States” on page 47 for more information. X X Palette The Palette contains elements that you can apply to the project scenario. If you think of Project Explorer as a picture of the project scenario, you might think of the Palette’s contents as the pigments and dyes used to first sketch out and then color in that picture. For example, if you wish to import areas or components from another scenario into your current scenario, you can double-click on the scenario in the Palette to get a listing of its areas and components and then drag the area/component to the Project Explorer’s Project View. (See “Importing Project Components” on page 345.) X 40 X 1 Getting Started Likewise, the Palette’s Libraries view contains libraries of Project Basis specification files that, in Project Explorer’s Project Basis view, you can select to use. From the Palette, you can develop the libraries by creating new files, modifying existing files, and importing files. (See “Specification Libraries” on page 239.) X X When you add a component to the project scenario, you can choose from the components listed in the Palette’s Components view. Then, after you add the component, it appears in Project 1 Getting Started 41 Explorer’s Project view. (See “Adding a Project Component” on page 324). X X Finally, you can use the Palette’s Templates tab to access templates, both those supplied with Aspen Capital Cost Estimator, and any you or others may have created. In the default interface arrangement, the Palette appears on the right side of the screen. Like Project Explorer, it can be displayed in a variety of ways. See “Customizing the Icarus Interface” 42 1 Getting Started (page 46) for display options. To hide/display the Palette, press ALT+1 or used the checked command on the View menu. X X As indicated previously, the Palette has four views: Projects, Libraries, Components, and Templates. The Components view, shown below, has a scrollable split window that displays details on equipment items. The division bar can be adjusted to hide or expand the details section. Note: The Palette pictured in this section has been dragged onto the Main Window and re-sized. In addition to letting you import the contents of other scenarios, the Projects view provides options for opening scenarios, viewing scenario properties, and deleting scenarios. Right-click on a project scenario to access the pop-up menu of options. The Projects view displays all projects in the default project folder and any other active project folders. (See “Preferences,” particularly the “Locations” subsection on page 63, for instructions.) X 1 Getting Started X 43 Properties Window When you select a field on a specifications form, the Properties Window provides a description of the field. The description often includes minimum, maximum, and default values. 44 1 Getting Started Here, the Properties window (docked on the right side of the screen) displays information on the Item Description field, which is selected on the specifications form. Click on the Properties window to freeze and unfreeze the content. When the content is frozen, you can move to another field while retaining the description of the original field in the Properties Window. Like the Palette and Project Explorer, the Properties Window can be displayed in a variety of ways. See “Customizing the Icarus Interface” on page 46 for display options. X X To hide/display the Properties window, press checked command on the View menu. ALT+2 or use the Templates Tab Use the Templates tab to access templates. Shown below are the ten templates included in Aspen Capital Cost Estimator. If you had created custom templates, they would appear on this list. 1 Getting Started 45 Customizing the Icarus Interface In the default interface arrangement, Project Explorer docks to the left edge and the Palette and the Properties Window share the right. When docked, windows remain attached to an edge and all other windows are sized to fit in the remaining space available. Right-clicking on a border of any of these three windows accesses a pop-up menu from which you can select Allow Docking. When Allow Docking is marked, the window can be docked to any edge. Note: When Float In Main Window is selected on the pop-up menu, the Allow Docking option is inactive. To dock to a different edge: 1 Click the border that contains the Close button ( ) and hold down the left mouse button. A bounding outline will appear as you drag the window. 2 Drag the outline to the desired edge and release the left mouse button. 46 1 Getting Started Here, Project Explorer is docked to the top of the screen. When multiple windows are docked to the same edge, you can use the division bar to adjust the relative sizes. You can also use the Contract/Expand ( / ) buttons to either switch from one window to the other or split the side. Undocking by Dragging onto Main Window One way to undock the window is by dragging it onto the Main Window. Its size can then be adjusted. Float In Main Window Option You can at any time select Float In Main Window on the pop-up menu. In this state, the window behaves like the List view or a specifications form, with a tab at the bottom of the Main Window. Saving Window States If you are using the default Preferences, Aspen Capital Cost Estimator saves the interface arrangement. This way, when you open Aspen Capital Cost Estimator the arrangement is the same as you left it. 1 Getting Started 47 You can also set the Preferences so that Aspen Capital Cost Estimator opens displaying the default arrangement. See the section on the General tab view of the Preference dialog box (page 58) for more information. X X Aspen Capital Cost Estimator Toolbar By default, the toolbar is docked under the menu bar. However, you can float the toolbar by clicking on a blank area of the toolbar and dragging it. You can also dock the toolbar to the bottom of the screen or vertically to the edge of the Project Explorer, Main Window, or the Palette. To do so, drag the toolbar over any one of these areas until an outline of the toolbar appears. Release the mouse button when the outline appears in the desired area. The following toolbar buttons are available in Aspen Capital Cost Estimator: Click this to Create a new project scenario. See “Creating a New Project Scenario” on page 23. X X Open an existing project scenario. See “Opening an Existing Project Scenario” on page 31. X X Save the current project. See “Saving a Project Scenario” on page 53. X X Print. Run project evaluation. See “Running a Project Evaluation” on page 607 for instructions. X X Load Capital Costs and other reports. See “Reviewing Reports in Aspen Icarus Reporter,” page 619, for instructions. X X Go back. Navigate back through previously viewed links. Go forward. Navigate forward through previously viewed links. Other buttons that appear on the toolbar are always inactive in Aspen Capital Cost Estimator. They are for use in other Icarus programs. 48 1 Getting Started Aspen Capital Cost Estimator Menu Bar Click this to New Start a new project scenario. Details on page 23. New Template Start a new template Open Open an existing project scenario. Details on page 31. Open Template Open an existing template. Close Close the current project scenario. X X X X Save Save the current project scenario. Details on page 53. Save As Save the current project scenario as a different file. Details on page 53. Import Access instructions for importing areas and components. Details on page 345. Import SP 3D Import Pipe Runs and Fitting Spreadsheets. Import PID Drawing Import PID Drawings. Export to SPECS file Save the current project scenario as an SPECS (*.ic2) project file. Print Print the form or report currently active in the Main Window. Print Preview Preview how form or report will appear printed. Print Setup View and modify printer name and properties, paper size and source, and orientation Page Setup Define page specifications. X X X 1 Getting Started X X X 49 Exit Close Aspen Capital Cost Estimator. Run Menu Click this to Evaluate Project Run a project evaluation. See page 607 for details. Develop Schedule This sub-menu contains commands for use in Aspen In-Plant Cost Estimator only. Decision Analyzer (Only active if you are using Aspen Decision Analyzer in the Aspen Capital Cost Estimator environment.) Accesses options for changing plant capacity and location. See Chapter 8. Scan for Errors Scan for potential errors in the project evaluation. Re-number Re-number project components or project areas so that the numbering contains no gaps. Details on page 350. X X 50 X X 1 Getting Started View Menu Use this to Toolbar View or hide the toolbar. See page 48 for description of the toolbar. Status Bar View or hide the status bar. See page 32 for description of the status bar. Project Explorer View or hide Project Explorer. See page 34 for a description of Project Explorer. Palette View or hide the Palette. See page 40 for description of the Palette. Properties Window View or hide the Properties Window. See page 44 for a description of the Properties Window. Workbook Mode Turn Workbook Mode on and off. See page 36 for an explanation of Workbook Mode. Capital Costs View Launch Aspen Icarus Reporter. The Project Evaluation needs to have already been run. See page 619 for details. Investment Analysis View Display Investment Analysis spreadsheets in Main Window. This option is not active until you have run a project evaluation. You must also be licensed to use Icarus Process Evaluator (Aspen Process Economic Analyzer) and/or Analyzer. See page 653 for information on reviewing the Investment Analysis. X X X X X X X X X X X X X X X X Block Flow Diagram Display Block Flow Diagram of the loaded simulator data. This option is not active until you have loaded simulator data. Process Flow Diagram Display Process Flow Diagram. This option is not active until you have mapped the simulator items. Streams List Display a read-only list of all simulator-derived stream properties in a spreadsheet. This option is not active until you have mapped similator items. You can customize some of the features of the spreadsheet (which stream properties to display, whether to display names of the properties, and the display style of the property values) by editing the stream list template file: ...\ Economic Evaluation V7.3\Data\ICS\strlist.fil 1 Getting Started 51 Tools Menu Use this to Report Editor Access ICEdit program. External Simulation Import Tool Import information from a simulator. Manpower Productivity Expert (MPE) Launch MPE. Options Access Options sub-menu. See below. Options Sub-menu 52 Use this to View Spreadsheets in Excel Access Excel spreadsheets. Reporting Assistant Access the Reporting Assistant feature that lets you create your own customized report spreadsheets, combining information from all other Icarus generated spreadsheets. Custom This command is reserved for future releases. 1 Getting Started Tasks Preferences Access Preferences. See page 58 for details. X X Window Menu Use this to Cascade View the Main Window contents in Cascade mode. See page 36. Tile View the Main Window contents in Tile mode. See page 36. Arrange Return all minimized windows to the bottom of the Main Window. # XXX View opened window in the Main Window. X X X X Help Menu Use this to Contents Access Aspen Icarus Help. Documentation Access Docs.pdf, which links to pdf’s of all Aspen Icarus documentation. You must have Acrobat Reader to access this file. Training Access Aspen Capital Cost Estimator training information on the web. Product Support on the Web Access support.aspentech.com. About Access program information, version number, and copyright information. Working with Project Scenarios This section explains how to save, delete, salvage, and unlock project scenarios. Saving Project Scenarios To save a project scenario:  Click on the toolbar or click Save on the File menu. Aspen Capital Cost Estimator saves any changes. 1 Getting Started 53 To save the scenario with a new name: 1 Click Save As on the File menu. Note: Save As is useful when studying alternatives. Note: You can save scenarios to project directories other than the default one provided by Aspen Capital Cost Estimator. See Preferences, particularly the Locations subsection on page 63, for instructions. 2 Specify a Project Name and Scenario Name and click OK. X X Aspen Capital Cost Estimator saves the scenario as specified. Deleting Project Scenarios You should delete project scenarios when they are no longer needed. Deleting old scenarios opens free disk space and makes working with scenarios easier. To delete a project or scenario: 1 To delete a project scenario, right-click on the scenario within the project directory and click Delete on the pop-up menu. 54 1 Getting Started A dialog box asks you to confirm deletion. Note: You can select in Preferences not to have this prompt appear (see page 58). 2 Click Yes to delete the project scenario. -orClick No to retain the project scenario. X X Salvaging Project Scenarios If you exit Aspen Capital Cost Estimator abnormally without being able to save the current project scenario, you can salvage the project scenario from cached project information. To salvage a project scenario: 1 Restart Aspen Capital Cost Estimator. A window appears asking if you wish to save the cached information found in storage. 1 Getting Started 55 2 Click Yes. Aspen Capital Cost Estimator displays the Salvage Project As dialog box. 3 Specify a project and scenario name. You cannot overwrite the scenario being salvaged; you must specify a project and scenario name different from that of the original scenario. 4 Click OK. Aspen Capital Cost Estimator creates the new scenario. Except in name, this project scenario will be identical to the scenario that was open when Aspen Capital Cost Estimator was abnormally exited. After creating the new scenario, Aspen Capital Cost Estimator asks if you wish to open it. Unlocking Project Scenarios If Aspen Capital Cost Estimator crashes while you have a project scenario open, Aspen Capital Cost Estimator remembers that you have the project scenario checked out. When you re-open Aspen Capital Cost Estimator, you will have to unlock the project scenario before opening it. Anyone trying to open a locked project is denied access and provided with a message that states the time the project scenario was checked out, the user name of the person who checked it out, and the computer on which it was checked out. 56 1 Getting Started A project can only be unlocked by the user who checked it out or by an administrator. To unlock a project scenario: 1 Right-click the project scenario in the Palette. 2 On the menu that appears, click Unlock. You can now open the project scenario as you normally would. Copying Project Directories Within a project directory, Aspen Capital Cost Estimator creates an independent folder for each project and also creates, within a project folder, an independent folder for each project scenario. This makes it easy to move project scenario files from one computer to another on the same network. Simply copy and paste the folder in Windows Explorer. You can also copy an entire project directory with multiple project and project scenario folders. Doing so creates an identical set of folders and files in the new location. See “Preferences,” particularly the “Locations” subsection on page 63, for information on adding project directories and setting a new default project directory. X 1 Getting Started X 57 Preferences The settings in Preferences let you specify how Aspen Capital Cost Estimator will act each time it is used. To access Preferences: 1 Click Options on the Tools menu, and then click Preferences on the sub-menu. Aspen Capital Cost Estimator displays the Preference dialog box. 2 Click To do this OK Save changes and close the Preferences. Apply Save changes without closing Preferences. Cancel Close Preferences without saving changes. (Clicking Apply and then immediately clicking Cancel would have the same effect as clicking OK.) General In the General tab view, you can select the following: 58 1 Getting Started  Prompts - Select which prompts appear. Close Project – prompt to save any changes when closing project. Overwrite Project – prompt to confirm overwriting project that has the same name as the one being created. Delete Project – prompt to confirm deletion of project. Delete Area – prompt to confirm deletion of area. Delete Component – prompt to confirm deletion of component. Cancel Component Edit – prompt to save changes when you click Cancel after editing a Component Specifications form. Delete Library – prompt to confirm deletion of a specifications library. Delete Report Group – prompt to confirm deletion of a report group.  Evaluation Display results after evaluation - mark to have Aspen Capital Cost Estimator open a detailed results report after you run an evaluation. Scan for Errors before evaluation – mark to have Aspen Capital Cost Estimator scan for errors before evaluation.  Item Report Select which type of report you wish to display when generating an Item Report. HTML Item Report – mark to display the HTML Item Report, like the one shown on page 678, in the Main Window. X X Capital Cost Report – mark to display the Capital Cost Report in Icarus Editor. Reporter Report – mark to display the Single Component Summary, exported from Aspen Icarus Reporter, in the Main Window.  Display Save Window States – mark to have Aspen Capital Cost Estimator save the position of Project Explorer, the Main Window, the Palette, and the Properties Window, as well as selected columns on the List view. Unmark to have Aspen Capital Cost Estimator open with the default interface arrangement (shown on page 32). X 1 Getting Started X 59 Display Options Choice Dialog on Aspen Capital Cost Estimator Startup – mark to have Aspen Capital Cost Estimator ask you at startup whether to use Aspen Process Economic Analyzer in the Aspen Capital Cost Estimator environment. Show Report Group in Aspen Capital Cost Estimator – mark to display report groups. For more information on report groups, see page 318. X X Forms The Forms tab view provides options related to Component Specification and Installation Bulk forms. Display P&I Installation Bulks in Grid – mark to have Aspen Capital Cost Estimator display all items on the Installation Bulk specification forms for Pipe and Instrumentation. If you unmark the checkbox, Aspen Capital Cost Estimator lets you select, when opening the form, the items to include. Use OK Button in Installation Bulks Form to Go to Main Component Form – mark to have Aspen Capital Cost Estimator return you to the main Component Specifications form when you click OK at an Installation Bulks form. Otherwise, clicking OK simply closes the Component specifications. Save Component When Switching to Different Installation Bulk or Main Component Form – mark to have Aspen Capital Cost Estimator save the Component specifications when you switch to a different form on the Component’s Options menu. Spreadsheet Views The Spreadsheet Views tab lets you customize individual spreadsheet views. Use the Spreadsheet View field to specify the spreadsheet view you want to customize. When you have selected the spreadsheet view you want to customize, use the Units of Measure group to specify what units of measure to use. You can select both. Use the Fields group to specify which fields will be visible on the spreadsheet view you selected. To make fields visible: 60 1 Getting Started  Move the field(s) from the Available to the Visible pane. To hide fields:  Move the field(s) from the Visible to the Available pane. Backup The Backup/Recovery tab lets you select when backups are to be performed. You can select both options. Automatic Task Backup – select this check box to have Aspen Capital Cost Estimator perform a backup before executing major tasks, such as a project evaluation. Timed Backup (Interval, in minutes) – select this check box to have Aspen Capital Cost Estimator perform a backup at a specified interval. Specify the interval in the box provided. Timed Recovery (Interval, in minutes) - select this check box to have Aspen Economic Evaluation write a recoverable file at the specified interval. Specify the interval in the box provided. If an Economic Evaluation application crashes, when you open the Aspen Economic Evaluation application that crashed, you are be prompted to recover your file and save it with a new name. Note: After a project has crashed and been recovered (under the new name), the original project that crashed should be deleted as it may no longer be in a stable state. After deleting the crashed project, you can rename the recovered project to the previous name if you want. You can also select to either have Aspen Capital Cost Estimator overwrite the project backups or create unique backups. Overwrite Project Backups – mark to have Aspen Capital Cost Estimator overwrite the previous backup every time the program performs a backup. Unique Project Backups – mark to have Aspen Capital Cost Estimator retain previous backups by creating a unique backup each time. Depending on the frequency of backups (see task and timed backup options above), selecting Unique Project Backups could result in large amounts of disk space being consumed by backups. 1 Getting Started 61 Process The Process tab view provides options for importing from an external project. Import Connected Streams – mark to include connected streams when importing an external project. Import Installation Bulks – mark to include installation bulks when importing an external project. The Process tab view also provides options for unsupported simulator models and custom models. Map Unsupported Models To Quoted Cost Item – mark to have Aspen Capital Cost Estimator map, by default, unsupported simulator models to quoted cost items. “Unsupported Models” refer to models not listed in the Project Component Map Specifications dialog box shown on page 188. Aspen Capital Cost Estimator does not recognize them and, therefore, cannot map them to Icarus project components. If this option is left unmarked, Aspen Capital Cost Estimator will not map unsupported models. As a result, a unit operation could appear disconnected in the Process Flow Diagram (PFD). X X Quoted cost items are not project components, but act as place markers to ensure that unit operations remain connected in the PFD. Note: Marking this option will not affect the mapping of supported simulator models. If a simulator model is listed in the Project Component Map Specification dialog box, then the specified mapping will be used. Further, if a simulator model is listed and has no default mapping (that is, Current Map List section is blank), then it is assumed that the user does not want to map such simulator models to any Icarus project components. For example, if this option is marked, a USER unit operation in Aspen Plus can be mapped to a quoted cost item if this option is marked. This ensures that the unit operation remains connected in the PFD. Activate Custom Model – mark to activate the Custom Model tool explained on pages 351 through 358. X X X X Use Automatic Mapping Selection when Available (Beta feature) – Mark to use the Mapping Selection feature explained in the section on "Default and Simulator Data" Mapping. 62 1 Getting Started Locations In the Locations tab view, you can select:  Project Directories Add/remove alternate project directories and set the default project directory. See “Adding Project Directories” on page 64 for instructions.  Other Location Specifications X X To specify the location of various specification files and data: 1 Click an item in the list to display its description and location. 2 Click the Browse button to select a new location. Notes:  In some cases the description warns against changing the location.  Make sure to create the IP and MET subfolder structure when changing the source locations for library files that are units dependent (for example, Basis for Capital Cost, EML, UML, Custom Piping Specs, and so on). 1 Getting Started 63 Logging The Logging tab view is reserved for future releases, in which it will be used to help clients with Technical Support issues. It is not currently activated. Unit Costs Adding Project Directories Aspen Capital Cost Estimator comes set up with two project directories: ...\AspenTech\Economic Evaluation V7.3\Data\My Econ_Project Projects ...\AspenTech\Economic Evaluation V7.3\Data\Archives_Econ_Project 64 1 Getting Started These directories, by default,are the sole choices of project directory when opening or saving a new project, as well as the only directories displayed on the Palette’s Projects view. On the Locations tab, however, you can enter alternate project directories, which will then appear on the Palette’s Projects view and as choices when opening and saving projects. You can also select an alternate project directory as the default. To add a project directory: 1 Click Add. The Browse for Folder dialog box appears. 2 Click the folder you want to add as an alternate directory; then click OK. Aspen Capital Cost Estimator adds the directory to the Alternate Project Directories list. 1 Getting Started 65 3 To set an alternate project directory as the default, click it; then click Set Default. Aspen Capital Cost Estimator displays a prompt asking you to confirm the change. Click Yes to set the new default. If the old default location is not on the list of alternate project directories, Aspen Capital Cost Estimator displays another prompt asking if you wish to add it to the list. 66 1 Getting Started Note: Adding the old default directory to the alternate project directory list lets you easily revert to it. 3 Click Yes or No. 4 Click OK to save the changes to Preferences. Before the added project directory appears on the Create New Project dialog box and elsewhere, you must either:  Restart Aspen Capital Cost Estimator. -or-  Right-click on the current project in the Palette and click refresh on the pop-up menu. Changing Location Specifications You can modify the location specification of any of the specification files. For example, to change the location of the Standard basis file: 1 Click StandardBasisRefDir. 2 Use the Browse button below to select another location. 3 After each change, click Apply to save your change. Note: If you are using more than one Icarus tool, remember to repeat the above steps for other systems (Aspen Process Economic Analyzer, Aspen In-Plant Cost Estimator, and so on.). Caution: Before performing the steps mentioned above, copy the system defaults (library folder structure) to the “myStd_Basis_[System]” folder. System Defaults: Economic Evaluation V7.3\Data\StdBasis_Aspen Capital Cost Estimator\Ip\Default.d0* Economic Evaluation V7.3\Data\StdBasis_Aspen Capital Cost Estimator\Met\Default.d0* Should Resemble: 1 Getting Started 67 CoABC\myStdBasis_Aspen Process Economic Analyzer\Ip\Default.d0* CoABC\myStdBasis_Aspen Process Economic Analyzer\Met\Default.d0* Logging The Logging tab view is reserved for future releases, in which it will be used to help clients with Technical Support issues. It is not currently activated. Schedule In the Schedule tab view, you can specify your Primavera user name. The Schedule tab view also contains the Schedule Administrator Tool for registering users and access rights in cases where Aspen In-Plant Cost Estimator and the scheduling program run on a network. This tool should only be used by a network administrator. Unzipping Files After Upgrading to Newer Versions of Aspen Capital Cost Estimator Sometimes when you upgrade to a newer version (for example, to a service pack) of Aspen Capital Cost Estimator, you will find your files zipped into two files with the extensions:  .izp  .szp There are two zip files per scenario:   XXX.IZP (containing the main database of the project) XXX.SZP (containing reports, results, projid files, and so on) You use the executable icziputil.exe, which is supplied with your Aspen Capital Cost Estimator application, to unzip these files. 68 1 Getting Started To unzip your files using the executable icziputil.exe: 1 Ensure that the executable icziputil.exe is in the \Program Files\AspenTech\Aspen Icarus x.x\Program\Sys directory. 2 Open a command prompt (Start | Run | Cmd); then press ENTER. 3 Change directories to the \Program Files\AspenTech\Aspen Icarus x.x\Program\Sys folder where you copied the icziputil.exe file. 4 To unzip a .szp or .izp file, use the following command: icziputil /u [Zip file path] [Destination path] For example: icziputil /u "d:\saved\project\sim_met\proii.szp" "d:\temp\sim_met\unzipped" 1 Getting Started 69 70 1 Getting Started 2 Defining the Project Basis The Project Basis defines specifications that pertain to the overall project scenario. These specifications influence the design and cost estimate by defining system defaults and environmental variables. Project Basis Specifications are accessed from the Project Basis view in Project Explorer. Notes:  A red arrow on an icon indicates that you can right-click on the item to access a pop-up menu.  In a pipeline project, specifications marked with a double-asterisk (**) do NOT apply. 2 Defining the Project Basis 71 This chapter describes the different Project Basis specifications, as well as how to customize specification libraries. Project Properties Project Properties are initially specified when creating a new project. To access project properties:  In the main Project Basis folder, right-click Project Properties; then click Edit. 72 2 Defining the Project Basis The Project Properties dialog box appears. You cannot edit Project Name, Scenario Name, or Units of Measure; they can only be specified when creating a new project. You can edit the following: Project Description: The description entered here appears as the Project Description on the Project Summary spreadsheet and as the Brief Description on the Executive Summary spreadsheet. All scenarios under the project share the project description. The description can be up to 500 characters in length and can be comprised of letters, numbers, and punctuation. Remarks: Any remarks entered will appear immediately after the Title Page of evaluation reports in Icarus Editor. Remarks can be up to 6,000 characters in length and can be comprised of letters, numbers, and punctuation. Remarks might include, for example, the intended purpose of the estimate, executive summary of results, or an explanation of assumptions. General Project Data General Project Data is initially specified when creating a project. To access General Project Data: 1 Right-click General Project Data in the main Project Basis folder. 2 Defining the Project Basis 73 2 On the menu that appears, click Edit. The Standard Basis Input File Specifications form appears. You cannot edit Units of Measure, Country Base, or Currency Symbol; these can only be specified when creating a new project. You can edit the following: Currency Conversion Rate: The number of currency units per one country base currency unit. This is for when you are using a currency other than that of the country base. Project Title: Appears as the project title on reports in Aspen Icarus Reporter and Icarus Editor, and also appears as the Scenario Description on the Project Summary spreadsheet. Estimate Class: Appears on the Title Page in Icarus Editor. Intended to indicate the purpose of specifications (for example, budget). Job Number: Appears on the Title Page in Icarus Editor. Prepared By: Appears at the top of reports generated by Aspen Icarus Reporter and on the Title Page in Icarus Editor. 74 2 Defining the Project Basis Estimate Date: Appears immediately under the project title at the top of the Title Page in Icarus Editor. Reports generated by Aspen Icarus Reporter also include an Estimate Date; however, the Estimate Date shown in Aspen Icarus Reporter is the date on which the project evaluation was run. Basis for Capital Costs The Basis for Capital Costs folder includes:  Units of measure customization.  General mechanical design rules for equipment, piping, civil, steel, instrumentation, electrical, insulation, and paint.  Contingency and miscellaneous project costs.  Escalation indices for material and labor costs.  Engineering workforce specifications by phase, discipline, and task.  Construction workforce wage rates and productivities, for both the overall project and by craft and workweek definition.  Code of Account (COA) re-definitions, additions and allocations.  Indexing of material costs and man-hours by COA.  Equipment rental items, durations, and rates. Input Units of Measure Customization Input Units of Measure Customization lets you customize the units of measure that appear on specification forms. Input Units of Measure Customization can only be accessed from outside of the project in the Palette’s Libraries view. It does not appear in the Project Explorer’s Project Basis view. To customize input units of measure: 1 With no project open, expand the Basis for Capital Costs folder in the Palette’s Libraries view. Expand the appropriate units of measure basis folder – Inch-Pound or Metric. Right-click on the specifications file that will contain the customized units of measure and click Modify. 2 Defining the Project Basis 75 Aspen Capital Cost Estimator displays the Basis for Capital Costs library in Project Explorer. 76 2 Defining the Project Basis 2 In the Units of Measure Customization folder, right-click Input; then, on the menu that appears, click Edit. 2 Defining the Project Basis 77 The Input Units of Measure Specifications dialog box appears. 3 If, for example, you want to use CM/H (centimeters per hour) instead of M/H (meters per hour) to specify conveyor belt speed in your metric-basis project, click Velocity and Flow Rate and then click Modify. 4 On the Velocity and Flow Rate Units form, enter “CM/H” as the new unit name for M/H. Then enter the conversion factor between the two units in the Conversion field. In this example, the conversion factor between the two units is 100 because: 100 CM/H = 1 M/H. 78 2 Defining the Project Basis 5 Click OK to accept the modifications and return to the previous dialog box. 6 When finished modifying input units of measure, click Close. Output (Reports) Units of Measure Customization Output (Reports) Units of Measure Customization lets you customize the units of measure that appear on Capital Costs and other reports. To customize output units of measure: 1 Right-click Output (Reports) Units of Measure Customization in the Basis for Capital Costs folder in Project Explorer’s Project Basis view, and then click Edit on the pop-up menu. The Output Units of Measure dialog box appears. 2 You can change the basis for all output units of measure by selecting a different basis in the Unit of Measure Basis section; however, note that this voids all previous customizations. To customize only individual units, such as velocity and flow rate units, select the unit type and click Modify. Then, for each unit 2 Defining the Project Basis 79 you wish to change, enter the new unit name and the conversion factor (between the old and new units). Note: In this example, centimeters per hour (CM/H) replaces meters per hour (M/H). A conversion factor of 100 has been entered because 100 CM/H = 1 M/H. For example, if you want to use CM/H (centimeters per hour) instead of M/H (meters per hour) to specify conveyor belt speed in your metric-basis project, enter “CM/H” as the new unit name for M/H. Then, enter the conversion factor between the two units in the Conversion field. In this example, the conversion factor between the two units is 100 because 100 CM/H = 1 M/H. 3 Click OK to accept the modifications and return to the previous dialog box. When finished modifying output units of measure, click Close. Design Basis 80 2 Defining the Project Basis Design Basis defines the general mechanical design rules for the entire project. Aspen Capital Cost Estimator uses built-in, industry-standard design procedures for the preparation of mechanical designs. The standards used include ASME (American Standards), BS5500 (British Standards), JIS (Japanese Standards), DIN (German Standards), or EN 13445 (European Standards). Design Basis influences the way Aspen Capital Cost Estimator evaluates all components of the facility (for example, equipment and bulk items — materials, manpower and indirects) and lets you define custom pipe specifications and custom insulation specs. Aspen Capital Cost Estimator uses default values if Design Basis information is not specified. The default values depend upon the selected country base. You can make one set of Design Basis selections and then override those selections for a particular area. See “Defining Area Specifications” on page 320 for instructions. X X Design Basis specifications are divided into the following categories:  Equipment Specs  Equipment design specifications, including design code for pressure vessels, size limits for shop fab equipment, maximum diameter of vessels fabricated using pipe, maximum horizontal deflection of vessels as a percentage of vessel height, when to apply vessel stress relief (always, never, or when required by code), whether to use welded or seamless tubes for heat exchangers and reboilers, percent of the rotating equipment cost for spare parts, and which equipment to use for heavy lifting (gin poles or cranes). Piping Specs General: Design specifications for all piping. Material: Design specifications for specific piping material. The information entered here lets you redefine default specifications for any system material. For example, if you define a material and later select that material when defining installation piping for a component, your material specifications are used instead of the system default specifications. Custom: Custom piping specifications. These specifications may consist of your company’s standard piping specifications 2 Defining the Project Basis 81 or simply the most commonly used specifications for pipe on the current project. You can have up to 999 custom piping specs. To use custom piping, you have to first select a piping spec file to open. To do so: 1 In the Piping Specs folder, right-click Custom; then click Select on the pop-up menu. Aspen Capital Cost Estimator provides two custom pipe specs files to help you get started:  CARBONST.DAT  DEFAULT.DAT 2 Click the file you want; then click OK. To edit your custom pipe spec file: 1 In the Piping Specs folder, right-click Custom; then click edit on the pop-up menu. The External Custom Pipe Specs dialog box appears. 82 2 Defining the Project Basis The External Custom Pipe Specs dialog box has three options, shown below: o Remarks o Units of Measure o Specifications Remarks dialog box Units of Measure dialog box 2 Defining the Project Basis 83 Specifications dialog box 2 On the External Custom Pipe Specs dialog box, click the dialog box you want to modify; then click Modify. 3 When you have finished modifying your custom piping spec, on the External Custom Pipe Specs dialog box, click Close. (Refer to the flowcharts in Icarus Reference, Chapter 18, for information on developing various aspects of piping.) Click New on the Customer Piping Specs Manager to add a custom pipe specification. You can have a maximum of 100 custom piping specs per project and 600 in one file. After creating a custom piping spec, you must export it to the library, giving it your new name. 84 2 Defining the Project Basis To export the file to the library: 1 In the Piping Specs folder, right-click Custom; then click Export to Library on the pop-up menu. The Duplicate Custom Piping Specs file based on PIPESPEC dialog box appears. 2 In the File Name field, type a file name for this piping spec. You can also add a description of the piping spec in the File Description field. 3 Click OK.  A dialog box appears confirming that you have successfully added your newly-created piping spec to the library. Civil/Steel Specs  Civil and Steel design specifications, including wind data, seismic data, comprehensive strength, concrete ready-mix costs, concrete overpour percentage, rebar type and cost, seal slab thickness, number of formwork reuses, concrete type (standard, higher grade, or chemical-resistant), structure analysis type, unit cost and percent of purchased backfill when used in place of excavated soil, excavation slope ratio, steel finish type (painted or galvanized), and steel galvanizing cost per weight unit. Instrumentation Specs Instrumentation design specifications, including instrumentation type (electronic or pneumatic) and specifications for instrument transmission and thermocouple transmission: control valve type, control valve positioner, 2 Defining the Project Basis 85 control valve position switch, temperature element type, flow element type, instrument transmitter type, distance from component to junction box, whether to exclude air regulators if low pressure air is available, control valve center type (analog, digital, or none), and whether to have a conventional 4-20 mA wired system or a digital Fieldbus system. Unlike a 4-20 mA system in which each instrument in the field requires its own set of wires to run to the local junction box and back to the control center, a Fieldbus system allows multiple instruments to share one set of cables. The Fieldbus systems are designed based on the distances involved (cable length), number of field instruments, instrument type, and power requirements. If you select to use a Fieldbus system, also select, in the Connection Type box, the type of bricks and cable termination. Select “SC” for spring clamp connections. Select “ST” for screw terminal bricks and terminations. Both “SC” and “ST” use standard instrument cable. Select “MP” for a system designed with cable that is pre-cut and molded with pluggable terminations (and bricks with pluggable terminals). “MP” does not require installation hours to connect “pig-tail” terminations – the cables snap onto the bricks. An “MP” implementation requires the purchase of one pluggable device gland per instrument. In an explosion-proof area, the Fieldbus system will consist of bricks and power supply units that are rated for intrinsically safe applications (I.S.-rated non-pluggable components by Hawke International). You can also, if using a Fieldbus system, select to include Fieldbus short-circuit protection for each “spur” in the Fieldbus segments. For 3-drop bricks, the short-circuit protection units are purchased separately; for all bricks of larger size, short-circuit protection is incorporated within the brick itself (if selected). For the Fieldbus system, you can also specify:  Whether the fieldbus has short circuit protection (area or project level)  The percent of active bricks (area level only)  Whether the fieldbus has a backup power supply (area or project level) You can override these project-level instrumentation specs for a particular area when defining an area (see page 320). For X 86 X 2 Defining the Project Basis example, you can select to use a Fieldbus system in the Design Basis, but then make an exception for one area by selecting the conventional 4-20 mA wired system in the area’s instrumentation specs. Fieldbus short-circuit protection can be defined at the project-level or the area-level. Notes:  The percent of active bricks can be specified at the area level only.  When you specify a percent active brick value for the MP connection type, two cost lines are generated: o Bricks with short circuit protection o Bricks without short circuit protection.  For molded pluggable connection types with short circuit protection specified as Y, the brick as a whole has short circuit protection capability.  For Spring clamp/screw terminal connection types with short circuit protection specified as Y, the short circuit protection capability is in the connection between the field devices and the bricks. When you specify a percent active brick value for these two connection types, the following cost lines are generated:  Field bus screw terminal brick (for Screw terminal type) or  Field bus spring clamp brick (for Spring clamp type) and  Field bus short circuit protection (for Spring clamp/Screw terminal type) Effect of Selecting Backup Power Supply Required (General Instrument Specs form):  If you select that no backup power supply is required (the default), the generated report appears as follows, with one Fieldbus item: 2 Defining the Project Basis 87   If you select that backup power supply is required, the generated report appears as follows, with two identical Fieldbus items: Electrical Specs Electrical design specifications, including power supply frequency, class and division or zone, whether to use 3- or 4wire distribution system, voltage levels, wire specifications at the different voltage levels, and cable placement.  Note: When you select the high voltage as 34.5kV (US, ME) / 33kV (UK, EU, JP) in the general electrical specifications, then all the high voltage motors in the project should be powered at the corresponding medium voltage, because all the motors in the system are at the most rated for 15kV (US, ME) / 11kV (UK, EU, JP) only. Insulation Specs Insulation design specifications, including thickness schedule, minimum temperature for hot insulation, equipment insulation type, equipment insulation jacket type, fire resistance rating for fireproofing on skirts, equipment fireproofing type, whether to include fireproofing on the outside or both sides of skirts, steel fire resistance fireproof rating, and steel fireproofing type, coverage, and installation (field or remote shop). You can specify a named insulation library for a project for a particular use. You can specify a named insulation library for an area for a particular use. You can create, duplicate, modify and delete:  Hot Insulation Schedule libraries  Cold Insulation Schedule libraries  Libraries of Insulation Equivalent Length rules You can create any number of Hot Insulation Schedule libraries with one insulation specification table/file. Each library has a name associated to it. You can use 20 Hot Insulation Schedule tables in a project. Hot Insulation Schedule files are named: 88 2 Defining the Project Basis INSHOT##.DAT, where ## is the number (up to 20) of the Hot Insulation Schedule file. You can create any number of Cold Insulation Schedule libraries with one insulation specification table/file. Each library has a name associated to it. You can use ten Cold Insulation Schedule tables in a project. Cold Insulation Schedule files are named: INSCLD##.DAT, where ## is the number (up to 10) of the Cold Insulation Schedule file. You can create any number of Insulation Equivalent Length libraries with one insulation specification table/file. Each library has a name associated to it. You can use one Insulation Equivalent Length table in a project. Example File Format (one Table/File) 2 Defining the Project Basis 89 Example Insulation Equivalent Length Table The Insulation Equivalent Length libraries included in Aspen In-Plant Cost Estimator are named:  Default  INSSPC_BLANK  INSSPC_IP  INSSPC_METRIC You can then specify in the project design basis insulation specifications using either the internal default Hot Light, Medium, or Heavy tables or you can specify a named insulation table to use as the default for all areas. You can then specify in the project design basis insulation specifications either using the internal default Cold table or you can specify a named insulation table to use as the default for all areas. You can then specify for each area Hot and Cold insulation specifications either an internal default table or you can specify a named insulation table to use. To create a new Insulation Thicknesses and Rules Library: 1 On the Palette’s Libraries tab, click Customer External Files. 90 2 Defining the Project Basis 2 On the Customer External Files dialog box, right-click Insulation Thicknesses and Rules. 3 On the dialog box that appears, click New. 4 On the New Insulation Thicknesses and Rules dialog box that appears, enter the name of the new library file and, optionally, a description of the new library file. 5 Click OK. To Modify an Insulation Thicknesses and Rules Library: 1 On the Palette’s Libraries tab, click Customer External Files. 2 On the Customer External Files dialog box, right-click Insulation Thicknesses and Rules. 3 Right-click the library file you want to modify. 4 On the Insulation Thicknesses and Rules dialog box that appears, enter your modifications. 5 Click Modify. To Duplicate an Insulation Thicknesses and Rules Library: 1 On the Palette’s Libraries tab, click Customer External Files. 2 On the Customer External Files dialog box, right-click Insulation Thicknesses and Rules. 3 Right-click the library file you want to duplicate. 4 On the Insulation Thicknesses and Rules dialog box that appears, click Duplicate. 2 Defining the Project Basis 91 The Duplicate Insulation Thicknesses and Rules dialog box appears. 5 In the File Name field, type the name of the file to be a duplicate of the one you are basing the duplicate on. 6 Click OK. A duplicate file is created. To Delete an Insulation Thicknesses and Rules Library: 1 On the Palette’s Libraries tab, click Customer External Files. 2 On the Customer External Files dialog box, right-click Insulation Thicknesses and Rules. 3 Right-click the library you want to delete. 4 A warning appears asking whether you want to delete this library file. Click Yes. The file is deleted. To Create a New Hot or Cold Insulation Schedule File: 1 On the Palette’s Libraries tab, click Customer External Files. 2 On the Customer External Files dialog box, right-click Hot Insulation Schedule or Cold Insulation Schedule. 3 On the menu that appears, click New. 4 On the New [Hot/Cold Insulation Schedules] dialog box that appears, enter the name of the new file and, optionally, a description of the new file. 92 2 Defining the Project Basis 5 Click OK. To modify a Hot or Cold Insulation Schedule Library: 1 On the Palette’s Libraries tab, click Customer External Files. 2 On the Customer External Files dialog box, right-click Hot Insulation Schedule or Cold Insulation Schedule. 3 Right-click the file you want to modify. 4 On the External Insulation Specs dialog box that appears, enter your modifications. 5 Click Modify. To Duplicate a Hot or Cold Insulation Schedule Library: 1 On the Palette’s Libraries tab, click Customer External Files. 2 On the Customer External Files dialog box, right-click Hot Insulation Schedule or Cold Insulation Schedule. 3 Right-click the file you want to duplicate. 4 On the Insulation Thicknesses and Rules dialog box that appears, click Duplicate. The Duplicate Hot/Cold Insulation Schedules file dialog box appears. 5 In the File Name field, type the name of the file to be a duplicate of the one you are basing the duplicate on. 6 Click OK. A duplicate file is created. 2 Defining the Project Basis 93 To Delete a Hot or Cold Insulation Schedule Library: 1 On the Palette’s Libraries tab, click Customer External Files. 2 On the Customer External Files dialog box, right-click Hot Insulation Schedule or Cold Insulation Schedule. 3 Right-click the file you want to delete. 4 A warning appears asking whether you want to delete this library file. Click Yes. The file is deleted. To Use an Insulation Equivalent Length Rules Library in a Project: 1 On the Project Basis tab, click Basis for Capital Costs | Customer External Files. 2 On the Customer External Files folder, click the Insulation External Files folder. 3 On the Insulation External Files folder, right-click Insulation Equivalent Length Rules. The Select an Insulation Thickness and Rules File dialog box appears. 4 On the Select an Insulation Thickness and Rules File dialog box, select the file you want to use in the project. 5 Click OK. To Use a Hot or Cold Insulation File in a Project: 1 On the Project Basis tab, click Basis for Capital Costs | Customer External Files. 2 On the Customer External Files folder, click the Insulation External Files folder. 94 2 Defining the Project Basis 3 On the Insulation External Files folder, right-click Hot/Cold Insulation Schedules. 4 Click Select. The Select Hot/Cold Insulation Specification dialog box appears.  5 Select the insulation specification(s) that you want to include in the project. You can select up to 20 Hot Insulation specifications and up to 10 Cold Insulation specifications. 6 Click OK. The specifications you selected are available in the project. Paint Specs Paint design specifications, including number of primer coats, number of finish coats, and whether painting is performed in field shop or remote shop. To edit Design Basis specifications: 1 Right-click the specification category that you want to define; then click Edit on the pop-up menu. 2 Defining the Project Basis 95 Aspen Capital Cost Estimator displays a specifications form for the selected category in the Main Window. 2 Enter the Design Basis specifications for the selected category. 3 Click OK to add the specifications to the project and close the specifications form. Contingency and Miscellaneous Project Costs Contingency and Miscellaneous Project Costs include material contingency (as a percentage of each contract cost) and miscellaneous special charges for royalties, licenses, land, and so on. To define Contingency and Miscellaneous Project Costs: 1 In the Basis for Capital Costs folder, right-click on Contingency and Misc. Project Costs and then click Edit on the pop-up menu. 96 2 Defining the Project Basis Aspen Capital Cost Estimator displays the cost specifications in the Main Window. 2 Enter the cost specifications. 3 Click OK to add the specifications to the project and close the specifications form. Escalation Escalation provides the ability to incorporate the effects of the constantly changing local and world economies. The Escalation feature lets you specify escalation indices for the following material and labor cost categories:  General materials  Design engineering  Construction manpower  Construction management To define escalation: 1 Right-click Escalation in the Basis for Capital Costs folder; then click Edit. Aspen Capital Cost Estimator displays the Escalation Specs dialog box in the Main Window. 2 Defining the Project Basis 97 2 In the Escalation Method field, you can choose one of two ways for reporting escalated costs: Click to SPREAD Define escalation to be included in all reported costs. ACCUM Define escalation to be segregated from all costs and to be accumulated (into each of the four categories above) for summary reporting, and with costs to be reported at a user-defined condition. Note: The system base indices are published in Icarus Reference. All user-entered costs (quoted cost items, quoted equipment costs, library items, material/labor lump sum additions, project indirects, and so on) are assumed to be valid at the user base time point. This may be a corporate-standard time point chosen as a basis for all projects. Three indices are used to develop escalated costs: o System Base Indices (SBI): System-defined indices that represent costs inherent to the particular version of the system. o User Base Indices (UBI): User-entered indices that reference user-entered cost values. All systemdeveloped costs (developed at SBI) are adjusted to UBI by multiplying the ratio (UBI/SBI). o Escalation Indices (EI): User-entered indices that escalate all costs (both user-entered and systemgenerated) from the user base (UBI) to some other 98 2 Defining the Project Basis point in time. This is done by multiplying all costs by the ratio (EI/UBI). 3 Enter or revise your specifications. 4 Click OK to apply your specifications to the project and close the specifications form. Engineering Workforce Aspen Capital Cost Estimator lets you define up to nine engineering workforces. For each engineering workforce, you can specify:  a percentage adjustment to the base (default) wage rates by engineering phase.  the exact wage rate of any discipline, replacing the base wage rate (as well as any percentage adjustments to the base). Icarus Reference, Chapter 31, lists engineering disciplines and their base wage rates. The disciplines are grouped by phase and assigned numbers. In addition to specifying engineering wage rates, you can specify:  engineering hours (by phase or discipline) and  engineering costs (either as lump sums or as percentages of total costs) Once defined, an engineering workforce can be linked to one or more contractors. If no workforce is specified, contractors use the default engineering workforce. Engineering Phase To define an engineering workforce by phase: 1 In the Engineering Workforce sub-folder, right-click By Phase; then on the menu that appears, click Edit. 2 Defining the Project Basis 99 The Engineering Phase Info dialog box appears in the Main Window. In defining a workforce, use one item column per engineering phase. A single item column (Item 1) is provided. Add more columns using the Add button . 2 Specify the engineering workforce number. 3 Select an engineering phase. The choices are: * All phases B Basic engineering D Detail engineering P Procurement H Home office construction services F Field office supervision S Startup, commissioning 100 2 Defining the Project Basis E Engineering management C Construction management Phases E and C are for multi-contract projects only. 4 To replace system-calculated hours and/or costs for the selected phase, enter engineering hours and/or engineering costs. 5 To increase or decrease wages for all disciplines under the selected phase, enter the percentage of the base wage rate. For example, entering “200” would double the wage rates; entering “50” would cut wage rates in half. 6 If desired, enter the payroll burden, indirects, and expenses for the selected phase, either as lump sums or as percentages of the total manpower cost. If you want to define additional phases, click Add and complete the process (steps 2 through 6). Note: In the form pictured here, Items 1 and 2 each define a phase for Engineering Workforce Number 1. Item 1 defines Basic Engineering (B). It sets the manhours at five percent over those calculated by the system (expressed as 105% of the calculated hours). It sets wages for all disciplines under Basic Engineering at ten percent above the base (expressed as 110% of the base wage rate). Item 2 defines Detailed Engineering, setting the wages for all disciplines under Detailed Engineering (D) at five percent below the base (expressed as 95% of the base wage rate). 2 Defining the Project Basis 101 7 Click OK to include the entered information in the project specifications and close the specifications form. Engineering Discipline Defining an engineering workforce by discipline lets you replace base (default) wage rates and/or system-calculated hours. To define an engineering workforce by discipline: 1 In the Engineering Workforce sub-folder, right-click on By Discipline and click Edit on the pop-up. Aspen Capital Cost Estimator displays the Engineering Discipline Info dialog box in the Main Window. 102 2 Defining the Project Basis A single item column defines up to four disciplines under a single phase. One item column (Item 1) is provided. Add more columns using the Add button . 2 Enter an engineering workforce number. 3 Select an engineering phase. 4 Enter the number of an engineering discipline under the selected phase. A list of discipline numbers and wage rates, grouped by phase, is provided in Chapter 34 of your Icarus Reference. 5 To replace the base wage rate for this discipline, as well as any adjustments to the base wage rate made on the Engineering Phase Info form, enter a new discipline wage rate. 6 To replace or adjust the system-calculated hours for this discipline, either enter discipline hours or enter a percentage adjustment. 7 Space is provided for defining up to three more disciplines under this phase. To define beyond three additional disciplines or to define disciplines under another phase, click Add and repeat the process (steps 2 through 7). Note: Item 1 defines two disciplines under Basic Engineering (phase B) for Engineering Workforce Number 1. It does the following: Sets Engineering Workforce Number 1‘s wage rate for process engineering (discipline number 02) performed in the Basic Engineering phase at $42.00 and increases by ten percent the system-calculated hours for this discipline. Sets Engineering Workforce Number 1‘s wage rate for instrument design (discipline number 04) performed in the Basic Engineering phase at $39.20. 2 Defining the Project Basis 103 8 When you are finished, click OK to save the specifications and close the form. Drawing Types and Counts Aspen Capital Cost Estimator lets you account for additional drawings that may need to be produced during the Basic Engineering and Detailed Engineering phases. To add a drawing type: 1 In the Engineering Workforce sub-folder, right-click on Drawing Types and click Edit on the pop-up. Aspen Capital Cost Estimator displays the Drawing Type Info dialog box in the Main window. 104 2 Defining the Project Basis 2 Select either Basic or Detailed as the engineering phase. 3 Enter either an existing drawing number (see Icarus Reference, Chapter 31, for drawing types and numbers) or enter a new drawing number in the range of 91-99. 4 Enter the title of the new drawing to be used in reports. 5 If you entered a new drawing number, select a drawing class account. For example, select P (piping account) for a piping model drawing. 6 If you entered a new drawing number, select a drawing class discipline. For example, select 4 (model building) for a piping model drawing. 7 If you entered a new drawing number, enter the total manhours required to produce the drawing. 8 Click OK to save specifications and close the form. To specify quantity of a drawing type: 1 In the Engineering Workforce sub-folder, right-click on Drawing Count and click Edit on the pop-up. 2 Defining the Project Basis 105 Aspen Capital Cost Estimator displays the Drawing Count Info form in the Main window. 2 Select either Basic or Detailed as the engineering phase. 3 Enter a drawing number. 4 Enter the number of the contractor to which the drawing is assigned. 5 Use the Action Code field to select whether to ADD to the calculated number of drawings, ADD new drawings (number 91-99), or CHANGE the calculated number of drawings. Note: The CHANGE option is not allowed for drawing numbers 91-99. 6 Depending on whether you chose ADD or CHANGE as the Action Code, enter the number of drawings to add to the system-calculated quantity or the number with which to replace the system-calculated quantity. If you selected CHANGE, you have the option to instead enter a percentage adjustment in the Percent of Calculated Drawings field. 7 To change manhours to reflect the changed drawing count, select “A” in the Labor Adjustment Selection field. If you want to adjust the count of a system developed drawing and also want to change engineering manhours to reflect the changed drawing count, DO NOT use the Action code ADD; always use the Action code CHANGE and Percent of calculated drawings for adjustments. 8 Click OK to save the specifications and close the form. 106 2 Defining the Project Basis Construction Workforce Aspen Capital Cost Estimator lets you define construction workforces, which you can then link to contractors (see page 142). For each construction workforce, you can specify wage rates (globally or by craft), workweek, productivities, overtime, and crew mixes. You can also make modifications to craft names, which apply to all construction workforces. X X If no construction workforce is defined, contractors use the default construction workforce. General Rates The General Wage Rates information defines wage rates, productivities, workweek, and overtime for all crafts in a construction workforce. To access, right-click Wage Rates in the Construction Workforce subfolder; then click Edit. 2 Defining the Project Basis 107 Aspen Capital Cost Estimator displays the General Wage Rate/Productivity specifications form in the Main window. In the column labeled Item 1, you can define your first construction workforce. To define additional construction workforces, click Add. Descriptions of the specifications follow. 108 Field Description Construction workforce number Number representing the workforce being defined. 2 Defining the Project Basis Field Description Number of shifts Number of shifts used during construction. If any premium pay is involved with second and third shift work (beyond overtime pay), such premium should be indicated by a properly averaged craft rate per shift. Specifies whether to use multi-shift /workweek adjustments or not. Productivity adjustment Indirects If wage rates are to be treated as all-inclusive, the indirects may be deleted for this workforce by specifying “-”. Selecting an all-in rate suppresses all construction indirects: fringes, burdens, small tools, construction rental equipment, and so on ALL CRAFTS PERCENT OF BASE Workforce reference base Enter B for system base. Wage Rate percent of base Wage rates for all crafts as a percentage of reference base wage rates. Productivity percent of base Productivities for all crafts as a percentage of reference base wage rates. ALL CRAFTS FIXED RATES Wage rate all crafts Specifies the fixed wage rate (in the project currency) for all crafts in the workforce. See discussion in Icarus Reference. Productivity all crafts Specifies the fixed productivity value for all crafts in this workforce. See discussion in Icarus Reference. If no value is specified, the system defaults to 100%. WORK WEEK PER SHIFT Refer to the description of workforces in Icarus Reference for the effect of changing the work week and number of shifts upon productivity and job duration. The standard workweek plus overtime must not exceed 84 hours per week per shift. Standard work week Specifies number of standard hours per week per man per shift. Overtime Specifies number of overtime hours per week per man per shift. Overtime rate percent standard Specifies overtime pay expressed as a percentage of standard pay (for example, time and one half = 150%). GENERAL CRAFT WAGES UK Base only. Specifies wage rate for craft 2 Defining the Project Basis 109 Field Description help as a fixed rate to be used in all crews. UK Base only. Specifies the wage rate for craft help as a percent of the principal craft in the crew. This value must be less than 100%. Specifies the wage rate for foremen as a fixed rate to be used in all crews. Default: 110% of rate of highest paid craft in crew. Specifies the wage rate for foreman as a percent of the highest paid craft in crew. This value must be greater than or equal to 100%. Default: 110% of rate of highest paid craft in crew. Craft Wage Rates Craft Rates set the wage rate and productivity individually for each craft. Note: Right-click the red arrow to define craft rates for a construction workforce. You can define up to 99 separate construction workforces. Craft Rates Craft Rates set the wage rate and productivity individually for each craft. To access Craft Rates: 1 In the Construction Workforce subfolder, click Construction Workforce | Wage Rates. 2 On the General Wage Rate/Productivity dialog box that appears, right-click the red arrow in the Craft Wage Rates field, as shown below. 110 2 Defining the Project Basis Aspen Capital Cost Estimator displays the Craft Wage Rate/Productivity dialog box. 2 Defining the Project Basis 111 Use these fields to set the wage rate and productivity individually for each craft in a workforce. Field Description Craft code Identifies the craft to which the following wage rate and productivity apply. The craft code must be an existing system craft code. 112 Craft Wage rate Specifies the wage rate (in the project currency) for this craft for standard hours. Productivity Specifies the productivity of this craft as a percentage of the system’s base. (See discussion in Icarus Reference.) 2 Defining the Project Basis To Add a Construction Workforce:  On the General Wage Rate/Productivity dialog box, click Add. A new construction workforce column appears to the right of the current construction workforce. To Delete a Construction Workforce: 1 On the General Wage Rate/Productivity dialog box, highlight one or more columns to delete. 2 Click Delete. 3 When prompted as to whether you want to delete the column(s), click Yes. Aspen Capital Cost Estimator deletes the column(s) you highlighted. Note: If you do not highlight a column and perform a delete, the right-most column is deleted. To Copy Craft Wage Rate/Productivity Information to an Excel Spreadsheet: 1 On the Craft Wage Rate/Productivity Information dialog box, click CopyAll. 2 Navigate to the Excel spreadsheet to which you want to copy the information. 3 Click CTRL-V. The information is pasted into the spreadsheet. Crew Mixes Use the Crew Mixes specifications form to allocate a percentage of man-hours from one craft to another for the purpose of modifying crew mixes. To modify crew mixes: 1 in the Construction Workforce subfolder, right-click Crew Mixes. 2 On the menu that appears, click Edit. Aspen Capital Cost Estimator displays the Wage Mixture Info form in the Main window. 2 Defining the Project Basis 113 For each item, you can make up to seven different re-allocations of man-hours. To add a new item: Click Add. 3 Enter the number of the Construction Workforce to which the modification applies. 4 In the From Craft Code column, enter the craft code of the craft that will lose man-hours. Note: See Icarus Reference, Chapter 30, for craft codes. 5 In the To Craft Code column, enter the craft code of the craft that will gain man-hours. 6 In the Craft Transfer Percent column, enter percentage of man-hours to be re-allocated. 7 Click OK to save the modifications and close the form. -orClick Cancel to close the form without saving modifications. Craft Names Aspen Capital Cost Estimator lets you modify the default craft names, which are listed in Chapter 30 of Icarus Reference. To modify craft names: 1 Right-click on Craft Names in the Construction Workforce subfolder. 2 On the menu that appears, click Edit. Aspen Capital Cost Estimator displays the Wage Name Info form in the Main window. 114 2 Defining the Project Basis For each item, you can make up to three name changes. To add a new item, click Add. 3 In the Craft Code column, enter the craft code of the craft you are re-naming. Craft Codes are listed in Icarus Reference, Chapter 30. 4 In the Craft Name column, enter the craft’s new name. 5 Click OK to save the modifications and close the form. Code of Accounts Aspen Capital Cost Estimator contains a base set of 3-digit Code of Accounts (COA) to which costs and man-hours are allocated. See Icarus Reference, Chapter 34, for a detailed Icarus COA list. Aspen Capital Cost Estimator lets you add your own COA’s and re-allocate costs from Icarus COA’s to your new COA’s. When you completely re-define your COA’s, you must also define and allocate all indirect COA’s. First, you must select the COA file. To select a COA file: 1 Right-click on Code of Accounts in the Basis for Capital Costs folder, and then click Select on the pop-up menu. Aspen Capital Cost Estimator provides the file named DEFAULT. After selecting this file, you can modify it and save it as another file. You can then have multiple COA sets from which to choose. 2 Defining the Project Basis 115 2 Select the file and click OK. Adding a COA Set and Allocating Costs The following instructions provide an example COA set for you to add. The instructions will then show you how to allocate material and labor costs to the new COA set. To add a COA set: 1 Right-click Code of Accounts in the Basis for Capital Costs folder; then click Edit on the pop-up menu. The Code of Accounts dialog box appears. 2 Click Definitions; then click Modify. 116 2 Defining the Project Basis The Code of account definition dialog box appears. 3 Click Add. A new item (in this example, Item 501, is added at the bottom of the grid. 4 For the new item, enter an account number, select a COA group, and enter a description (all in upper-case). 5 Repeat this step for each new COA in the set. Example set: COA COA Group Description 1000 EQ ALL CATEGORY A EQUIPMENT 2000 EQ ALL CATEGORY B EQUIPMENT 3000 P ALL PIPING 4000 C ALL CIVIL 2 Defining the Project Basis 117 5000 ST ALL STEEL 6000 I ALL INSTRUMENTATION 7000 E ALL ELECTRICAL 8000 IN ALL INSULATION 9000 PT ALL PAINT 6 When you are finished adding COA’s, click OK. To re-allocate costs from Icarus COA’s to your new COA’s: 1 In the Code of Accounts dialog box, double-click Allocations. The Code of account allocation dialog box appears. 2 In the Code of account allocation dialog box, enter an Icarus COA or range of Icarus COA’s (using the From Icarus 118 2 Defining the Project Basis COA and To Icarus COA fields) and then enter the new COA to which you want to allocate the Icarus COA’s material and labor. Entering a COA only in the Alloc to Icarus/ User Matl COA field allocates both material and labor to the COA entered in the Material field. You could allocate material to one COA and labor to another. 3 Click OK when you are finished making the entry, and then continue to allocate each Icarus COA or range of Icarus COA’s to one of the new COA’s. Example set: From To Material 100 199 1000 200 299 2000 300 399 3000 400 499 4000 500 599 5000 600 699 6000 700 799 7000 800 899 8000 900 999 9000 Specifying Exceptions to Account Allocations After you have defined the account allocations, you may choose to specify exceptions to these new allocations. Example: We have allocated the costs of all piping — Icarus COA’s 300-399 — to COA 3000. However, we wish to allocate the material costs of 6-8 INCH 304P Pipe to a new account, COA 3201, and we wish to allocate the labor costs of 6-8 INCH 304P Pipe to another new account, COA 3202. To specify the exceptions in the above example: 1 First, create COA 3201, type P, with the description MATL SS PIPE 6-18 INCH and create COA 3202, type P, with the description MATL SS PIPE 6-18 INCH. 2 Identify in Icarus Reference, Chapter 34, “Code of Accounts,” which range of Icarus COA’s to allocate to 3201 and 3202. In this case, it is COA’s 320 to 327, representing stainless steel pipe. 2 Defining the Project Basis 119 3 Click in a cell above which you want to add the new item, then click Insert. 4 Enter “320” in the From Icarus COA field and “327” in the To Icarus COA field. Enter “3201” in the Alloc to Icarus/ User matl COA field and enter “3202” in the Alloc to Icarus/ User labor COA field. 5 In the COA exception flag field, from the drop-down select E (Allow account exception) 6 In the Material selection field, enter “304P” as the Material. Note: Icarus Reference, Chapter 28, “Material Selections,” provides the symbols for stainless steel and other materials. Many stainless steels are available. This example is limited to 304P for brevity. 7 In the Pipe diameter – lower limit field, enter “6.” In the Pipe diameter – upper limit field, enter “18.” 8 Make sure that I (Inch-Pound) is selected in the Pipe dia. units of measure field. Note: COA Modifier and Subtype let you be more specific about the items you want allocated to a new COA. They are described in Icarus Reference, Chapter 35, “Database Relations”. 9 Click OK. This moves all material costs for all 6-18 INCH 304P pipe, fittings, and valves to COA 3201 and all labor costs for these items to COA 3202. 10When you are finished, review the Account Allocation order to see that the accounts are in the correct order. Then click OK to save your work and exit the COA code of account allocation dialog box. Overriding Code of Accounts at the Component Level You can override a Code of Account for a specific component. To Override a Code of Account for a specific component: 1 In a project, on the Project View tab, right-click the component whose Code of Account you want to change. 2 On the menu that appears, click Modify Item. The Equipment Spec sheet appears. 120 2 Defining the Project Basis 3 On the Equipment Spec sheet, left-click the red arrow in the Code of account field. The Slot Template dialog box appears. 4 On the Slot Template dialog box, click Select. The Equipment COA Selection dialog box appears. 2 Defining the Project Basis 121 5 On the Equipment COA Selection dialog box, scroll to the Equipment and COA you want to assign to your equipment; then click Select. The Equipment Spec sheet reappears with the COA you selected in the Code of Account field. Choosing between the Icarus Code of Accounts and User Code of Accounts at the Component Level To specify whether an equipment unit should use the Icarus Code of Accounts or the User Code of Accounts: 1 In a project, on the Project View tab, right-click the component whose Code of Account you want to change. 2 On the menu that appears, click Modify Item. The Equipment Spec sheet appears. 3 On the Equipment Spec sheet, in the Icarus/User COA Option field, click the drop-down arrow. 4 Click the appropriate COA option. Indexing The Material and Man-hour specification forms in the Indexing folder let you manipulate the material and/or manhour costs for process equipment and installation bulks. You can also adjust these indexes by location by using the Location specification form. For example, you could specify to increase the material costs associated with a type of process equipment. Indexing is used to tailor Aspen Capital Cost Estimator to mimic your work methods and costs. If your equipment costs for a category are consistently offset from Aspen Capital Cost Estimator’s values, use Indexing to correct that. When calibrating a new cost basis, you can update an existing Project Level Indexing file into a new one. In this case the old and new Project Level Indexing will not be different but will be direct replacements. 122 2 Defining the Project Basis Material, Manhour, and Location indices are externalized to a single external file. You can select an external indexing file at the project level, edit it, and use the local file in a project. At the area level, you can edit the indexing, but you cannot choose another external indexing file. The evaluation engine uses indices from the external file for project evaluation. Adjusting Indexes To adjust the Material or Man-hour index: 1 Right-click Material or Man-hour and click Edit. 2 To adjust the index for all equipment or for all of one of the installation bulks, enter the index value in the box provided. For example, entering “200” in the Equipment box will double the material costs for all items under the equipment account group. To adjust the index for a sub-category, click the arrow-button in the box. This accesses a similar form listing sub-categories corresponding to the Code of Accounts (see Icarus Reference, Chapter 34, for a complete list). Adjustments to a sub-category over-ride adjustments to the account-group. 3 Click OK to close the form and apply changes. 2 Defining the Project Basis 123 To adjust by location: 1 Right-click on Location and click Edit. 2 Type the location description. 3 Type the Code of Account (COA) to indicate the start of the COA range, or click the red arrow; then click Select by the subcategory on the COA Subcategory Selection window. 124 2 Defining the Project Basis The Equipment COA Selection dialog box appears. 4 Click Select again by the COA. The COA is entered on the form. 5 Do the same to indicate the end of the COA range. 6 Type the amount to escalate material costs and/or the amount to escalate man-hour costs. 7 To escalate another range, click Add. 8 Click OK to close the form and apply changes. Editing an Index file inside a project To edit an Index inside a project: 1 In Project Basis view, right-click Indexing. 2 Click Select. 2 Defining the Project Basis 125 The Indexing dialog box appears with three options (Material, Man Hour, and Location.) 3 Click the type of index you want to edit; then click Modify. 4 Edit the index; then click OK. Deleting an Index File 1 In Project Basis view, right-click Indexing. 2 Click Select. A list of the available index files appears. 3 Click the type of index you want to delete; then click OK. 126 2 Defining the Project Basis The Index file is loaded. 4 In the Project Basis view, right-click Indexing. 5 Click Remove Selection. A warning message appears telling you that the specifications file will be deleted. 6 If you want to remove the Index file you selected, click Yes. Adding Modified Index Files to the Library To add a modified index file to the library: 1 In Project Basis view, right-click Indexing. 2 Click Select. The Indexing dialog box appears with three options (Material, Man Hour, and Location.) 3 4 5 6 Click the type of index you want to edit; then click Modify. Edit the index; then click OK. In Project Basis view, right-click Indexing. On the menu that appears, click Export to Library. 2 Defining the Project Basis 127 A warning message telling you that the current COA specifications must also be exported appears. 7 Click OK. The Duplicate Code of Accounts file based on Indexing ndexing dialog box appears. 8 On the Duplicate Code of Accounts file based on Indexing dialog box, ttype a file name (required) and description (optional) for the new file file. 9 Click OK. A message appears indicating the new indexing file was successfully cr created eated in the Library. The new indexing file appears in the Palette window under Indexing. Modifying an empty Indexing file outside the project 1 Launch Aspen Capital Cost Estimator without any project open. 2 In Palette view, click the Libraries tab. 3 On the Librraries tab, expand the Indexing Library folder. 4 Double-click click EMPTY to open the Indexing dialog box. box 128 2 Defining the Project Basis The Indexing dialog box appears displaying four options. 5 Right-click COA file; on the menu that appears, click Modify. The Select a Code of Account File dialog box appears. 6 In the Code of Account Files list, click DEFAULT COA file as the Indexing COA. 7 In the Indexing dialog box that appears, click one of the following: Material Man Hour Location All indices are initialized to 100%. You can modify the indices to your specifications. 8 When you have modified the index or indices, save the external file. Equipment Rental Aspen Capital Cost Estimator automatically develops rental equipment durations and costs based on your project work items. You may adjust or delete these items and/or add your own to more accurately reflect the project. 2 Defining the Project Basis 129 Adjusting and Deleting System Items To adjust or delete system equipment rental items: 1 In the Basis for Capital Costs folder, right-click on Equipment Rental, then, on the menu that appears, click Edit on the pop-up menu. Aspen Capital Cost Estimator displays the Equipment Rental Info specifications form in the Main Window. A column for the first rental item, labeled Item 1, is provided. If you need to add a column, click Add. 2 Enter an item description and rental equipment number. See Icarus Reference, Chapter 32, for a complete list of construction equipment and associated equipment numbers. 3 Click a Rental Action Code. Click to ADD Add days to the rental item’s Rental Days Required. You cannot use this option to adjust Monthly Rental Rate. CHANGE Replace the rental item’s Rental Days Required and/or the Monthly Rental Rate. DELETE Delete the rental item. Note: To change an existing item’s rental rate, you must select CHANGE. 4 In the Rental Days Required field, depending on the action code, either enter the number of days to add (action code is ADD) or the total number of days (action code is CHANGE). 5 If you’ve selected the CHANGE action code, you can enter a new rate in the Monthly Rate field or leave it blank to use the system’s default rate. You cannot adjust an existing item’s monthly rate using the ADD action code. 130 2 Defining the Project Basis Here, the number of days required for Item 1, DUMP TRUCK, is being changed to 5, and its monthly rate is being changed to $6,500. Two days are being added to the days required for Item 2, CRANE. 6 Click OK to save the specifications and close the specifications form. Entering New Rental Items Aspen Capital Cost Estimator provides empty slots in every equipment class for user-entered equipment items. Any that you enter are added to those that Aspen Capital Cost Estimator develops based on your project work items. To enter a new rental item: 1 In the Basis for Capital Costs folder, right-click on Equipment Rental and then click Edit on the pop-up menu. Aspen Capital Cost Estimator displays the equipment rental specifications form in the Main Window. A column for the first rental item, labeled Item 1, is provided. If you need to add a column, click Add. 2 Enter an item description. The first 20 characters will appear in the Description column on the Equipment Rental Summary report. The next 16 characters will appear in the size column on the Equipment Rental Summary report. Note: The Equipment Rental Summary report is not available for Aspen Capital Cost Estimator. However, while the detail description will not appear in any report at this time, the cost of the item will be included in the equipment rental cost total provided on the Project Indirect Summary report. 3 Enter an equipment number. Numbers 1-20 are for the equipment class AUTOMOTIVE. All other numbers will share 2 Defining the Project Basis 131 4 5 6 7 the equipment class of the equipment number before it. For example, an item assigned equipment number 79 would be classified EARTHMOVING because that is the equipment class of equipment number 78. Each equipment class includes unused numbers for user-entries. Refer to Icarus Reference, Chapter 32, for a complete list of construction equipment and associated equipment numbers. Click Add as the Rental Action Code. Enter the Rental Days Required. Enter the Monthly Rate. Click OK to save the specifications and close the specifications form. Systems Use the features of the Systems tree diagrams to define, track, and revise power distribution and process control networks. Power Distribution The Power Distribution tree diagram lets you define the electrical configuration and loads in areas and process control centers. You can specify:  the quantity and size of transmission line(s)  main and unit substation(s)  the degree of redundancy  the type and method of placement of distribution cable The Power Distribution specifications work in conjunction with the electrical specifications at the project and area levels. Most users define the distribution configuration (for example, which main substation is to feed which “downstream” unit substation) and cable placement. Aspen Capital Cost Estimator then sizes the items to satisfy the start-up and running electrical loads (drivers, lighting, tracing, and so on) always heading “upstream.” 132 2 Defining the Project Basis To define power distribution: 1 In the Systems subfolder, right-click on Power Distribution and then click Edit on the pop-up. Aspen Capital Cost Estimator displays the Power Distribution tree in the Main window. New projects include one default main substation feeding a default unit substation. The main substation is assumed to be an existing one, so no electrical bulk quantities will be generated for it. If the electrical bulk quantities are required in the estimate, you should change the input parameters for this default main substation. All newly added and imported areas, and newly added process control items, are automatically linked to the default unit substation. 2 Use the tree diagram to define the power distribution network. A description of the tree diagram actions follows. Adding Power Distribution Items Power distribution items include:  Transmission lines  Main substations  Unit substations Power distribution items are sized and cost estimated based on information provided with the project design basis, power distribution specifications, area specifications, and the list of equipment and bulk items requiring electrical power. To add a power distribution item: 1 Select an item in the tree diagram. The added power distribution item is added to the tree diagram under the select item. 2 Defining the Project Basis 133 To add Do this Transmission line Select the “Project” item. Main substation Select the “Project” or a transmission line item. Unit substation Select the “Project,” a transmission line, a main substation, or a unit substation item. 2 Right-click on the item and, depending on the item selected, click: Add Transmission Line –or– Add Main Substation –or– Add Unit Substation A dialog box appears in which to enter a name for the item. 3 Enter a name and click OK. Aspen Capital Cost Estimator displays the specifications form for the new item. 4 Enter the specifications; then click OK. 134 2 Defining the Project Basis Adding Links to Areas You can link a unit substation to an area (or multiple areas), making it the power source for load centers in the specified area(s). To add a link to an area: 1 Right-click on the unit substation in the tree diagram and click Link Area on the pop-up menu. Aspen Capital Cost Estimator displays the Link to Area dialog box. 2 Select an unlinked area and click OK. On the tree diagram, the linked area is shown under the unit substation. Adding Links to Control Systems You can link a unit substation to a process control system (or multiple systems). To add a link to a process control system: 1 Right-click on the unit substation and click Link Control System on the pop-up menu. 2 Select an unlinked control system and click OK. On the tree diagram, the linked control system is shown under the unit substation. 2 Defining the Project Basis 135 To unlink a control system:  Right-click on the control system in the tree diagram; then click Unlink on the pop-up menu. Unlinking The Unlink command lets you disconnect an area or process control item from a unit substation: To unlink an area from a process control item:  In the tree diagram, right-click on the area you want to delete; then, on the menu that appears, click Unlink. Deleting Power Distribution Items Should power distribution network specifications for the project change, or when you want to explore alternatives, it may be necessary to delete previously defined power distribution items (transmission lines, main substations, unit substations). To delete a power distribution item: 1 In the tree diagram, right-click on the item you want to delete. 2 Click Delete. Aspen Capital Cost Estimator displays a confirmation dialog box. 3 Click Yes to confirm the deletion. Process Control If you do not enter Process Control specifications, Aspen Capital Cost Estimator assumes that process control is provided to all areas by a default digital control system consisting of a digital control center reporting to an operator center. The control and operator centers are automatically sized to meet requirements. 136 2 Defining the Project Basis You can define a process control network using the Process Control tree diagram. The tree diagram items represent the process control network, consisting of:  Operator centers (digital only)  Control centers (digital or analog)  Programmable Logic Control (PLC) Centers  Specialty (SPC) centers Use the tree diagram to define the network from the top down. Reporting to the “Project” item, you may add operator centers, control centers, or PLCs. Control centers may report to operator centers. Digital, analog, and PLC control centers may be mixed within the same project. When a project estimate is run, Aspen Capital Cost Estimator sizes all process control items and reports their sizes, ratings, and installation details at the end of the report for the last area. Details on field instrumentation and final control elements with their associated air supply details are reported on a component basis. Details for area junction boxes, cable trays, and so on are reported on an area basis. To define process control: 1 In the Systems folder, right-click Process Control; then, on the menu that appears, click Edit The Process Control tree diagram appears, displaying the process control network. 2 Use the tree diagram to define the desired process control network and its reporting structure. A description of the tree diagram actions follows. Adding Process Control Items Process control items include:  Operator centers 2 Defining the Project Basis 137    Control centers PLC centers. Specialty centers To add a process control item: 1 Select an item in the tree diagram. The new process control item will be placed under the selected item. To add Do this Operator center Select the “Project” item. Control center Select the “Project” item (for analog or digital) or an operator center item (for digital). PLC center Select the “Project” item or operator center. Specialty center Select the “Project” item or operator center. 2 Right-click on the item and, depending on the item being added, click one of the following on the pop-up menu: Add Operator Center Add Control Center Add PLC Center Add SPC Center (Specialty center) A dialog box appears in which to enter a name for the item. 3 Type the name of the item and click OK. The item is added to the tree diagram. 4 To edit the item’s specifications, right-click on the item and click Edit on the pop-up menu. 138 2 Defining the Project Basis 5 Click OK to save the specifications. Adding Links to Areas You can link control centers, PLC centers, and SPC centers to areas. A center serves instrumentation within the area(s) to which it is linked. To add a link to an area: 1 Right-click the item in the tree diagram; then, on the menu that appears, Link Area. Aspen Capital Cost Estimator displays the Link to Area dialog box. 2 Click an unlinked area; then click OK. 2 Defining the Project Basis 139 On the tree diagram, the linked area is shown under the selected process control item. Unlinking The Unlink option lets you disconnect an area from a process control item. To unlink an area from a process control item: 1 In the tree diagram, right-click the area you want to delink. 2 On the menu that appears, click Unlink. Deleting Process Control Items As the specifications for the project scenario change, or when you want to explore alternatives, it may be necessary to delete process control items (operator centers, control centers, PLC centers, and SPC centers). To delete a process control item: 1 In the tree diagram, right-click the item you want to delete. 2 Click Delete. Aspen Capital Cost Estimator displays a confirmation dialog box. 3 Click Yes to confirm deletion. Contracts The tree diagrams in the Contracts folder let you define responsibility and assign scope of effort to contractors for engineering, procurement, and construction. There are two tree-diagrams: 140 2 Defining the Project Basis   Contractors: Use to specify each contractor’s indirect cost structure and establish the responsibility of one contractor to another for cost reporting. In addition, engineering and construction workforce characteristics can be assigned to each contractor. Scope: Use to specify sets of contractors and assign scope of work to each contractor in each set. Contractors To access the Contractors tree diagram:  In the Contracts subfolder, right-click Contractors; then, on the menu that appears, click Edit. Aspen Capital Cost Estimator displays the Contractors tree diagram in the Main window. Aspen Capital Cost Estimator comes set up with one default contractor with the name Owner. From the pop-up menu accessed by right-clicking on an item in the tree diagram, you can:  Add contractors  Link contractors to workforces  Edit contractor definitions  Delete contractors  Close the tree diagram Descriptions of these actions follow. 2 Defining the Project Basis 141 Adding a Contractor To add a contractor: 1 In the tree diagram, right-click Owner; then, on the menu that appears, click Add Contractor. Aspen Capital Cost Estimator displays the Add a New Contractor dialog box. 2 Type the name of the contractor and click OK. Adding Links to Workforces Workforces are defined in the Project Basis view’s Engineering Workforce folder (page 99) and the Construction Workforce folder (page 107). Once you have defined workforces, you can link contractors to them. X X X X To link a contractor to a workforce: 1 Right-click on the contractor in the tree diagram and, depending on the type of workforce you wish to add, click: Link to Constr. Work Force –or– Link to Engg. Work Force Aspen Capital Cost Estimator displays a dialog box listing workforces by number. 142 2 Defining the Project Basis 2 Click the number representing the desired workforce and click OK. In the tree diagram, the workforce appears under the contractor. Unlinking The Unlink command lets you disconnect a workforce from a contractor. To unlink a workforce from a contractor:  Right-click on the workforce in the tree diagram and click Unlink on the pop-up menu. Editing Contractor Definitions To edit a contractor definition: 1 Right-click the contractor in the tree diagram; then, on the menu that appears, click Edit. 2 Defining the Project Basis 143 2 Type or revise specifications on the Contract Definition dialog box. 3 Click OK to save and close. Deleting a Contractor To delete a contractor: 1 Right-click the item in the tree diagram; then, on the menu that appears, click Delete. 144 2 Defining the Project Basis You are prompted to confirm deletion of the contractor from workforce link. 2 Click Yes. Scope Use the Scope tree diagram to specify contractor sets and assign scope of work to each contractor in each set. To access the Scope tree diagram:  In the Contracts subfolder, right-click Scope; then click Edit. Aspen Capital Cost Estimator displays the tree diagram in the Main window. Note: All areas (whether added or imported), power distribution items, and process control items are automatically linked to the default contract set until otherwise specified. 2 Defining the Project Basis 145 Adding Contractor Sets A contractor set (Conset) is a subset of all contractors defined in a project. A contractor joins a Conset when it is assigned responsibility for categories of work. To add a Conset: 1 Right-click Project in the tree diagram; then, on the menu that appears, click Add Conset. 146 2 Defining the Project Basis Aspen Capital Cost Estimator displays the Contract Scope specifications form. 2 Use the Scope Description field to describe the responsibilities for the Conset (for example, All Engineering, Above Ground Mechanical, Substations). 3 To assign a contractor to a category of work, click the drop-down arrow in the category field and select a contractor number. 4 Click OK to apply the specifications to the project and close the specifications form. The newly added Conset will appear in the tree diagram. Adding Links The Link commands allow you to assign each contractor set responsibility for the scope of work in a segment of the project. To link an item to a contractor set: 1 Right-click a Conset in the tree diagram and click one of the following commands on the pop-up menu that appears: Click To do this Link Area Link a previously defined area to the selected contractor set. Link to Power Distribution Link a previously defined power distribution item to the selected contractor set. Link to Process Control 2 Defining the Project Basis Link a previously defined process control item to the selected contractor set. 147 2 A dialog box appears corresponding to the selected link command. The following dialog box appears if you select the Link to Process Control command. Note: All areas, power distribution items, and process control items are automatically linked to the default Conset until otherwise specified; therefore, you may first have to unlink items from the default Conset in order to make them available. See “Unlinking” on page 148 for instructions. 3 Click OK to link the selected item to the Conset. X X The item appears under the Conset on the tree diagram. In the tree diagram shown below, the process control item named “Monomer CTL (CTL 2)” is linked to the Conset named Substations (Conset Number 4). Unlinking The Unlink command lets you remove responsibility for the scope of work in a segment of the project. To unlink an item from a Conset:  Right-click a linked item in the tree diagram; then, on the menu that appears, and click Unlink. The item no longer appears under the Conset and is now available to be linked to another Conset. 148 2 Defining the Project Basis Editing Contractor Sets The Edit command lets you assign responsibility for engineering, purchasing materials, and installation to previously defined contractors for the selected contractor set (Conset). To edit a Conset: 1 Right-click on a Conset in the tree diagram; then, on the menu that appears, click Edit. The Conset Specifications dialog box appears. 2 Select a specification. Select to Engineering Assign responsibility for engineering tasks. Purchase materials Assign responsibility for purchasing on an account-by-account basis. If you select Purchase Materials, skip to Step 6. Installation Define responsibility for installation of all field material on an account-by-account basis. Construction equipment rental appropriate for each work item is automatically assigned to the installation contractor. If you select Installation, skip to Step 6. Exceptions Specify exceptions to scope by Code of Account (COA) or COA range. If you select Exceptions, skip to Step 10. If you selected Engineering: 3 Click Modify to assign responsibility for engineering. The Contract Scope Form appears. 4 Enter the specifications. 5 Click OK to apply your specifications to the project and return to the Conset Specifications dialog box. 2 Defining the Project Basis 149 If you selected Purchase Materials or Installation: 6 Click Modify to assign responsibility for the selected task. A form appears listing categories of materials to be purchased or installed (depending upon your selection). 7 Click the arrow on a material category field to select the contractor who will be responsible for purchasing/installing this category of material in this Conset. 8 Click OK to apply the specifications to the project and return to the Conset Specifications dialog box. 9 Click Close to close the dialog box. If you selected Exceptions: 10Click Modify to assign exceptions. The Contract Scope Exception dialog box appears. One blank item column is provided. To add an item column, click Add. 150 2 Defining the Project Basis 11Enter the Code of Account (COA) or COA range for which the exception applies. 12Enter the number of the contractor responsible for this COA or COA range. 13In the Exception Type field, select whether the contractor is responsible for purchase (PURC) or installation (INSTL) of this COA or COA range. 14Click OK to apply the exceptions and close the form. Deleting Contractor Sets The Delete command lets you delete previously defined contractor sets (Consets). Note: Consets can only be deleted if no items are linked to the contractor set. Any linked items must first be unlinked. To delete a Conset:  Right-click the Conset in the tree diagram; then, on the menu that appears, click Delete. Importing old Standard basis files 1 2 3 4 5 Open your Aspen Capital Cost Estimator Software. Go to the Libraries tab. Click Basis for Capital Costs. Right-click either Inch-Pound or Metric. Click IMPORT. The dialog that appears defaults to looking for the ICARUS 2000 specs file. 6 Browse to the specs file you want to import. 7 Click the specs file to import. Your ICARUS 2000 template (standard basis file) is now in the new Aspen Capital Cost Estimator system. 2 Defining the Project Basis 151 Merging Projects You can create a merged project from multiple projects that have identical project bases. To Merge Projects: 1 Create a starting project basis for use in all sub-projects. 2 Create ‘partial’ projects to work on different parts of the project, using this starting project basis in all projects. 3 Open a copy of one of the ‘partial’ projects (or a fresh copy of the starting design basis). The project in the open state from which other ‘partial’ projects will be merged into is known as the target project. 4 On the main menu, click Run | Merge | Merge Project. 5 On the Select Projects to Merge dialog box, select a second project to merge into the current (that is, the ‘target’) project. 6 Click OK. The projects are merged. Notes:  If any of the projects’ bases are not identical, you receive a warning message specifying which basis is not identical, and the merge is aborted.  None of the project basis data is copied and any links to project basis definition are disconnected.  All target project links are preserved.  All source project links are un-linked.  Source project RG/Areas are added at the end of the project. Merging Areas Into Projects You can merge areas from separate projects into a ‘target’ project. The project from which the areas will be merged and the ‘target’ project must have identical project bases. To Merge Areas into a Project: 1 Open a project into which you want to merge areas from other projects. This project is the ‘target’ project. 2 On the main menu, click Run | Merge | Merge Areas. 152 2 Defining the Project Basis 3 On the Select Projects to Merge dialog box, select a project to from which to merge areas into the ‘target’ project. 4 In the source project select the area(s) to merge. 5 Click OK. The areas from the source project are merged into your ‘target’ project. Notes:  If the two projects’ bases are not identical, you receive a warning message specifying which basis is not identical, and the merge is aborted.  None of the project basis data is copied and any links to project basis definition are disconnected.  All target project links are preserved.  All source project links are un-linked.  Source project RG/Areas are added at the end of the project. Customer External Files When certain specifications, such as pipe insulation thickness, are not entered by the user, Aspen In-Plant Cost Estimator refers to ASCII format files to make the appropriate selection. These files are accessible in the Palette’s Libraries view. There, in the Customer External Files library, these files are divided into subfolders that correspond to the categories in Project Explorer’s Customer External Files folder. When no project is open, you can create in the Palette a duplicate of a default or template file, assigning it a different name (see page 243 for instructions). You can then open the file (stored at AspenTech/Economic Evaluation V7.3/Data, unless location is changed in Preferences) in any ASCII text editor and customize the rules and specifications. (Refer to Icarus Reference when customizing files. Chapter 23 of Icarus Reference provides instructions on how to customize an insulation specs file.) X X To use a customer external file, you must select it in Project Explorer. Otherwise, Aspen In-Plant Cost Estimator uses the default file. To select a file: 1 Right-click the category. 2 On the menu that appears, click Select. 2 Defining the Project Basis 153 A selection dialog box appears. 3 Click the file you want to use. 4 Click OK. Project Execution Schedule Settings Aspen Capital Cost Estimator generates a CPM barchart planning schedule based on the scope of work defined for the project. The project schedule includes dates and durations for the following:  Design engineering  Procurement  Delivery of materials and equipment  Site development  Construction  Start-up and commissioning 154 2 Defining the Project Basis The construction schedule is integrated with the cost estimate to provide a basis for the schedule-dependent costs such as equipment rental requirements, field supervision, and construction management. Adjusting Schedule and Barcharts To adjust schedule and barcharts: 1 In the Project Execution Schedule Settings subfolder, right-click on Adjust Schedule and Barcharts and click Edit on the pop-up menu. The Schedule Adjustments specifications dialog box appears in the Main Window. 2 In the Start Engineering Phase field, select whether to start engineering with the Detailed Engineering or Basic Engineering. 2 Defining the Project Basis 155 3 Specify starting dates for engineering and construction (required to generate barchart schedule reports). 4 Specify percent adjustments to the system-generated schedule for engineering, delivery of equipment and plant bulk items, and construction manpower activities. 5 Specify total construction duration in weeks. Construction includes sitework, civil, and mechanical erection. 6 Specify up to five equipment classes for which to include separate procurement/installation activity bars (see Icarus Reference, Chapter 36, Equipment Fabricate/Ship Items, for a list of equipment classes). See the next subsection for instructions on setting delivery times for equipment classes. 7 If desired, change the symbols used for printing elements of the barchart. 8 Click OK to save the schedule and barchart adjustments and close the specifications form. -orClick Cancel to close the form without saving changes. Setting Delivery Times for Equipment Classes To set vendor fabrication and shipping times for equipment class: 1 In the Project Execution Schedule Settings subfolder, right-click on Equipment Class Delivery Times and click Edit. 156 2 Defining the Project Basis The Schedule Equipment Classes specifications form appears in the Main Window. 2 For each equipment class, specify the number of weeks needed to fabricate and ship equipment after vendor data approval. 3 Click OK to save the specifications and close the form. -orClick Cancel to close the form without saving changes. Scheduling Individual Project Components You can specify up to five project components to appear with separate procurement and installation activity bars in the barchart. For each specified component, you can set vendor fabrication and shipping time. To schedule project components: 1 In the Project Execution Schedule Settings subfolder, right-click on Equipment Item Delivery Times and click Edit. The Schedule Equipment Items specifications form appears in the Main window. 2 Defining the Project Basis 157 2 Enter the tag number of the project component for which to include a separate activity bar in the barchart. 3 Enter the number of weeks required for the vendor to fabricate and ship the project component. 4 Repeat this process (steps 2 and 3) to schedule up to five project components. 5 Click OK to save the specifications and close the form. -orClick Cancel to close the form without saving changes. Adding Bar Chart Items You can define up to four custom-designed bars. For example, you might define specific bars for funding approval and permits. (These bars have no effect on the calculated construction duration.) To add bar chart items: 1 In the Project Execution Schedule Settings subfolder, right-click on Add Barchart Items; then click Edit. 158 2 Defining the Project Basis The Schedule Bar Items specifications form appears in the Main Window. Note: A blank column is included for Item 1. To add an additional item, click Add. 2 Enter a description for the activity bar being added. 3 Specify a start and finish date for the activity. 4 Select a bar position: top of barchart (T), basic engineering (B), detailed engineering (D), procurement (P), sitework (S), construction (C), end of barchart (E). 5 To add another bar, click Add and repeat steps 2-4. You can have a maximum of four user-defined bars. 6 Click OK to save the specifications and close the form. -orClick Cancel to close the form without saving changes. IPS Project Schedule Settings Note: IPS Project Schedule Settings are only included in Aspen Capital Cost Estimator if you are licensed to use Aspen Icarus Project Scheduler (IPS). If you are licensed to use Aspen Icarus Project Scheduler (IPS) and you selected at startup to use IPS in the Aspen Capital Cost Estimator environment, the IPS Project Schedule Settings folder is included in the Project Explorer’s Basis view. Using these settings, you can make adjustments to the Primavera Enterprise schedules produced by Aspen Capital Cost Estimator. 2 Defining the Project Basis 159 Using Aspen Icarus Project Scheduler (IPS) in the Aspen Capital Cost Estimator Environment At Startup, select the Aspen Icarus Project Scheduler check box in the Options dialog box. This option is not selected by default. Note: If the Options dialog box does not appear at Startup, open Preferences (Tools | Options | Preferences). On the General tab, select the Display Options Choice Dialog on Aspen Capital Cost Estimator Startup check box. As a result of selecting to use Aspen IPS within Aspen Capital Cost Estimator, an additional folder for IPS Project Schedule Settings appears in Project Explorer’s Project Basis view. Note: Double-asterisks (**) indicate that the specifications do not apply to pipeline projects. 160 2 Defining the Project Basis Changes made to the IPS Project Schedule Settings will be reflected in the scheduling reports generated for display in Primavera. The following are descriptions of the settings. Schedule Appearance Adjustments Title To enter a project schedule title to replace the systemgenerated title: 1 Right-click on Title and click Edit. 2 Enter a title, up to 60 characters. 3 Click Apply. 2 Defining the Project Basis 161 Description Modification - Engineering To modify an engineering activity description: 1 Right-click on Engineering and click Edit on the pop-up menu. If you have not previously entered a description modification, there should be one blank column (Item 1). If it has already been filled-in, click Add to add a new column in which to enter a modification. 2 Select an activity or group of activities for which the description modification is to be made. This is done by specifying all or part of the Activity Number. The parts of the Activity Number are broken up into the fields under ACTIVITY NUMBER. Activity Numbers, which are listed on pages 731 through 770 in Appendix A, have 10 characters. If you want to modify a group of activities, you can enter “wildcard” asterisks in some fields. At least one of the fields (besides the two preset fields) must contain numbers. X X X X Note: See Appendix A for a list of Activity Numbers.  Preset engineering field 1 The first three characters of the Activity Number are fixed and the same for all activities. They are always “000”. 162 2 Defining the Project Basis   Engineering phase The fourth character of the Activity Number indicates the major engineering phase: 0 – Basic engineering phase 1 – Detail engineering phase 2 – Procurement phase To select all phases, enter an asterisk (*). Engineering contractor number The fifth and sixth characters of the Activity Number indicate the engineering contract number. For fixed project-level activities, these characters will be “00”. The engineering contract number is determined based on your specifications for contractors under Basis for Capital Costs in the Project Basis (see page 141). It must be a number between 01 and 40. If all engineering contractor numbers are to be selected, enter two asterisks (**). Account group number X  X Exception: Where applicable, the seventh and ninth characters of the Activity Number indicate the process equipment class (0126). Equipment classes are defined in Appendix C. The seventh character of the Activity Number indicates the account group number. It is derived from the first character of the Code of Accounts. 0, 1, 2 – Equipment or general 3 – Piping 4 – Civil 5 – Steelwork 6 – Instrumentation 7 – Electrical 8 – Insulation 9 – Painting If all account groups are to be selected for modification, enter one asterisk (*).  Preset engineering field 2 The eighth character of the Activity Number is fixed and the same for all activities. It is always “0”.  Sequence in account group number The ninth and tenth numbers provide sequential grouping within the major hierarchy of the first eight characters. If 2 Defining the Project Basis 163 all numbers within a sequence group are to be selected, enter two asterisks (**). Note: where applicable, the seventh and ninth characters of the Activity Number indicate the process equipment class (01-26). Equipment classes are defined on page 779. In the Description and tag mod. Option field, select whether to modify both the description and the tag (default), only the description, or only the tag. If you are modifying the activity description, enter the new description in the Engg. activity description field (up to 32 characters). If you are modifying the tag, enter the new tag in the Tag field (up to 12 characters). It will be used in place of the tag (if any) provided by the system. The tag may be used as a continuation of the description. To modify another activity description, click Add. A new column will appear. Repeat the process for the other activity description. Click Apply when done. Click Cancel to close the form. X 3 4 5 6 7 8 164 X 2 Defining the Project Basis Description Modification – Construction To modify a construction activity description: 1 Right-click on Construction and click Edit on the pop-up menu. If you have not previously entered a description modification, there should be one blank item column (Item 1). If it has already been filled-in, click Add to add a new item column in which to enter a modification. 2 Select an activity or group of activities for which the description modification is to be made. This is done by specifying all or part of the Activity Number. The Activity Number is broken up into the fields under ACTIVITY NUMBER. Construction Activity Numbers, which are listed in Appendix B, have 10 characters. If you want to modify a group of activities, you can enter “wildcard” asterisks in some fields. However, at least one of the fields must contain numbers. Area number The first and second characters of the Activity Number indicate the Area number, 01 through 90, or other projectlevel items, such as substations, control panel and power transmission lines, which always use 91. If activities from all Areas are to be selected, enter two asterisks (**). Identification number 2 Defining the Project Basis 165 The third through fifth characters contain the userspecified reference number from the specifications form for equipment items and plant bulks. For substations, the fourth and fifth characters contain the substation reference number (01-99) specified by the user or, if not specified, the System default reference number of 00. If all reference numbers are to be selected, enter three asterisks (***). Note: See Appendix D for the Equipment Code definitions. Equipment type The sixth and seventh characters contain the Equipment Code. See Appendix D, page 781, for Equipment Code definitions. All other activities have a fixed identifier in positions six and seven of the activity number, as listed in Activity Numbering Conventions table on page 772. Enter two asterisks (**) if all Equipment Type numbers are to be selected. X X X X Note: The construction activities are listed, beginning on page 772 (in Appendix B), by the last three characters of the Activity Number. These last three characters form the account group number and account code. Account group number X X The eighth character, the account group number, refers to the type of work performed in the activity. The account group number combined with the account code (in the field below), form the three-character code by which the construction and site development activities are listed beginning on page 771 (Appendix B). If all account group numbers are to be selected, enter an asterisk (*). Account code X X Enter the ninth and tenth digits of the Activity Code for the activities to be selected for modification (that is,, excluding the first character, which is the Account Group number, above). If all Activity Codes are to be selected, enter two asterisks (**). Contractor number The eleventh and twelfth characters are the contractor numbers. If all contractors are to be selected, enter two asterisks (**) 166 2 Defining the Project Basis 3 In the Description and tag mod. Option field, select whether to modify both the description and the tag (default), only the description, or only the tag. 4 If you are modifying the activity description, enter the new description in the Constr. activity description field (up to 32 characters). 5 If you are modifying the tag, enter the new tag in the Tag field (up to 12 characters). It will be used in place of the tag (if any) provided by the system. The tag may be used as a continuation of the description. 6 To modify another activity description, click Add. A new column will appear. Repeat the process for the other activity description. 7 Click Apply when done. Schedule Adjustments by Duration The activity duration and construction crew size are interrelated, such that an adjustment to the duration will cause an inversely proportional adjustment to the activity crew size, and vice versa. You may specify either a duration adjustment, a maximum crew size, a minimum crew size, or all three. If a conflict occurs, the crew size adjustment will override the duration adjustment. If not adjusted, durations are calculated for each activity based on the type of activity and associated direct construction man-hours. Crew Size You can adjust the system activity durations by entering minimum/maximum crew sizes for various construction activities within each account group. 2 Defining the Project Basis 167 To adjust crew size: 1 Right-click on Crew Size and click Edit on the pop-up menu. 2 Specify minimum and maximum crew sizes; then click Apply. Crafts The Craft Adjustments form lets you modify the system-defined crafts. The craft code and craft description may be completely replaced by a user-defined code and description. In addition, the maximum craft pool sizes may be modified as required. Modifying the craft pool sizes will affect the activity durations and the overall job durations. To adjust a craft: 1 Right-click on Crafts and click Edit on the pop-up menu. 2 Select the craft to be adjusted by entering the System craft code. See Icarus Reference, Chapter 30, for lists of craft codes by Country Base. 3 Enter a numeric (01-99) User craft code to substitute for the preceding System craft code. 168 2 Defining the Project Basis Note: If you specify a craft code already in use (that is,, a system craft code or a previously added user craft code), Aspen Capital Cost Estimator will combine all pool sizes and resource requirements for the specified craft code and the existing code. 4 Enter a description for the craft in the User craft description field, up to 20 characters. 5 Enter the number of men in the user craft pool or enter an adjustment relative to the system craft pool size. The system craft pool size is calculated based on the system craft man-hours and schedule duration. 6 Enter a 4-character user craft symbol. If nothing is entered, the system craft symbol is used. 7 To enter another adjustment, click Add. This adds another column where you can repeat the process. 8 When done, click Apply. Durations You can use to the specification forms for engineering, construction, and procurement durations to adjust the durations by percentage.  Engineering Engineering Duration Adjustments You can enter a percentage adjustment to the durations calculated by the system for Basic Engineering, Detail Engineering, and Procurement. Client Review Period You can use the Basic engineering review period field to set the duration of Activity 0000003013, “CLIENT 2 Defining the Project Basis 169 APPROVAL-ESTIM&SCHED”. Since all Detail Engineering activities are preceded, directly or indirectly, by this activity, you may impose a delay of any duration on the continuation of engineering activity. This effectively breaks up the work flow to simulate, for example, budget approval delay. 170  Construction You can enter a percentage adjustment to the durations calculated by the system for nine different construction activities. Any change in activity duration will cause a corresponding change in activity resource (crew).  Procurement For each equipment group, you may enter the number of weeks needed to fabricate and ship the equipment to the site after vendor data approval. 2 Defining the Project Basis If you make no adjustment, Aspen Capital Cost Estimator uses the following durations: Equipment Group Duration Vessels 24 weeks Towers 36 weeks Storage Tanks 32 weeks Pumps 22 weeks Compressors 50 weeks Turbines 50 weeks Heat Exchangers 32 weeks Boilers 55 weeks Furnaces 40 weeks Air Coolers 28 weeks Package Refrigeration 44 weeks Generators 26 weeks Air Dryers 24 weeks Conveyors 28 weeks Mills 45 weeks Fans 16 weeks Elevators 26 weeks Motors 16 weeks Dust Collectors 30 weeks Filters 16 weeks Centrifuges 40 weeks Mixers 16 weeks Cooling Towers 32 weeks Miscellaneous 26 weeks 2 Defining the Project Basis 171 Equipment Package Items 36 weeks Packings and Linings 20 weeks Schedule Adjustments by Activity and Logic Logic Modification Aspen Capital Cost Estimator provides sequencing logic, varying with the activities present, for all engineering and construction activities, except as follows:  Where logical relationships cannot be predicted for system-designed activities, such as project site development.  Where logical relationships cannot be predicted because the activity is user-specified.  Where a logical chain of activities has been substantially broken by deletion of activities. The Logic Modification forms provide the means to either add relationships between successor and predecessor activities not provided by the Aspen Capital Cost Estimator logic or to modify the Aspen Capital Cost Estimator logic by adding and deleting relationships. Separate forms are provided for engineering and construction sections of the network. When adding relationships, a particular relationship type may be specified. However, when deleting relationships, all relationships between the specified activities are deleted, regardless of relationship type. For engineering activities, only engineering predecessors are allowed. For construction activities, engineering and construction predecessors are allowed. 172 2 Defining the Project Basis To add or delete an engineering relationship: 1 Right-click Engineering; then click Edit to display the Logic Modification form for engineering. 2 In the Add/delete logic option field, select + or – to indicate whether you are adding or deleting a relationship. 3 Select a successor activity, or group of activities, for which logic modifications are to be made. This is done by specifying all or part of the Activity Number. The parts of the Activity Number are broken up into the fields under SUCCESSOR ACTIVITY. Activity Numbers, which are listed on pages 731 through 770 (in Appendix A), have 10 characters. If you want to modify a group of activities, you can enter “wildcard” asterisks in some fields. At least one of the fields (besides the two preset fields) must contain numbers. X X X X Note: See Appendix A for a list of Activity Numbers.  Preset engineering field 1 The first three characters of the Activity Number are fixed and the same for all activities. They are always “000”. 2 Defining the Project Basis 173  Engineering phase The fourth character of the Activity Number indicates the major engineering phase: 0 – Basic engineering phase 1 – Detail engineering phase 2 – Procurement phase  To select all phases, enter an asterisk (*). Engineering contractor number  The fifth and sixth characters of the Activity Number indicate the engineering contract number. For fixed project-level activities, these characters will be “00”. The engineering contract number is determined based on your specifications for contractors under Basis for Capital Costs in the Project Basis (see page 141). It must be a number between 01 and 40. If all engineering contractor numbers are to be selected, enter two asterisks (**). Account group number X X Exception: where applicable, the seventh and ninth characters of the Activity Number indicate the process equipment class (0126). Equipment classes are defined in Appendix C, page 779. X X The seventh character of the Activity Number indicates the account group number. It is derived from the first character of the Code of Accounts. 0, 1, 2 – Equipment or general 3 – Piping 4 – Civil 5 – Steelwork 6 – Instrumentation 7 – Electrical 8 – Insulation 9 – Painting If all account groups are to be selected for modification, enter one asterisk (*). Preset engineering field 2 174 2 Defining the Project Basis The eighth character of the Activity Number is fixed and the same for all activities. It is always “0”. Sequence in account group number The ninth and tenth numbers provide sequential grouping within the major hierarchy of the first eight characters. If all numbers within a sequence group are to be selected, enter two asterisks (**). Note: where applicable, the seventh and ninth characters of the Activity Number indicate the process equipment class (01-26). Equipment classes are defined in Appendix C, page 779. 4 Select an activity, or group of activities, to be added or deleted as predecessor(s) to the specified Successor. Use the fields under PREDESSOR – ENGG. ACTIVITY to select an activity the same way you selected a successor activity. 5 In the Relationship type field, select the specific type of logical sequence to use when adding relationships: X X A – Finish-to-Start (default) S – Start-to-Start F – Finish-to-Finish Finish-to-Start (A) and Start-to-Start (S) relationships use the Predecessor’s work week to calculate calendar lag between activities. Finish-to-Finish (F) relationships use the successor’s work week. The Relationship Type field is not used by the system when deleting relationships; all relationships between the specified activities will be deleted, regardless of relationship type. 6 Enter the Lag time, in whole working days, associated with the relationship type to be added. The default is 0 days. 7 Click Apply. 8 To add or delete another relationship, click Add and repeat the process. To add or delete a construction relationship: Note: Enter either an engineering or a construction predecessor, not both. 1 Right-click on Construction and click Edit on the pop-up menu. 2 Defining the Project Basis 175 2 In the Add/delete logic option field, select + or – to indicate whether you are adding or deleting a relationship. 3 Select a successor construction activity, or group of activities, for which logic modifications are to be made. This is done by specifying all or part of the Activity Number. The Activity Number is broken up into the fields under SUCCESSOR ACTIVITY. Construction Activity Numbers, which are listed in Appendix B, have 10 characters. If you want to modify a group of activities, you can enter “wildcard” asterisks in some fields. However, at least one of the fields must contain numbers. Area number 176 2 Defining the Project Basis The first and second characters of the Activity Number indicate the Area number, 01 through 90, or other projectlevel items, such as substations, control panel and power transmission lines, which always use 91. If activities from all Areas are to be selected, enter two asterisks (**). Identification number The third through fifth characters contain the userspecified reference number from the specifications form for equipment items and plant bulks. For substations, the fourth and fifth characters contain the substation reference number (01-99) specified by the user or, if not specified, the System default reference number of 00. If all reference numbers are to be selected, enter three asterisks (***). Note: See Appendix D, page 781, for the Equipment Code definitions. Equipment type X X The sixth and seventh characters contain the Equipment Code. See Appendix D, page 781, for Equipment Code definitions. All other activities have a fixed identifier in positions six and seven of the activity number, as listed in Activity Numbering Conventions table on page 772. Enter two asterisks (**) if all Equipment Type numbers are to be selected. X X X X Note: The construction activities are listed in Appendix B by the last three characters of the Activity Number. These last three characters form the account group number and account code. Account group number The eighth character, the account group number, refers to the type of work performed in the activity. The account group number combined with the account code (in the field below), form the three-character code by which the construction and site development activities are listed beginning on page 771 (Appendix B). If all account group numbers are to be selected, enter an asterisk (*). Account code X X Enter the ninth and tenth characters of the Activity Code for the activities to be selected for modification (that is,, excluding the first character, which is the Account Group number, above). If all Activity Codes are to be selected, enter two asterisks (**). 2 Defining the Project Basis 177 Contractor number The eleventh and twelfth characters are the contractor numbers. If all contractors are to be selected, enter two asterisks (**). 4 You can select either an engineering or a construction activity, or group of activities, to be added or deleted as predecessor(s) to the specified Successor. This is done by entering all or part of an engineering or construction Activity Number. 5 In the Relationship type field, select the specific type of logical sequence to use when adding relationships: A – Finish-to-Start (default) S – Start-to-Start F – Finish-to-Finish Finish-to-Start (A) and Start-to-Start (S) relationships use the Predecessor’s work week to calculate calendar lag between activities. Finish-to-Finish (F) relationships use the successor’s work week. The Relationship Type field is not used by the system when deleting relationships; all relationships between the specified activities will be deleted, regardless of relationship type. 6 Enter the Lag time, in whole working days, associated with the relationship type to be added. The default is 0 days. 7 Click Apply. 8 To add or delete another relationship, click Add and repeat the process. Activity Modification The Activity Modification forms for engineering and construction allow you to modify the coding of activities. Activities may be combined within a common activity number or deleted entirely. Activities can be combined by changing an activity number to another existing number. Specify all or part of an existing activity number, then all or part of the other activity number that will replace it. Icarus Project Scheduler (IPS) will sort the activities into numerical order, merging all identically numbered activities, including the craft resources. 178 2 Defining the Project Basis Activities can be deleted by selecting an activity and then entering asterisks instead of the number of a modified activity. To modify engineering activities: 1 Right-click on Engineering and click Edit on the pop-up menu. 2 Select a source activity. This is done by specifying all or part of the Engineering Activity Number. The parts of the Engineering Activity Number are broken up into the fields under SOURCE ACTIVITY. Engineering Activity Numbers, which are listed in Appendix A, have 10 characters. If you want to modify a group of activities, you can enter “wildcard” asterisks in some fields. At least one of the fields (besides the two preset fields) must contain numbers. Note: See Appendix A for a list of Engineering Activity Numbers. Preset engineering field 1 The first three characters of the Activity Number are fixed and the same for all activities. They are always “000”. Engineering phase 2 Defining the Project Basis 179 The fourth character of the Activity Number indicates the major engineering phase: 0 – Basic engineering phase 1 – Detail engineering phase 2 – Procurement phase To select all phases, enter an asterisk (*). Engineering contractor number The fifth and sixth characters of the Activity Number indicate the engineering contract number. For fixed project-level activities, these characters will be “00”. The engineering contract number is determined based on your specifications for contractors under Basis for Capital Costs in the Project Basis (see page 141). It must be a number between 01 and 40. If all engineering contractor numbers are to be selected, enter two asterisks (**). Account group number X X Exception: Where applicable, the seventh and ninth characters of the Activity Number indicate the process equipment class (01-26). Equipment classes are defined in Appendix C, page 779. X X The seventh character of the Activity Number indicates the account group number. It is derived from the first character of the Code of Accounts. 0, 1, 2 – Equipment or general 3 – Piping 4 – Civil 5 – Steelwork 6 – Instrumentation 7 – Electrical 8 – Insulation 9 – Painting If all account groups are to be selected for modification, enter one asterisk (*). Preset engineering field 2 The eighth character of the Activity Number is fixed and the same for all activities. It is always “0”. 180 2 Defining the Project Basis Sequence in account group number The ninth and tenth numbers provide sequential grouping within the major hierarchy of the first eight characters. If all numbers within a sequence group are to be selected, enter two asterisks (**). Note: where applicable, the seventh and ninth characters of the Activity Number indicate the process equipment class (01-26). Equipment classes are defined in Appendix C, page 779. 3 In the fields under MODIFIED ACTIVITY, specify the changes that are to be made to the source activity. 4 Click Apply. 5 To modify another activity, click Add and repeat the process. X X To modify construction activities: 1 Right-click on Construction and click Edit on the pop-up menu. 2 Select a source activity. This is done by specifying all or part of the Construction Activity Number. 2 Defining the Project Basis 181 The Construction Activity Number is broken up into the fields under ACTIVITY NUMBER. Construction Activity Numbers, which are listed in Appendix B, have 10 characters. If you want to modify a group of activities, you can enter “wildcard” asterisks in some fields. However, at least one of the fields must contain numbers. Area number The first and second characters of the Activity Number indicate the Area number, 01 through 90, or other projectlevel items, such as substations, control panel and power transmission lines, which always use 91. If activities from all Areas are to be selected, enter two asterisks (**). Identification number The third through fifth characters contain the userspecified reference number from the specifications form for equipment items and plant bulks. For substations, the fourth and fifth characters contain the substation reference number (01-99) specified by the user or, if not specified, the System default reference number of 00. If all reference numbers are to be selected, enter three asterisks (***). Note: See Appendix D, page 781, for the Equipment Code definitions. Equipment type X X The sixth and seventh characters contain the Equipment Code. See Appendix D, page 781, for Equipment Code definitions. All other activities have a fixed identifier in positions six and seven of the activity number, as listed in Activity Numbering Conventions table on page 772. Enter two asterisks (**) if all Equipment Type numbers are to be selected. X X X X Note: The construction activities are listed in Appendix B by the last three characters of the Activity Number. These last three characters form the account group number and account code. Account group number The eighth character, the account group number, refers to the type of work performed in the activity. The account group number combined with the account code (in the field below), form the three-character code by which the construction and site development activities are listed 182 2 Defining the Project Basis beginning on page 771 (Appendix B). If all account group numbers are to be selected, enter an asterisk (*). Account code X X Enter the tenth and eleventh characters of the Activity Code for the activities to be selected for modification (that is,, excluding the first character, which is the Account Group number, above). If all Activity Codes are to be selected, enter two asterisks (**). Contractor number The eleventh and twelfth characters are the contractor numbers. If all contractors are to be selected, enter two asterisks (**). 3 In the fields under MODIFIED ACTIVITY, specify the changes that are to be made to the source activity. 4 Click Apply. 5 To modify another activity, click Add and repeat the process. Primavera Information To edit Primavera information: 1 Right-click on Project manager information in the Primavera information folder and click Edit on the pop-up menu. 2 You can specify the following information: User name Password 2 Defining the Project Basis 183 Database name Name of Primavera database where Aspen IPS data will be loaded (for example, pmdb). Remote or local host server Indicates mode of operation, remote server (RMT) or local machine (LCL). Enterprise project structure ID Project structure ID for Primavera Enterprise. If nothing is entered, the Aspen Capital Cost Estimator project name will be used. Enterprise project structure name Project structure name for Primavera Enterprise. If nothing is entered, the Aspen Capital Cost Estimator project name will be used. Enterprise project manager name Name of manager (OBS) responsible for Primavera Enterprise. If nothing is entered, the Aspen Capital Cost Estimator project name will be used. Enterprise project WBS name Work Breakdown structure name for Primavera Enterprise. If nothing is entered, the Aspen Capital Cost Estimator project name will be used. 3 Click Apply to save changes. Process Design Note: Process Design specifications are only included in Aspen Capital Cost Estimator if you are licensed to use Aspen Icarus Process Evaluator (Aspen Process Economic Analyzer) or Aspen Decision Analyzer. If you are licensed, you can select at startup to use Aspen Process Economic Analyzer or Analyzer in the Aspen Capital Cost Estimator environment. The Process Design specifications are used in Aspen Capital Cost Estimator projects that contain a simulator input. These specs allow Aspen Capital Cost Estimator to map simulator models into Icarus project components. For example, a distillation column model in a simulator may be mapped to a combination of equipment such as a double diameter tower, an air-cooler (for a condenser), a horizontal tank (for a reflux drum), a general service pump (for a reflux pump) and a thermosiphon reboiler. 184 2 Defining the Project Basis The Process Design Specifications indicate the default settings that the system uses for mapping all models of the same class. These specs can be customized in files and used in many projects. Simulator Type and Simulator File Name Simulator Type and Simulator File Name are described under Loading Simulation Data on page 275. X X Simulator Units of Measure Mapping Specs The Simulator Units of Measure Mapping Specs are used in mapping simulator units to Aspen Capital Cost Estimator units, serving as the cross-reference. To access, right-click on Simulator Units of Measure Mapping Specs in the Project Basis view’s Process Design folder. The Units of Measure Specification dialog box appears. Note: Each simulator cross-reference UOM file contains a basis (which may be METRIC or I-P). The basis indicates the Aspen Process Economic Analyzer base units set to which simulator units will be converted. 2 Defining the Project Basis 185 The left side of the screen displays the simulation output units. The right side of the screen displays the corresponding Aspen Capital Cost Estimator units. The conversion factors between the two units are entered in the lower-center section of the screen. Aspen Capital Cost Estimator provides a set of common simulator units and their conversions to Aspen Capital Cost Estimator units. You can modify and/or add units to these files. Specifying the Mapping for a Simulator Unit To specify the mapping for a simulator unit: 1 Select the simulation unit from the Units Used list in the Simulation Output section. In the example below, the simulation unit is CM/HR (Centimeters/Hour). 2 Select the appropriate units category from Units Category list in the Aspen Capital Cost Estimator section. In the example below, the units category is Velocity. 3 Select the appropriate Aspen Capital Cost Estimator unit from Units list in the Aspen Capital Cost Estimator section. In the example below, the Aspen Capital Cost Estimator unit is M/H (Meters/Hour). 4 Enter the conversion factor between the two units (the simulation unit and the Aspen Capital Cost Estimator unit) in 186 2 Defining the Project Basis the Conversion Factor box. In the example below, the conversion factor between the two units is 100 because: 100 CM/HR = 1 M/H Note: If an equivalent Aspen Process Economic Analyzer unit is not found, select Miscellaneous as the Units Category and map the simulator unit to Other in the Units window. 5 Click Save to save the mapping. When a unit has been mapped and saved, a green box appears next to the simulation unit. A yellow box indicates the unit is not mapped. Deleting a Mapping To delete a mapping, select the simulator unit and then click Delete. Removing a Unit To remove a particular unit from the simulation units list, first select the unit and then click Remove. Adding a Unit To add a new unit to the list, enter the new unit symbol in the New Units to Add box in the Simulation Output section and click Add. Changes will not affect existing project components. 2 Defining the Project Basis 187 Changing Existing Components To change existing components, you should unsize the item or unmap the items and then re-map and re-size. Once all of the units have been specified, click OK to store and save the specifications. It is critical that all simulator units of measure be mapped into Aspen Capital Cost Estimator units. When the simulator output is loaded, Aspen Capital Cost Estimator identifies all units of measure in the file. Any units not mapped in the project’s current simulator cross-reference UOM specification are automatically added to the list and you are alerted to the need to define the mapping and re-load the file. You must correct this in order to continue without problems. Complete the steps above to specify the mapping for a simulator unit. Scroll through the Units Used list for any yellow-tagged units. Map all these, save the file, and re-load the simulator data. Project Component Map Specifications The Project Component Map Specifications dialog box contains a list of models for the selected simulator and a list of the corresponding Icarus project components to which the simulator models will map. To access: 1 Right-click on Project Component Map Specifications in the Project Basis view’s Process Design folder. 2 On the menu that appears, click Edit. 188 2 Defining the Project Basis Models that are mapped in the current file are marked with an asterisk (*). If no asterisk is present, then that model will not generate any project components when loaded, mapped, and sized. 3 Exclude simulator models from the mapping process by selecting the simulator item and then clicking Delete All Mappings. You can select a simulator item and review the mapping(s) for that item. To change one of the mappings, select an item in the Current Map List, click Delete One Mapping, and then create a new mapping. To create a new mapping, click New Mapping and then select an appropriate Icarus project component. For simulator column models, an additional specification can be made. Since a column may be mapped to multiple pieces of equipment, Aspen Capital Cost Estimator requires an identification for each of these mappings. Refer to Mapping Simulator Models in Chapter 4 for tower/column configuration mapping identifications. 2 Defining the Project Basis 189 Note: You can select in Preferences to have Aspen Capital Cost Estimator map unsupported simulator models (that is,, models not included in the list of simulator models on the Project Component Map Specifications dialog box) to quoted cost items. See page 62 for instructions. X X Default Simulator Mapping Specs The following tables list models that are mapped to Aspen Capital Cost Estimator project components. Models that are not supported can be mapped to a quoted item if you mark “Map Unsupported Models To Quoted Cost Item” in Preferences (Process tab). AspenTech’s Aspen Plus Map Specs Model Name Model Description Aspen Capital Cost Estimator Default CCD Countercurrent decanter Rotary drum filter CFUGE Centrifuge filter Centrifuge SOLID-BOWL COMPR Compressor/turbine Centrifugal gas compressor / Gas turbine with combustion chamber CRUSHER Solids crusher Jaw crusher CYCLONE Solid-gas cyclone Cyclone Dust collector DECANTER Liquid-liquid decanter Vertical vessel – process DISTL Shortcut distillation rating Single-diameter trayed tower DSTWU Shortcut distillation design Single-diameter trayed tower ESP Electrostatic precipitator Low voltage electrical precipitator FABFL Baghouse filter Cloth bay baghouse FILTER Continuous rotary vacuum Rotary drum filter FLASH2 Two-outlet flash Vertical vessel – process FLASH3 Three-outlet flash Vertical vessel – process FSPLIT Stream splitter HEATER Heater/cooler Floating head heat exchanger HEATX Two-stream heat exchanger Floating head heat exchanger HYCYC Solid-liquid hydrocyclone Water only cyclones - mineral PUMP Pump/hydraulic turbine Centrifugal single or multi-stage pump RADFRAC Rigorous fractionation  Single-diameter trayed tower (column)  Floating head heat exchanger (condenser)  U-tube reboiler (reboiler)  Horizontal drum (accumulator)  Centrifugal single or multi-stage pump (reflux pump) 190 2 Defining the Project Basis PETROFAC Consists of 42 configurations. It has been confirmed that the following can be mapped to Aspen Capital Cost Estimator:  Single-diameter trayed tower (column) PREFLIF- preflash block with furnace, zero pumparounds and zero sidestrippers.  U-tube reboiler (reboiler) CDUIOF – crude block with furnace, three pumparounds and three sidestrippers.  Floating head heat exchanger (condenser)  Horizontal drum (accumulator)  Centrifugal single or multi-stage pump (reflux pump)  Furnace block CDU 3 – vacuum block with two pumparounds and two sidestrippers. RBATCH Batch reactor Agitated Tank – enclosed, jacketed RCSTR Continuous stirred tank Agitated Tank – enclosed, reactor jacketed REQUIL Equilibrium reactor Agitated Tank – enclosed, jacketed RGIBBS Equilibrium reactor-gibbs Agitated Tank – enclosed, energy jacketed minimization RPLUG Plug-flow reactor Single diameter packed tower RSTOIC Stoichiometer reactor Agitated Tank – enclosed, jacketed RYIELD Yield reactor Agitated Tank – enclosed, jacketed SCFRAC Short-cut distillation Single-diameter trayed tower SCREEN Wet or dry screen separator Vibrating system SWASH Single-stage solids washer Rotary drum filter VSCRUB Venturi scrubber Washer dust collector AspenTech’s Aspen Plus Map Specs Model Name Model Description Aspen Capital Cost Estimator Default CCD Countercurrent decanter Rotary drum filter CFUGE Centrifuge filter Centrifuge SOLID-BOWL COMPR Compressor/turbine Centrifugal gas compressor / Gas turbine with combustion chamber CRUSHER Solids crusher Jaw crusher CYCLONE Solid-gas cyclone Cyclone Dust collector DECANTER Liquid-liquid decanter Vertical vessel – process DISTL Shortcut distillation rating Single-diameter trayed tower DSTWU Shortcut distillation design Single-diameter trayed tower ESP Electrostatic precipitator Low voltage electrical precipitator FABFL Baghouse filter Cloth bay baghouse FILTER Continuous rotary vacuum Rotary drum filter FLASH2 Two-outlet flash Vertical vessel – process FLASH3 Three-outlet flash Vertical vessel – process FSPLIT Stream splitter HEATER Heater/cooler 2 Defining the Project Basis Floating head heat exchanger 191 HEATX Two-stream heat exchanger Floating head heat exchanger HYCYC Solid-liquid hydrocyclone Water only cyclones - mineral PUMP Pump/hydraulic turbine Centrifugal single or multi-stage pump RADFRAC Rigorous fractionation  Single-diameter trayed tower (column)  Floating head heat exchanger (condenser)  U-tube reboiler (reboiler)  Horizontal drum (accumulator)  Centrifugal single or multi-stage pump (reflux pump) PETROFAC Consists of 42 configurations. It has been confirmed that the following can be mapped to Aspen Capital Cost Estimator:  Single-diameter trayed tower (column) PREFLIF- preflash block with furnace, zero pumparounds and zero sidestrippers.  U-tube reboiler (reboiler) CDUIOF – crude block with furnace, three pumparounds and three sidestrippers.  Floating head heat exchanger (condenser)  Horizontal drum (accumulator)  Centrifugal single or multi-stage pump (reflux pump)  Furnace block CDU 3 – vacuum block with two pumparounds and two sidestrippers. RBATCH Batch reactor Agitated Tank – enclosed, jacketed RCSTR Continuous stirred tank Agitated Tank – enclosed, reactor jacketed REQUIL Equilibrium reactor Agitated Tank – enclosed, jacketed RGIBBS Equilibrium reactor-gibbs Agitated Tank – enclosed, energy jacketed minimization RPLUG Plug-flow reactor Single diameter packed tower RSTOIC Stoichiometer reactor Agitated Tank – enclosed, jacketed RYIELD Yield reactor Agitated Tank – enclosed, jacketed SCFRAC Short-cut distillation Single-diameter trayed tower SCREEN Wet or dry screen separator Vibrating system SWASH Single-stage solids washer Rotary drum filter VSCRUB Venturi scrubber Washer dust collector ChemCAD V Map Specs 192 Model Model Description Aspen Capital Cost Estimator Default BAGH Baghouse filter Cloth bay baghouse dust collector COMP Adiabatic (isentropic) or polytopic Compression Centrifugal Axial Gas Compressor CFUG Basket centrifugal filter Atmospheric suspended basket centrifuge CRYS Crystallizer or melting by cooling/heating Batch vacuum crystallizer 2 Defining the Project Basis CSED Solid-wall basket centrifuge separating solids from liq slurry Solid bowl centrifuge CYCL Gas-solid cyclone separator Cyclone dust collector DRYE Dryer Direct rotary dryer EREA Equilibrium reactor Agitated tank reactor ESPT Electrostatic precipitator Low voltage electrical precipitator FIRE Fired heater Floating head heat exchanger FLAS Multipurpose flash Vertical cylindrical vessel FLTR Vacuum or constant-pressure filter Rotary disk filter GIBS Gibbs reactor Agitated tank reactor HCYC Hydrocyclone Water cyclone (separation equipment) HTXR Heat exchanger Floating head heat exchanger KREA Kinetic reactor (plug flow or continuous stirred tank reactors) Agitated tank reactor LLVF Vapor/liquid/liquid flash Vertical cylindrical vessel MIXE Stream mixer (flash calculation at output pressure) Vertical cylindrical vessel PUMP Liquid pump (to increase pressure of liquid stream) Centrifugal pump REAC Stoichiometric reactor Agitated tank reactor SCDS Simultaneous correction rigorous fractionation (single column)  Single diameter trayed tower  Floating head heat exchanger (condenser)  U-tube reboiler (reboiler)  Horizontal drum (accumulator)  Centrifugal single or multi-stage pump (reflux pump) SCRE Screen Single deck rectangular vibrating screen TOWR Inside/out rigorous fractionation (single column)  Single diameter trayed tower  Floating head heat exchanger (condenser)  U-tube reboiler (reboiler)  Horizontal drum (accumulator)  Centrifugal single or multi-stage pump (reflux pump) WASH Washer Washer dust collector Hysim Map Specs Model Name Model Description Aspen Capital Cost Estimator Default BAG FILTER Baghouse filter Dust collector cloth bay 2 Defining the Project Basis 193 COLUMN Distillation column  Single-diameter trayed tower  Floating head heat exchanger (condenser)  U-tube reboiler (reboiler)  Horizontal drum (accumulator)  Centrifugal single or multi-stage pump (reflux pump) COMPRESSOR Compressor Centrifugal gas compressor CSTR Continuous stirredtank Agitated Tank - enclosed, jacketed CYCLONE Gas-solid separator Cyclone dust collector EXPANDER Expander Gas turbine FILTER Rotary drum filter Rotary drum filter HEATER Heater/cooler Floating head heat exchanger HEATEX Simple heat exchanger Floating head heat exchanger HYDROCYCLONE Solid-liquid hydrocyclone Water only cyclones - mineral separation PIPING Pipeline PLUG Plug-flow reactor Single-diameter packed tower and others PUMP Pump Centrifugal single or multi-stage pump RATEHEATEX Rigorous heat exchanger Floating head heat exchanger REQUI Equilibrium reactor Agitated Tank - enclosed, jacketed RGIBBS Gibbs-energy reactor Agitated Tank - enclosed, jacketed RSTOIC Stoichiometric reactor Agitated Tank - enclosed, jacketed SOLIDSEP Solids separator Cyclone dust collector HYSYS Map Specs Model Name Model Description Aspen Capital Cost Estimator Default AIR COOLER Air cooler Air cooler, free-standing or rack-mounted. BAG FILTER Baghouse filter Dust collector cloth bay COLUMN Distillation column Single-diameter trayed tower COMPRESSOR 194 Compressor Centrifugal gas compressor CSTR Continuous stirredtank Agitated Tank – enclosed, jacketed CYCLONE Gas-solid separator Cyclone dust collector EXPANDER Expander Gas turbine FILTER Rotary drum filter Rotary drum filter HEATER Heater/Cooler Floating head heat exchanger HEATX Simple heat exchanger Floating head heat exchanger HYDROCYCLONE Solid-liquid hydrocyclone Water only cyclones – mineral separation PLUG Plug-flow reactor Single-diameter packed tower and others 2 Defining the Project Basis PUMP Pump Centrifugal single or multi-stage pump REQUI Equilibrium reactor Agitated Tank – enclosed, jacketed RGIBBS Gibbs-energy reactor Agitated Tank – enclosed, jacketed RSTOIC Stoichiometric reactor Agitated Tank – enclosed, jacketed SOLIDSEP Solids separator Cyclone dust collector SimSci’s Pro/II Map Specs Model Name Model Description Aspen Capital Cost Estimator Default CENTRIFUGE Centrifuge Solid bowl centrifuge COLUMN UNITS Distillation column  Single-diameter trayed tower  Floating head heat exchanger (condenser)  U-tube reboiler (reboiler)  Horizontal drum (accumulator)  Centrifugal single or multi-stage pump (reflux pump) COMPRESSOR Compressor Centrifugal gas compressor CRYSTAL Crystallizer Oslo growth type crystallizer CSTR Continuous stirred tank Agitated Tank - enclosed, jacketed DECANTER Countercurrent decanter Rotary drum filter DEPRESSURE Non-steady-state depressure Vertical vessel - process DRYER Solids dryer Atmospheric tray dryer EXPANDER Expander Gas turbine FLASH FLASH Vertical vessel - process HEATEX Simple heat exchanger Floating head heat exchanger PLUG Plug-flow reactor Single diameter packed tower PUMP Pump Centrifugal single or multi-stage pump REACTOR Reactor Agitated Tank - enclosed, jacketed RIGHTEX Rigorous heat exchanger Floating head heat exchanger ROTDRUM Rotary drum filter Rotary drum filter SHORTCUT Distillation column Single-diameter trayed tower Design Criteria After the simulator model is loaded into Aspen Capital Cost Estimator, mapping and sizing of the items can be performed. If an item is already sized inside the simulator, the sizing parameters are automatically brought into Aspen Capital Cost Estimator and used. 2 Defining the Project Basis 195 Items not sized by the simulator can be sized following the instructions in Chapter 6. In addition to process information obtained from the simulator, certain design specifications may be required before sizing can be accomplished. Aspen Capital Cost Estimator’s Sizing Expert uses design values based on the user-defined field values on specification forms in the Design Criteria sub-folder. The values on these forms provide the basis for developing design specifications from operating conditions for all equipment to be sized. You can enter design conditions (design pressure and temperature) for all equipment (using the Common form) and also enter design conditions for types of equipment. (Conditions entered on the equipment type forms override those on the Common form). Common Design pressure and temperature entered on the Common specifications form applies to all equipment except equipment for which you have separately specified these design conditions.  Design Pressure Click on the Design Pressure field to open the Design Pressure Specifications form. The specifications form lets you specify rules for calculating the design pressure based on the range in which the operating pressure falls. The design pressure is calculated from the operating pressure using the formula shown on the form. You can modify the pressure limit (upper and lower limit) as well as parameters A and B. 196 2 Defining the Project Basis  Note: In earlier versions of Aspen Process Economic Analyzer, the Design Pressure – Multiplier field was used. This field has now been replaced by the Design Pressure Specifications form. If projects created using these earlier versions are opened, then the parameters A and B are automatically adjusted based on the multiplier value specified. This ensures that old projects can be carried over using the same design criteria. Design Temperature Click on the Design Temperature field to open the Design Temperature Specifications form. The specifications form lets you specify rules for calculating the design temperature based on the range in which the operating temperature falls. The design pressure is calculated from the operating temperature using the formula shown on the form. You can modify the temperature ranges (upper and lower limit) as well as parameters A and B. 2 Defining the Project Basis 197 Note: In earlier versions of Aspen Process Economic Analyzer, the Design Temperature - Increase field was used. This field has now been replaced by the Design Temperature Specifications form. If projects created using these earlier versions are opened, then the parameters A and B are automatically adjusted based on the multiplier value specified. Pumps In addition to entering design pressure and temperature (see instructions under Common, page 196), you can enter the following design criteria for pumps:  Pump Overdesign Factor X X The pump overdesign factor is used by Aspen Capital Cost Estimator to increase the volumetric throughput of the pump and the power requirement of the pump. The total volumetric flow rate calculated from the simulator information is multiplied by the value provided in this field to estimate the design flow rate for the equipment. For example: Operation flow rate: 250 GPM Pump overdesign factor: 1.1 Calculated design capacity: 250 X 1.1 = 275 GPM Compressors In addition to entering design pressure and temperature (see instructions under Common, page 196), you can enter the following design criteria for compressors:  Driver Type X X Specifies the driver type used for compressors. The default value is None. The selections are NONE, GAS ENGINE, MOTOR, TURBINE. Heat Exchangers Using TEAMS detailed Heat Exchanger costing for Icarus cost estimation of TEAM Heat Exchangers. 198 2 Defining the Project Basis To use TEAMS for heat exchange sizing: 1 In your project, add a TEMA shell and tube heat exchanger to the main area. 2 Enter values to all the required fields (boxes with red and yellow highlight) 3 Enter values for the following Material of Construction fields: o Tube material o Shell material o Tube sheet material o Channel material 4 Click the arrow next to the Size button. 5 Click Launch TEAMS for sizing. The Icarus window will be hidden and in a couple of seconds, Icarus project evaluation dialog will appear After the evaluation is over – in a second or two - a message box saying The TEAMS GUI will now be launched appears. 6 Click OK to launch the TEAMS GUI. 2 Defining the Project Basis 199 The TEAMS GUI appears. 7 In the TEAMS GUI, specify the details of the heat exchanger. 8 When you have specified the details of the heat exchanger, click Run | Run TEAMS | Calculations + Cost Estimate. A program status dialog box will pop up during the TEAMS run. 9 After TEAMS has finished calculations, close the program status dialog box. 200 2 Defining the Project Basis 10Close the TEAMS GUI by clicking File | Close. After the TEAMS GUI closes, the Icarus window reappears. 11Evaluate the heat exchanger to import TEAMS design values into the Icarus item report. In addition to entering design pressure and temperature (see instructions under Common, page 196), you can enter the following design criteria for heat exchangers:  Launch MUSE X X MUSE™ performs detailed simulation of multi-stream plate-fin heat exchangers made from brazed aluminum, stainless steel or titanium. A valid MUSE version 3.3 license is required to use this feature.  Select “Yes” to launch MUSE during interactive sizing of plate fin heat exchangers. Select “No” to run MUSE in the silent mode. Furnace Fractional Efficiency  The furnace duty obtained from the simulator is the absorbed duty. Total fired duty is obtained by dividing the absorbed duty by fractional efficiency. This value should be <1.0. Fuel Heating Value  The Lower Heating Value (LHV) used to estimate the fuel consumption by fired furnaces. Air Cooler Inlet Temperature  This field represents the default value that shall be used as the inlet air temperature in the case of Air Coolers. Air Cooler Exit Temperature Air Cooler Exit Temperature is used when estimating the surface area of air cooled heat exchangers. The value given in this field is used as the exit temperature for the air cooler. If the field is empty or has value of 0.0, then the Sizing Expert assigns the exit air temperature value to be 10.0 DEG F greater than the inlet air temperature.  For example, if the Air Cooler Inlet Temperature is 77.0 DEG F and you do not enter the Air Cooler Exit Temperature, Aspen Capital Cost Estimator uses 87.0 DEG F as the default value. Apply 2/3 Rule for Design Pressure 2 Defining the Project Basis 201 In the design of shell and tube heat exchangers, design engineers sometimes apply the 2/3rd rule in calculating the design pressure. As per ASME heat exchanger code, if the design pressure of the lower-pressure side (either tube or shell) is at least 2/3rd the design pressure on the highpressure side, then overpressure in the high-pressure side will not result in rupture in the lower-pressure side (provided relief devices have been properly sized).  When specified, the 2/3 rule will increase the design pressure of the low pressure side to at least 67% of the design pressure of the high pressure side, even when the operating pressure on the low pressure side could result in a lower design pressure as per the Design Pressure field. Heat Exchanger Area Minimum Overdesign Factor The calculated heat transfer area is multiplied by the value given in the field. The mechanical design is performed for the final heat transfer area. For example: Calculated surface area = 1000 SF Heat Exchanger Area Minimum Overdesign Factor = 1.1 Surface area used for mechanical design: 1000 X 1.1 = 1100 SF Note that the final surface area in general is greater than the calculated value because of mechanical considerations. Towers In addition to entering design pressure and temperature (see instructions under Common, page 196), you can enter the following design criteria on the Towers form (applies to all towers):  Bottom Sump Height (For Trayed and Packed Towers) X X For both trayed and packed towers, extra height in addition to that required for separation is provided at the bottom for liquid level and reboiler return.  The value in this field is added to the calculated height of the tower. R/R-Minimum (For SHORTCUT model in Pro/II) The SimSci simulator shortcut distillation model calculates the number of theoretical stages required for different ratios of 202 2 Defining the Project Basis operating reflux ratio (R) to minimum reflux ratio (RMinimum).  The number of stages should be available in the simulator report for the ratio chosen. Vapor Disengagement Height (For Trayed and Packed Towers) For both trayed and packed towers, extra height in addition to that required for separation is provided at the top for vapor disengagement before passing to the condenser. The value in this field is added to the calculated height of the tower. Packed Towers In addition to entering design pressure and temperature (see instructions under Common, page 196), you can enter the following design criteria for packed towers:  Packing Type X X Two types of packings, random and structured, are used in packed towers. The type of packing affects the flood point pressure drop estimation and the packing efficiency (HETP) value. The value in this field is used by the Sizing Expert in the calculation of the tower diameter and height.  Packing Factor for Packings Packing factor is used in the Kister and Gill correlation to estimate pressure drop at the flood point. Once the pressure drop is known, the flood velocity is calculated using the latest versions of the generalized pressure drop correlation (GPDC) charts for both the random and structured packings.  Packed Tower Derating Factor With certain systems, traditional flooding equations consistently predict higher flood points than those actually experienced. To allow for such discrepancies, an empirical derating factor (< 1.0) is applied. The derating factor is multiplied by the predicted flood vapor load or liquid load obtained from the traditional equation to obtain the actual or derated flood load for the given system. The derating factors are often vaguely related to the foaming tendency of the system. The higher the foaming tendency, the lower the derating factor. If you do not enter a value, Aspen Capital Cost Estimator uses 1.0 as the derating factor.  Packed Tower Flooding Factor Packed towers are usually designed for 70 to 80 percent of the flood point velocity. This allows a sufficient margin for uncertainties associated with 2 Defining the Project Basis 203 the flood point concept and prediction and to keep the design point away from the region at which efficiency rapidly diminishes (just below the flood point). The Sizing Expert uses the default value specified if the user-provided value is not available.  HETP The concept of HETP (height equivalent of a theoretical plate) enables comparison of efficiency between packed and plate columns. Because there are only a few variables that significantly affect HETP and due to the unreliability of even the best mass transfer models, rules of thumb for HETP successfully compete with the mass transfer models. For the packing types available in Aspen Capital Cost Estimator (given in the Icarus Reference), Aspen Capital Cost Estimator estimates the HETP value based on the packing shape, dimensions and type of material. If a user-provided value is available, then the Sizing Expert uses the value in the above field for calculating the height of the packed tower.  Packed Section Height The value represents the height of each packed section and is used in the design of packed towers to estimate the number of packed sections.  Surface Area Per Unit Volume Higher specific surface areas (surface area per unit volume) increases vapor-liquid contact area and therefore, efficiency. For structured packings, Aspen Capital Cost Estimator determines this value empirically and uses it in estimating HETP if you have not already specified an HETP value. A default value of 75 SF/CF is used in the absence of a user-entered value. Trayed Towers In addition to entering design pressure and temperature (see instructions under Common, page 196), you can enter the following design criteria for trayed towers:  Trayed Tower Flooding Factor X X Flooding is the condition where pressure drop across a tray is sufficient to cause the dynamic liquid head to be equivalent to the tray spacing plus the weir height. At this point, the liquid backup in the downcomer is just at the point of overflowing the weir on the plate above. When this happens, the column fills with a foamy liquid and becomes inoperable. The flood factor is the fractional velocity approach to flooding, that is,, (Actual Vapor Velocity)/(Vapor velocity at the point of flooding). The Sizing Expert uses the default value specified if the user-provided value is not available.  Foaming Tendency Vapor disengagement is easy in non-foaming, low-pressure systems. However, vapor disengagement from downcomer liquid in foaming 204 2 Defining the Project Basis systems is difficult as the liquid hangs on to the entrained vapor. Sufficient residence time must be provided in the downcomer to allow adequate disengagement of vapor from the descending liquid. Industrial practice has created a guideline for the mum downcomer velocity of clear liquids based on their foaming tendency. The following values for the downcomer liquid velocity are used based on the choice for the above field. Downcomer Liquid Velocity, (FPS) Tray Spacing, INCHES Foaming Tendency 18 24 30 Low 0.4 – 0.5 0.5 – 0.6 0.6 – 0.7 Moderate 0.3 – 0.4 0.4 – 0.5 0.5 - 0.6 High 0.2 – 0.25 0.2 – 0.25 0.2 - 0.3 With certain systems, traditional flooding equations consistently predict higher flood points than those actually experienced. To allow for such discrepancies, an empirical derating factor (< 1.0) is applied. The derating factor is multiplied by the predicted flood vapor load or liquid load obtained from the traditional equation to obtain the actual or derated flood load for the given system. The trayed derating factors are often related to the foaming tendency of the system. The higher the foaming tendency, the lower the derating factor. If the user-specified value is not available, a derating factor is selected based on the value of foaming tendency. The default value for foaming tendency is Moderate.  Trayed Tower Derating Factor With certain systems, traditional flooding equations consistently predict higher flood points than those actually experienced. To allow for such a discrepancy, an empirical derating factor (< 1.0) is applied. The derating factor is multiplied by the predicted flood vapor load or liquid load obtained from the traditional equation to obtain the actual or derated flood load for the given system. The derating factors are often vaguely related to the foaming tendency of the system. The higher the foaming tendency, the lower the derating factor. If the user-provided value is not available, or the value 0.0 is entered in the field, then the derating factor is selected based on the foaming tendency of the liquids in the column.  Relative Volatility of Key Components The number of theoretical stages for a trayed tower is obtained from the simulator report. The actual number of trays is calculated by using the tray efficiency value provided by the user in the design criteria file. However, if the field is empty or has a 0.0 value, the tray efficiency for the separation is estimated by using the correlation of relative volatility of key components with tray efficiency. The O’Connell correlation is used to estimate the overall tray efficiency. 2 Defining the Project Basis 205  Tray Efficiency Overall column efficiency is defined by: E_oc = N_t/ N_a where: N_t = Number of theoretical stages required for the separation minus the sum of theoretical stages provided by the reboiler, condenser, and intermediate heat exchangers. N_a = Number of actual trays in the column. Several empirical correlations are available in the literature. Also, rigorous theoretical predictions based on gas and liquid film resistances are available to assist in predicting the tray efficiency. If the user specification is not available for the field, then the value is estimated using empirical correlations from the literature. Configurations Towers Use this form to specify design criteria for tower configurations. Vessels In addition to entering design pressure and temperature (see instructions under Common, page 196), you can enter the following design criteria on the Vessels form (applies to all process vessels):  Residence Time X X The amount of liquid holdup in the vessel is estimated by the liquid volumetric flow through a vessel in a specified amount of time. The vessel volume divided by volumetric flow rate is defined as the residence time for the vessel. For example:  Liquid flow through the vessel: 100 CFM  Residence time: 5 MIN  Calculated liquid volume in the vessel: 100 CFM X 5 = 500 CF.  Process Vessel Height to Diameter Ratio (For Vertical and Horizontal Vessel Design) Aspen Capital Cost Estimator defaults for this field are used if the field is empty or has the value of “0.0.” The Aspen Capital Cost Estimator defaults depend on the operating conditions for the vessel. Based on the operating pressure of the vessel obtained from the simulator report, the following values are used: Pressure (PSIA) 0 – 250 250 – 500 > 500 Process Vessel Height to Diameter Ratio 3 4 5 For example: 206 2 Defining the Project Basis    Vessel operation pressure: <250 PSIA Diameter: 6 FEET Calculated vessel height: 6 X 3 = 18 FEET Residence time overrides Process Vessel Height to Diameter Ratio.  Minimum Vessel Diameter The Minimum Vessel Diameter field is used if the vessel diameter calculated by the sizing routines is less than this value.  Vapor/Liquid Separator Sizing Method When sizing vertical and horizontal vapor liquid separators, Aspen Capital Cost Estimator computes the maximum allowable vapor velocity using the method selected in this field.  Liquid Entrainment Method: This is an empirical correlation developed by Watkins and is a function of vapor and liquid densities, and the parameter Kv, which itself is a polynomial function of vapor and liquid flows and densities.  Particle size separation method: This method estimates the disengagement velocity of the liquid droplet in the continuous vapor phase. The design velocity is determined as a percentage of the disengagement velocity.  Average Liquid Particle Diameter (For particle size separation method) This field specifies the default average liquid droplet diameter. This value is used in the design of horizontal and vertical vessels by the particle size separation method (which can be selected in the Vapor/Liquid Separator Sizing Method field right above this field).  Design Factor Multiplier for Disengagement Velocity (For particle size separation method) This field is used in the calculation of the maximum allowable design velocity, which is a percentage of the disengagement velocity. For example:  Disengagement velocity : 10 FEET/SECOND  Design factor multiplier for disengagement velocity: 0.5  Maximum allowable design velocity: 10 X 0.5 = 5 FEET/SECOND  Separation Factor (For liquid entrainment method) In the liquid entrainment method, the separation factor is used to determine the maximum allowable vapor velocity. The separation factor is either entered by the user in this field or computed by Aspen Capital Cost Estimator using the relation described in the vessel sizing design procedure. Agitated Vessels In addition to entering design pressure and temperature (see instructions under Common, page 196), you can enter the following design criteria for agitated vessels: X 2 Defining the Project Basis X 207  Agitator Type The various types of agitators that can be chosen for design are described in the Icarus Reference. The type of agitator selected determines the default driver power and impeller speed. This is used to estimate the agitation requirements in tanks. Storage Vessels In addition to entering design pressure and temperature (see instructions under Common, page 196), you can enter the following design criteria for storage vessels:  Number of Holding Days X X Storage vessel sizing is determined by estimating the volume of liquid required for a certain period of operation. Aspen Capital Cost Estimator uses this field to determine the liquid volume stored in the vessel. For example:  Inlet flow rate: 500 CF per day.  Number of holding days: 30 (specified by user).  Liquid volume inside the storage vessel: 500 X 30 = 1,500 CF.  Holding Hours in a Day Storage vessel sizing is determined by estimating the volume of liquid required for a certain period of operation. Aspen Capital Cost Estimator uses this field to determine the liquid volume required per day. For example:  Inlet flow rate: 500 CFH.  Holding Hours in a Day: 24 (specified by user).  Final volume per day : 500 X 24 = 12,000 CF/day.  Storage Vessel Height to Diameter Ratio Once the volume of the storage vessel is determined based on the process fluid flow rate and design conditions, the actual dimensions (height and diameter) of the equipment must be estimated. You can specify the dimensional requirements of the equipment using this field. A default is used if the field is empty or has value 0.0. The default depends on the operating conditions for the vessel.  Vapor Free Space (% of Total Storage Vessel Volume) A percent volume of the sized vessel in excess of the required liquid volume. Horizontal Vessels In addition to entering design pressure and temperature (see instructions under Common, page 196), you can enter the following design criteria for horizontal vessels:  Vapor Area /Cross-Sectional Area X 208 X 2 Defining the Project Basis Once Aspen Capital Cost Estimator calculates the maximum vapor velocity, the velocity and flow rate are used to determine the vapor space required. The vapor space is then divided by the vapor area /crosssectional area to get the total required cross-sectional area. The process vessel height to diameter ratio overrides this field.  Separation Factor Multiplier For horizontal vessels, the separation factor is normally higher under similar operating conditions than for vertical vessels. Therefore, the calculated separation factor is multiplied by the separation factor multiplier.  Minimum Boot Length When horizontal vessels are used for three phase separations, the heavy second liquid phase is removed in the drip leg situated at the bottom of the vessel.  Minimum Boot Diameter This field represents diameter of the boot leg which is designed to remove the heavy second liquid.  Boot Leg Liquid Velocity The bootleg cross-sectional area is estimated using the liquid velocity field specified in this field and the process vessel height to diameter ratio. Vertical Vessels In addition to entering design pressure and temperature (see instructions under Common, page 196), you can enter the following design criteria for vertical vessels:  Minimum Disengagement Height X X This is the height from the liquid level to the mist eliminator.  Minimum Height Above the Mist Eliminator Used in the calculation of the total vessel height.  Height of Mist Eliminator Height of mist eliminator section.  Minimum Ht. Btw Low and High Liquid Level Taps The liquid level based on residence time should meet this minimum specification. (Field is at bottom of form, not in Vertical Vessels section.)  Ht. Btw Inlet Nozzle and High Liquid Level Tap Represents the height between the inlet nozzle (center line) and the high liquid level tap. (Field is at bottom of form, not in Vertical Vessels section.)  Ht. Btw Low Liquid Level Tap and Tangent Line Represents the height between the low liquid level tap and the tangent line. (Field is at bottom of form, not in Vertical Vessels section.) 2 Defining the Project Basis 209 Miscellaneous  Vibrating Screen Feed Material This field specifies the solid material type used by solids handling equipment. The material type affects the screen unit capacity which is defined as the amount of solids (TPH) flowing through one square foot of screen cloth based on material, having 6 to 8% moisture, screen cloth having 50% or more open area; 85% screen efficiency. Based on the choice made for this field and the screen opening size, the screen unit capacity is estimated. The following choices are available for this field:  Sand and Gravel  Limestone/Crushed Stones  Coal  Cinders  Coke  Wood  Cyclone Inlet Linear Velocity In case of cyclones, the sizing program assumes a default linear velocity of 150 FPS. You can enter a different velocity here. Configurations Flash Use this form to specify design criteria for flash configurations. Utility Specifications Most chemical processes require heating or cooling process utility fluids to operate. The choice of which utilities to use often plays an important role in determining the total project cost, since the utility type affects heat transfer equipment sizing. In addition, utility costs form an important part of the operating costs of the plant. In the design of heat exchangers and reboilers, Aspen Capital Cost Estimator permits you to select appropriate process utility fluids for the application. You can select utility fluids from those already available in Aspen Capital Cost Estimator or create your own based on utility fluid classes allowed by Aspen Capital Cost Estimator. Once the utility resource for the equipment is selected (either by you or the Sizing Expert), Aspen Capital Cost Estimator creates a utility process stream for the equipment. The utility stream information includes the amount of utility used by the equipment. During the operating cost evaluation, Aspen Capital Cost Estimator processes all the utility streams connected to the equipment to determine the utility cost for every utility resource used in the project. 210 2 Defining the Project Basis You can override these selections by a combination of disabling/enabling appropriate utilities and re-mapping and re-sizing the equipment items. Alternately, you can specify the desired utility in the interactive Sizing Expert. This method is available even if the utility has been disabled. To modify or create a utility stream: 1 Right-click on Utility Specifications in the Project Basis view’s Process Design folder, and then click Edit on the pop-up menu. The Develop Utility Specifications dialog box appears. Aspen Capital Cost Estimator provides 11 default utility streams resources: Cooling Water High Temp Heating Oil * Low Temp Heating Oil ** Refrigerant – Ethane 2 Defining the Project Basis 211 Refrigerant - Ethylene Refrigerant - Freon 12 Refrigerant - Propane Refrigerant - Propylene Steam @165 PSI Steam @100 PSI Steam @400 PSI * High temperature heating oil has the properties of DOWTHERM A. ** Low temperature heating oil has the properties of DOWTHERM E. 2 To modify an existing utility stream, highlight it on the Modify Existing Stream list and click Modify. To create a new utility stream: 1 Click Create in the Option section. 2 In the Create New Utility Stream section, type the name and select one of the following fluid classes: High Temp Heating Oil * Low Temp Heating Oil ** Refrigerant – Ethane Refrigerant – Ethylene Refrigerant – Freon 12 Refrigerant – Propane Refrigerant – Propylene Refrigerant 50 Utility Steam Water * High temperature heating oil has the properties of DOWTHERM A. ** Low temperature heating oil has the properties of DOWTHERM E. 3 Click Create. 4 Enter or modify the specifications on the Utility Specifications form. 212 2 Defining the Project Basis The form contains the following fields:  Description: Describes the utility fluid resource in the sizing report generated by Aspen Capital Cost Estimator. Also, the field value is used to represent the utility fluid usage and its related cost on the Project Summary investment analysis spreadsheet (PROJSUM.ICS).  Fluid: Determines the type of utility fluid described by the current specification. The fluid class is used to determine the heat transfer coefficient, fouling tendency and related thermal and transport properties used by Sizing Expert.  Design Temperature Specifies the temperature, which will be considered in the estimation of the design temperature for the process equipment carrying the utility fluid.  Design Pressure: Specifies the pressure, which will be considered in the estimation of the design pressure for the process equipment carrying the utility fluid.  Inlet temperature: Provides the inlet temperature for the utility fluid.  Exit temperature: Provides the exit temperature condition for the utility fluid.  Pressure: Provides the operating pressure for the utility fluid.  Energy transfer per unit mass: Specifies the amount of energy provided or removed by the utility fluid over the specified temperature range. The value in this field is used to estimate the amount of utility required for the given process conditions.  Unit Cost: Provides the cost value used to estimate the utility cost for the project.  Unit Cost Units: Provides the units for the value provided in the unit cost field. 2 Defining the Project Basis 213  When you specify a new utility fluid resource, all the information on the specification form must be provided; otherwise, the Sizing Expert will not be able to use the utility fluid resource properly. Using the utility specification form, you can specify a maximum of 20 utility fluids. If different utility fluid resource was used by simulation, then it is added to the utility resource in Aspen Capital Cost Estimator. Utility type: Describes the usage of the utility fluid. Select either Heat source or Heat sink. 5 Click OK when done entering the utility specifications. Investment Analysis Note: Investment Analysis specifications are only included in Aspen Capital Cost Estimator if you are licensed to use Aspen Icarus Process Evaluator (Aspen Process Economic Analyzer) or Aspen Decision Analyzer. If you select at startup to use one of these in the Aspen Capital Cost Estimator environment, the Investment Analysis specifications appear in the Project Basis view. Investment Parameters To specify parameters required for investment analysis: 1 Right-click on Investment Parameters in the Project Basis view’s Investment Analysis folder. 2 On the menu that appears, click Edit. Aspen Capital Cost Estimator displays the Investment Parameters in the Main Window. 214 2 Defining the Project Basis A description of the parameters follows. General Investment Parameters  Period Description This field lets you enter text indicating the name/description of a period. The period is defined in “Number of Weeks per Period.” The period description is used in the display of some of the results in the spreadsheets.  Number of Weeks per Period The period used for investment analysis is defined in terms of number of weeks.  Number of Periods for Analysis The number of periods to include in the cashflow and other project totals and calculations.  Tax Rate 2 Defining the Project Basis 215 The tax rate for investment analysis, in terms of percent per period, is used to calculate the percentage of earnings before taxes that must be paid to the government.  Desired Rate of Return The desired rate of return, in percent per period, for the investment.  Economic Life of Project This field indicates the length of time in terms of periods over which capital costs will be depreciated.  Salvage Value (Percent of Initial Capital Cost) This number indicates the approximate worth of capital costs at the end of the Economic Life of Project. The number is expressed as a percent of initial capital cost.  Depreciation Method There are four depreciation methods allowed in Aspen Capital Cost Estimator. The description of each follows:  Straight Line The straight line method is used most commonly. In this method, the Salvage Value is subtracted from the Total Project Cost. This result is then divided by the Economic Life of Project, so that the project is depreciated evenly over its economic life.  Sum of the Digits When this method is used, the Depreciation Expense decreases during each period of the Economic Life of Project. Therefore, the highest value for the depreciation occurs in the first period and decreases every period thereafter. The sum of the digits multiplier is n/((N(N+1))/2), where N is the Economic amount is the Total Project Cost less its Salvage Value. For the duration of the project’s economic life, this factor is multiplied by the depreciable amount.  Double Declining (Balance) When this method is used, the project is depreciated in geometric increments. The multiplier for the first period is 2/N, where N is the Economic Life of Project. For the second period the depreciation rate, D2, is (1-D1)D1 where D1 is 2/N. For the third period, the depreciation rate, D3, is (1-D1)D2. For the fourth period, the depreciation rate is (1-D1)D3. These factors are multiplied by the Total Project Cost. This process (multiplying the factor by the capital cost) continues until the Straight Line Method produces a higher value for the depreciation. When the Straight Line Method produces a higher value, this higher value is used for the remaining depreciation calculations.  Accelerated Cost Recovery System (ACRS) The ACRS approach assumes that operations begin during the second half of the first period and stop during the first half of the last period. Therefore, as a result of the two half-periods (one at the beginning and one at the end of the operating cycle), it takes 6 periods to depreciate a project which has an Economic Life of 5 periods. The ACRS adapts the Double Declining Balance Method to the half-life system. The depreciation rate for the first period, D1, is 2/N, where N is the Economic Life of Project. However, the half-life convention reduces this factor to 1/N. For the second period the depreciation rate, 216 2 Defining the Project Basis D2, is D1(1-1/ N). For the third period the depreciation rate, D3, is D1(1-1/N-D2). This process (multiplying the factor by the Total Project Cost continues until the Straight Line Method produces a higher value for the depreciation. When the Straight Line Method produces a higher value, this higher value is used for the remaining depreciation calculations. Escalation Parameters  Project Capital Escalation This number indicates the rate at which project capital expenses may increase expressed in percent per period. If the addition of EngineerProcure-Construct (EPC) period and start-up period is greater than one whole period, Project Capital Escalation is used to escalate the capital expenses for periods beyond the first period.  Products Escalation This is the rate at which the sales revenue from products of the facility are to be escalated (increased) in terms of percent per period.  Raw Material Escalation This is the rate at which the raw material costs of the facility are to be escalated (increased) in terms of percent per period.  Operating and Maintenance Labor Escalation This is the rate at which the operating and maintenance costs of the facility are to be escalated (increased) in terms of percent per period. The operating labor costs include operators per shift and supervisory costs.  Utilities Escalation User-entered percentages reflecting the anticipated utility price increase each period. Project Capital Parameter  Working Capital Percentage The working capital expressed as a percentage of total capital expense per period indicates the amount required to operate the facility until the revenue from product sales is sufficient to cover costs. It includes current assets such as cash, accounts receivable and inventories. When the facility starts producing revenue, this cost item can be covered by the product sales. Operating Costs Parameters  Operating Supplies This field indicates the cost of miscellaneous items that are required in order to run the plant in terms of cost per period.  Laboratory Charges This is a cost per period indicating the cost of having product analyzed each period. 2 Defining the Project Basis 217  Operating Charges This includes operating supplies and laboratory charges. It is specified as a percentage of the operating labor costs. (If you specify a value for either “Operating Supplies” or “Laboratory Charges”, the system will add the two entered values and calculate the percentage of Operating Labor Costs. (This is done for compatibility with earlier releases of the system.)  Plant Overhead This field consists of charges during production for services, facilities, payroll overhead, and so on This number is specified as a percent of operating labor and maintenance costs. This number should not be used for the construction of the facility, only for operation after start-up.  G and A Expenses This represents general and administrative costs incurred during production such as administrative salaries/expenses, R&D, product distribution and sales costs. Specify this number as a percentage of subtotal operating costs. Facility Operation Parameters  Facility Type This field defines the facility type. The following types are currently available:  Chemical Processing Facility  Food Processing Facility  Oil Refining Facility  Petrochemical Processing Facility  Pharmaceutical Facility  Pulp and/or Paper Processing Facility  Specialty Chemical Processing Facility (A specialty chemical is defined as a chemical which is produced in low quantity and has a usually high price per unit.) The type of facility affects the number of operators/shift and maintenance costs of facility equipment.  Operating Mode This refers to the operating mode of the facility. The available options are:  Continuous Processing - 24 Hours/Day  Continuous Processing - Less than 24 Hours/Day  Batch Processing - 24 Hours/Day  Batch Processing - 1 Batch per Shift  Batch Processing - More than 1 Batch per Shift  Intermittent Processing - 24 Hours/Day  Intermittent Processing - Less than 24 Hours/Day The operating mode of the facility affects the number of operators/shift and maintenance costs of facility equipment.  218 Length of Start-up Period 2 Defining the Project Basis After the facility has been constructed (that is,, gone through engineering, procurement and construction), the plant must go through the owner’s start-up period until it starts producing the product to be sold. This period is referred to as Length of Start-up Period in weeks and is added into the EPC duration.  Operating Hours per Period This field refers to the number of hours per period that the plant will be operating.  Process Fluids Process Fluids indicate the types of fluids involved in the process. The selection affects operating and maintenance costs. The selections are:  Liquids  Liquids and Gases  Liquids and Solids  Liquids, Gases, and Solids  Gases  Gases and Solids  Solids Operating Unit Costs To specify operating unit costs: 1 In the Project Basis view’s Investment Analysis folder, rightclick Operating Unit Costs. 2 On the menu that appears, click Edit. Aspen Capital Cost Estimator displays the Operating Unit Costs in the Main Window. 2 Defining the Project Basis 219 The Operating Unit Cost form specifies Labor Unit Costs and nonheat transfer Utility Unit Costs. Labor Unit Costs are given for Operators and Supervisors. The total cost of operating labor is calculated by: 1 Determining the total number of operators and supervisors necessary to run the facility for a certain number of hours. 2 Adjusting that number for the number of hours the facility operates per period. 3 Multiplying that number by the respective Labor Unit Costs and adding them together. Labor Unit Costs  Operator The loaded wage rate paid for operating the facility in terms of the cost per operator per hour. Operator labor includes labor that is associated with operating the facility.  Supervisor The loaded wage rate paid for supervision in terms of the cost per supervisor per hour. Supervision includes all labor associated with overseeing personnel who operate the facility.  Utility Unit Costs The non-heat transfer utility unit costs are also specified in this file as “over the fence” costs. Utilities used for process heating and cooling are given in the Utility Specifications File.  Electricity The unit cost per KWH of electricity used for the facility.  Potable Water The potable water unit cost per MMGAL or MB used for the plant. 220 2 Defining the Project Basis  Fuel The fuel unit cost per MMBTH or MEGAWH used for the plant.  Instrument Air The instrument air unit cost per KCF or MB. Raw Material Specifications An investment analysis conducted on any process needs to provide an accurate figure for total project expenditure. Since operating costs are usually a large part of this cost, it is important to accurately account for all raw materials consumed in the process. Aspen Capital Cost Estimator lets you identify simulator streams as raw materials for the process. The raw material costs will be directly placed in the PROJSUM.ICS spreadsheet for use in cash flow analyses. To develop raw material specifications: 1 Right-click on Raw Material Specifications in the Project Basis view’s Investment Analysis folder, and then click Edit on the pop-up menu. 2 Defining the Project Basis 221 The Develop Raw Material Specifications dialog box appears. 2 In the Option group, click Create. 3 In the Create New Stream group, type a name for the stream. 4 Select the Basis (Mass, Volume, or Energy) and the Phase (Solid, Liquid, or Gas) for the stream. 5 Click Create. The Raw Material Specifications dialog box appears. 6 The following input information is required in order to estimate the raw material costs during the evaluation of the operating costs for the project: Process Stream (or “none” if user-defined); Rate (do not specify a rate if a process stream is selected); and Cost Per Unit. In addition to the above minimum information, you have to specify certain field values for the raw material fluid program to estimate the raw material rate necessary for the cost estimate. 222 2 Defining the Project Basis If you specify “none” in the Process Stream field, then the value for the Rate field must be specified in the appropriate units. If you specify a process stream, then the program determines the raw material rate in the desired Specification Basis and units. You can specify a maximum of 150 raw material streams. The Raw Material Specifications form contains the following fields:  Description The value you provide in this field will be used to describe the raw material in the Project Summary investment analyses spreadsheet (PROJSUM.ICS)  Specification Basis This field describes the raw material properties from the following list: Mass, Gas Mass, Liquid Mass, Solid Volume, Gas Volume, Liquid Volume, Solid Energy    Process Stream This field provides a list of fluid streams present in the current project. You can select any stream to represent the raw material. Also, there is a provision in Aspen Capital Cost Estimator for you to provide actual value for the raw material rate if none of the process streams represent the raw materials for the project. In this case, you must specify the field value as “none.” Rate This field gives the total rate of raw materials consumed for the process in the desired rate units. When a new raw material fluid is specified, Aspen Capital Cost Estimator checks whether enough information has been specified to estimate the raw material cost. Rate Units This field describes the flow rate units for the current raw material. The choices available for the field vary with the selection made for Specification Basis and your choice of Base UOM: Specification Basis I-P METRIC Mass, Gas LB/H KG/H KLB/H MEGAG/H MLB/H TON/H TPH 2 Defining the Project Basis 223 Mass, Liquid LB/H KG/H KLB/H MEGAG/H MLB/H TON/H TPH Mass, Solid LB/H KG/H KLB/H MEGAG/H MLB/H TON/H TPH Volume, Gas GPH M3/H MMGAL/H L/S CFH KCFH Volume, Liquid GPH M3/H MMGAL/H L/S CFH KCFH Volume, Solid GPH M3/H MMGAL/H L/S CFH KCFH Energy BTU/H W MMBTU/H KW MEGAW CAL/H  Unit Cost This field provides the cost value per unit mass, volume or energy used to estimate the raw material cost for the project. 7 When you are done entering raw material specifications, click OK. The new stream appears in the Existing Stream list on the Develop Raw Materials Specifications dialog box. You can enter a maximum of 150 raw material streams using this dialog box. When done, click Close. Product Specifications An investment analysis conducted on any process needs to include an accurate figure for the project’s total revenue. In order to do so, it is very important to accurately account for all the products obtained from the process. Aspen Capital Cost Estimator lets you identify simulation streams as product materials for the process. Once the simulation stream is defined, Aspen Capital Cost Estimator determines the 224 2 Defining the Project Basis necessary amount of product materials generated based on the information provided in the product material specification file. The product material costs are directly placed in the PROJSUM.ICS spreadsheet, where they are used for further cashflow analyses. To develop product specifications: 1 Right-click Product Specifications in the Project Basis view’s Investment Analysis folder, and then click Edit on the pop-up menu. The Develop Product Specifications dialog box appears. 2 In the Option group, click Create. 3 Enter a new stream name, select a basis and phase; then click Create. The Product Specifications dialog box appears. 2 Defining the Project Basis 225 4 The following input information is needed for Aspen Capital Cost Estimator to estimate the product material costs during the evaluation of the operating costs for the project:   Description The value specified in this field is used to describe the product material fluid in the investment analyses spreadsheet (PROJSUM.ICS). Specification Basis This field describes the product material properties from the following list: Mass, Gas Mass, Liquid Mass, Solid Volume, Gas Volume, Liquid Volume, Solid Energy    226 Process Stream This field provides a list of streams present in the current project. You can select any of the streams to represent the product material. Also, there is a provision in Aspen Capital Cost Estimator for providing an actual value for the product material rate if none of the process streams represent the product materials for the project. In this case, you must specify the field value as “none.” Rate This field defines the total rate of product materials obtained for the process in the desired rate units. Do not enter a value if you have specified a process stream. When a new product material is specified, Aspen Capital Cost Estimator checks whether the minimum information necessary to estimate the product material cost has been specified. The following minimum information must be present before Aspen Capital Cost Estimator can proceed with the estimate. Rate Units 2 Defining the Project Basis This field describes the flow rate units for the current product material. The choices available for the field vary with the selection made for Specification Basis and your choice of Base UOM: Specification Basis I-P METRIC Mass, Gas LB/H KG/H KLB/H MEGAG/H MLB/H TON/H TPH Mass, Liquid LB/H KG/H KLB/H MEGAG/H MLB/H TON/H TPH Mass, Solid LB/H KG/H KLB/H MEGAG/H MLB/H TON/H TPH Volume, Gas GPH M3/H MMGAL/H L/S CFH KCFH Volume, Liquid GPH M3/H MMGAL/H L/S CFH KCFH Volume, Solid GPH M3/H MMGAL/H L/S CFH KCFH Energy BTU/H W MMBTU/H KW MEGAW CAL/H Unit Cost The field provides the cost value used to estimate the product material cost for the project. 5 When you are done entering product specifications, click OK. The new stream appears in the Existing Stream list on the Develop Product Specifications dialog box. You can enter a maximum of 150 product material streams using this dialog box. When done, click Close. 2 Defining the Project Basis 227 Developing Streams After opening a project, new streams can be developed. You have the option to develop completely new streams or use an existing stream as a base. When an existing stream is used as a base, the new stream can be either copied from the existing stream (Absolute Basis mode) or copied from and linked dynamically to the existing stream (Relative Basis mode). To develop streams, right-click on Streams in the Project Basis view’s main folder (at the bottom), and then click Edit on the pop-up menu. The Develop Streams dialog box appears. Viewing or Modifying an Existing Stream To view or modify an existing stream, select the stream on the Modify tab view. You may need to use the scrollbar(s) to locate 228 2 Defining the Project Basis a stream if a large number of streams exist in the project. With the desired stream highlighted, click Modify to have the stream information displayed in a specifications form. The functions of the six buttons on the Develop Stream specifications form are explained below: Click To do this: OK Perform a check on the information currently present in the Develop Stream specifications form to ensure that all information needed to specify the stream is completed. Aspen Capital Cost Estimator generates error messages indicating missing data. Generate estimates for any specifications not entered. Save the information in the Develop Stream specifications form. The Develop Stream specifications form closes and the Develop Streams dialog box re-appears. Apply Same as clicking OK, but does not exit the Develop Stream specifications form. This lets you review the estimates and revise the data. Update Same as clicking Apply, except that if the Primary Fluid Component, the Temperature, and/or the Pressure were changed, then all the physical properties of the stream will be estimated using these new values. Cancel Exit the Develop Stream specifications form without making checks and does not save or change any information in the database. Reset Reset the information in the Develop Stream specifications form to the values previously saved into the database. Any changes have been made since opening the form will be lost. Mixture Define a stream as a mixture. Opens the Mixture Information dialog box discussed below. 2 Defining the Project Basis 229 Most Develop Stream specifications need no further explanation. Those that do are described below.  Primary Fluid Component One of the most important specifications in this form is Primary Fluid Component, which is classifies the chemical components of a stream. The fluid selected here is used as the basis for any properties that are unavailable and need to be estimated to complete the specifications for the stream. The available general fluid classifications are:  Alcohol  Medium Hydrocarbon Liquid  Aromatic Liquid  Miscellaneous Inorganic Liquid  Halogenated Gas  Miscellaneous Organic Gas  Heavy Hydrocarbon Liquid  Organic Acid  Hydrocarbon Gas  Inorganic Gas  Very Heavy Hydrocarbon Liquid  Solid  Light Hydrocarbon Liquid The following pure components are also available for selection as the Primary Fluid Component of a stream:  Acetic Acid  Ammonia  Argon  Carbon Monoxide  Carbon Dioxide  Ethane  Ethanol  Ethyl Benzene  Ethylene  Glycerol  Hydrogen  Isopropyl Alcohol  Methane  Methanol  N-Butanol  Nitric Acid  Nitrogen  Oxygen  Phosphoric Acid  Propane  Propanol  Propylene  Steam  Sulfuric Acid  Toluene  Water If the Primary Fluid Component is specified, the other needed information will be filled in with default values. This feature is only apparent when no temperature or pressure is entered into the Develop Stream specifications form and the Primary Fluid Component is changed. After changing the Primary Fluid Component, either press Enter or click on another field and the default values will be loaded. If either the pressure or temperature value is changed from the default value, clicking OK , Apply, or Update will estimate the properties at the new condition(s).  Base Stream The Base Stream field contains the name of the stream on which the displayed stream was based. This cannot be changed. If the name begins with the character “$”, the stream was created using Absolute Basis and the stream name following this character is that of the parent stream. A stream created using Absolute Basis uses the data from the parent stream; however, if the parent steam’s data changes afterward, the Absolute Basis stream is not updated. If the value begins with the character “@”, the stream was created using the Relative Basis and the stream name following this character is that of the parent stream. A stream created using Relative Basis is updated when its parent stream’s data changes. 230 2 Defining the Project Basis  Description Select information from the menu to describe the particular stream. For example, you can indicate the source component of the stream (for example, From Pump P-103) or tag it with one of the available utility stream names.  Mass Flow The Mass Flow fields are used to determine the phase of the stream. For instance, if the stream has only Liquid Mass Flow specified, the stream is totally liquid; therefore, it will have no vapor properties estimated for it. The reverse is true for a case with only a Vapor Mass Flow specified. For cases with both types of flow, all properties will be estimated and the Primary Fluid Component will belong to the phase of the largest mass flow.  Note: Aspen Capital Cost Estimator automatically calculates Total Mass Flow from the individual mass flow values. Density The Density fields are required information. Thus, if a particular phase has a mass flow rate specified, then the corresponding density must also be specified. Clicking Update will estimate any required Density fields based on the flow rate, except in the case of Solid Mass Density. It is recommended that you enter a Liquid Mass Density if one is available. Mixture Specs Dialog Box Clicking Mixture on the Develop Stream specifications form accesses the Mixture Specs dialog box. Note: After you click Apply, Aspen Process Economic Analyzer normalizes the Fraction values to total a sum of one. The values shown to the right would change into the values shown on the next page. 2 Defining the Project Basis 231 The mixture information specified in this dialog box is used to estimate properties as a mixture of the specified composition. If no mixture information is present, the stream is assumed to be pure Primary Fluid Component. The fraction information can be entered on either a Mass or Mole Fraction Basis, as specified in the Fraction Basis section. The Cancel and Reset buttons behave in a similar manner as their respective buttons on the Develop Stream specifications form. The OK and Apply buttons also behave in a similar manner as their respective buttons on the Develop Stream specifications form, except the checking is different. Here, a check is made to ensure that the fractions have a total sum of one. If not, the values are normalized to give a total sum of one, as indicated below. 232 2 Defining the Project Basis The check also combines duplicate entries into one entry by combining the two fraction specifications. After the check is done, the components are sorted in order of decreasing fractional amount, as shown above. When you click OK, Aspen Capital Cost Estimator loads into the specifications form the name of the fluid with the highest fraction and the properties of the mixture generated from the contributions of the individual components. Estimation of Utility Usage and Resulting Costs in Aspen Capital Cost Estimator Utility usage estimation is based on the stream information. All the streams that are present in the project are taken into consideration for the estimation of the utility usage for the project. This includes all utility streams, user-defined streams, simulator streams, and pre-map Streams. The Description field on the Develop Stream spreadsheet can be used to designate streams as utilities. If the Description field for a stream exactly matches (exact text characters and spaces) the Description field for any utility resource as given on the Utility Specifications spreadsheet, then that stream is included in the utility usage calculation. If you change the description of any of the simulator or pre-map streams, then the new description you provided is used for this calculation. Also, stream connectivity information is used to identify the nature of the stream. If the stream is being generated then it is considered to be revenue for the project, and if it is being consumed it is considered an expense. ( Note: Streams that are 2 Defining the Project Basis 233 connected at both ends to process equipments are ignored in estimating the utility usage costs. Also, utility streams that have a zero unit cost do not show up in the final report.) User-defined streams that are not connected to any equipment (do not show up in the PFD) are considered as input streams, that is,, consumption. System-generated utility streams are included in the utility usage calculation as long as they are connected to equipment. A case where they would be disconnected would be if you manually disconnect these streams or if the equipment to which these streams are connected is deleted. Stream Connectivity Process streams are “connected” to project components in a real way. You can see this in the Process Flow Diagram (PFD), which you can display after loading and mapping simulator blocks. Each stream has a Source end and a Sink end. The Source end connects to an Outlet port on a component and the Sink end to an Inlet as depicted below: In the PFD view, when you Edit Connectivity (see page 310) for the Sink end of a stream and move the cursor over a component, only Inlet port(s) turn green, thereby indicating their availability for making a connection to a Sink end. X X The same concept also carries into the Interactive Sizing form (see page 366). Only streams whose Sink ends are not connected are listed in the pulldown for any Inlet. This explains why the Inlet and Outlet pulldowns will include different streams. X 234 X 2 Defining the Project Basis Since the connectivity in the PFD and the Interactive Sizing form are two ways of looking at the same information, Aspen Capital Cost Estimator tracks your changes and synchronizes them in both views. Thus, if you change the connectivity in one view, Aspen Capital Cost Estimator automatically changes it in the other view. When you first map and size components, the streams in the simulator will be connected to the project components and the underlying process conditions of those streams are available for further use. For example, you may create new streams based on the properties of any stream, connected or not, then use these new streams as Sources/Sinks for connecting new components (you might do this to set up spares). You may also add a New Mapping to an item already mapped and the newly mapped and sized item utilizes the underlying stream properties. Creating A New Stream Streams can be created from scratch or by using a base stream. To create a stream from scratch: 1 Go to the Create tab view on the Develop Streams dialog box. Without selecting a stream from the Base Streams list, click Create. (The Basis selection will not matter.) The Create Stream dialog box appears. 2 Enter a name for the new stream in the Create Stream dialog box. This name must not be the same as any existing streams in the project. Click OK. The Develop Stream specifications form appears. Note: See page 229 for descriptions of the buttons and fields on this form. X 2 Defining the Project Basis X 235 3 Type values for the new stream. See page 230 for descriptions of the different fields. When done, click OK. X X To create a stream based on an existing stream: 1 On the Create tab view on the Develop Streams dialog box, click the stream to be used as the base. 2 Select the Basis mode. o If the Basis mode is Relative, the data from the two streams will be linked so that when the base stream is changed the new stream will inherit these changes. 236 2 Defining the Project Basis o If the Basis mode is Absolute, the data from the base stream is copied to the new stream at the time the new stream is created. Changes in a base stream will not affect a new stream created via Absolute basis. 3 Click Create. The Create Stream dialog box appears. 4 On the Create Stream dialog box Stream Name field, type a name for the new stream. This name must not be the same as any existing streams in the project. 5 Click OK. Aspen Capital Cost Estimator displays the specifications form for the newly created stream. The data is that of the Base Stream. Data appears gray (dimmed) to indicate that it is relative to a referenced Base Stream. Note: See page 229 and 230 for descriptions of the buttons and fields on this form. X 2 Defining the Project Basis X X X 237 Even in a Relative Stream, you can override any value with a manual entry. If you do so, the text turns black, indicating that that value is absolute and therefore no longer references a Base Stream. 6 Make modifications to the data; then click OK. Deleting a Stream To delete a stream: 1 On the Delete tab view, click the stream to be deleted. You may need to use the scrollbars to locate a stream if a large number of streams exist in the currently opened project. Note: Only user-added streams and streams added by the Sizing Expert as utilities can be deleted. 238 2 Defining the Project Basis 2 Click Delete. A dialog box will appear asking for confirmation of the delete action. 3 Click OK to delete the stream. – or – Click Cancel to retain the stream. Specification Libraries The default specifications are derived from files that you can access, when outside of a project, from the Palette’s Libraries view. 2 Defining the Project Basis 239 When you create a project scenario, Aspen Capital Cost Estimator selects the specification files to use based upon the selected units of measure basis. However, you can right-click on any of the Project Basis specification that have corresponding libraries in the Palette, click Select on the pop-up menu, and select a different file from which to derive the default specifications. Customizing Specification Libraries When no project is open, you can create your own specification files or edit existing files. Then, when in a project, you can select your specification files. For example, if you frequently created project scenarios that used the same design basis, you could create a Basis for Capital Costs specification file with those design basis specifications. Then you could just select this file, instead of entering the specifications every time. If, after making modifications to your libraries, you wish to revert to the original libraries, you can copy or import the copy of the installed libraries provided in the following folder: …\AspenTech\Economic Evaluation V7.3\Program\Sys\Libraries Creating a File To create a specification file: 1 With no project open, go to the Libraries tab view in the Palette, and expand the desired specification category. 2 Except for Code of Accounts, right-click on the units of measure basis folder – Inch-Pound or Metric. For Code of Accounts, right-click on the Code of Accounts folder. 3 On the menu that appears, click New. 240 2 Defining the Project Basis The New [Specification Category] dialog box appears. 3 Type a file name and, if desired, a file description. 4 Click OK. Aspen Capital Cost Estimator creates the file and displays the specifications in a separate window. 5 Edit the specifications just as in a project. 6 When you are done, close the specifications window. If a library file is open, you cannot access another library file or open a project. See page 250 for instructions on selecting the newly created file for use in a project. X 2 Defining the Project Basis X 241 Modifying a File To modify an existing specification file: 1 In the Palette (Libraries view), right-click the specification file. 2 On the menu that appears, click Modify. Importing a File You can import specification files from elsewhere on your computer or network. To import a file: 1 In the Palette (Libraries view), expand the library to which you wish to import a file. 2 Except for Code of Accounts, right-click on the units of measure basis folder – Inch-Pound or Metric. For Code of Accounts, right-click the Code of Accounts folder. 3 On the menu that appears, click Import. 242 2 Defining the Project Basis 4 In the Select a File for Import dialog box, locate the file and then click Open. The file is copied to the appropriate sub-folder. Duplicating a File To duplicate a file: 1 In the Palette (Libraries view), right-click on the file you want to duplicate. 2 On the menu that appears, click Duplicate. 2 Defining the Project Basis 243 3 Type a file name and description (optional) for the new file. 3 Click OK. Aspen Capital Cost Estimator creates the file and displays the specifications in a separate window. 4 Edit the specifications just as in a project. 5 When you are done, close the specifications window. If a library file is open, you cannot access another library file or open a project. See below for instructions on selecting the newly created file for use in a project. 244 2 Defining the Project Basis Deleting a File To delete a specification file:  In the Palette (Libraries view), right-click on the file to be deleted, and then click Delete on the pop-up menu. Note: You cannot delete files named Default, only modify them. Customizing Steel Costs Using an External File You can customize the unit prices for steel plant bulks in the system using an external file. The weight break-down for structural steel columns and beams can also be customized. You can specify the prices of the following plant bulk steel items using the external file: Plant bulk steel items Weight used by the system Extra heavy steel > 80LB/FT [122KG/M] Heavy steel 40 to 80LB/FT [60 to122KG/M] Medium steel 20 to 40LB/FT [30 to 60KG/M] Light steel 12 to 20LB/FT [18 to 30KG/M] Extra light steel < 12LB/FT [18KG/M] Reinforcing bars (Rebar) Ladders with cage 18 LB/FT Ladders without cage 10 LB/FT Handrails 17 LB/FT Stair channels 13.4 LB/FT Stair treads 30.4 lb/each Platforms 20.62 LB/SF Grating 1x3/16 IN [25x5 MM] CS welded bar Diagonal Bracing To use the external steel file: 1 In the project basis view, under Customer External Files, right-click Steel Material; then click Select. 2 Defining the Project Basis 245 A Default file is provided as an example for you. 2 Click OK to select this file. You can modify this file and save it for future use. You can also create new files in the libraries view similar to other external library files. To edit the selected external file:  Right-click Steel Material; then click Edit. In    246 the dialog box that appears, you can edit: Units of measure Currency conversions Steel cost specifications 2 Defining the Project Basis Units of Measure: You can specify whether the weight values in the file are in I-P (Inch-Pound) or METRIC units of measure. The Default file has I-P units of measure. The weights in the Default file are in LB and the costs are in Currency/LB. Currency Conversions: The costs specified in your external file are interpreted to be in the currency you are using. You must specify conversion rates from the user currency to the various project basis currencies. In the Default file, all the costs specified are in USD/LB. Therefore, the conversion rate for US country base is 1.00. If you want to enter costs in another currency, you must specify the appropriate conversion rates (your currency/country base currency) in the Currency Conversions dialog box. 2 Defining the Project Basis 247 Specifications: Use the Specifications dialog box to specify the weight break-downs for structural steel and the unit costs for all the items. Specify the weight only for the structural steel members. Weights specified for other items will be ignored by the system. To specify the weigh break-down for structural steel members:  Enter the minimum weight for a given category. For example, in the Default file all structural steel above 80 LB/FT is 248 2 Defining the Project Basis considered Extra heavy steel and will get the COA modifier 5 for Extra heavy steel. Specify the costs should be specified in your currency per unit weight. If using I-P units, costs should be in your currency/LB. For metric units costs should be in your currency/KG. The cost-base year should not be greater than the cost-base year for the version of Economic Evaluation being used. If the cost-base year is less than the cost-base year of the system, the costs are indexed to the current year by the system. The COA modifier is given for reference only and cannot be edited. Notes: Reinforcing bars (Rebar) costs: If you have specified the Rebar costs in the Design basis | Civil/Steel Specs dialog box, then the value specified in the external file will be ignored and the value you entered in the design basis will be used. Grating costs: The grating costs in the external file are applicable only to the default (1x3/16 IN [25x5 MM] CS welded bar) grating in the system. If you specify any other grating type then the cost specified in the external file will not be used for that grating. Exporting a Customized External Steel Costs File To save a customized external steel costs file for future use in other projects:  Right-click Steel Materials; then click Export to Library. 2 Defining the Project Basis 249 You can also create customized external steel files in the libraries outside of a project. Files created in the libraries can then be selected for use within any project. Selecting Specification File for Use in a Project After creating a new specification file, you still need to select it in Project Explorer for Aspen Capital Cost Estimator to use its specifications. To select a specification file: 1 Open the project scenario in which you wish to use the file. 2 In Project Explorer (Project Basis view), right-click on the appropriate specification category. 3 On the menu that appears, click Select. 250 2 Defining the Project Basis Aspen Capital Cost Estimator displays a dialog box listing the files available for the selected category. 4 Select a new file from which to derive default specifications; then click OK. Changing File Directory Location If you decide to store specification library files in a directory other than the default, move the default files to the new location and recreate the same sub-folder arrangement. Otherwise, Icarus will generate an error when you point to the new location. Instrument Field Hook-Up Customization When you include a component with an instrumentation loop in your project, Aspen Capital Cost Estimator accounts for instrument field hook-up in the project’s direct costs and includes the parts for the instrument field hook-up on the Direct Costs – Overall Installation Details report. 2 Defining the Project Basis 251 The defaults are detailed in two ASCII files:  Sample_Inasmbly.dat  Sample_Inparts.dat These two files are stored in the UserData folder. To customize the instrument field hook-ups: 1 Open and modify these files in Wordpad or any other ASCII text editor. 2 Save the files as Inasmbly.dat and Inparts.dat. 252 2 Defining the Project Basis The Sample_Inasmbly.dat file is shown below. There are extensive instructions for use provided toward the top of the scrollable document. Be sure to read these carefully before modifying. The editor must not introduce non-printing characters other than a space or CR/LF, that is,, no tabs are allowed. The field hook-up assembly data is organized into the following columns:  LOOP SYMBOL: Symbol that describes the sensor loop.  DESCRIPTION: Place for comments; does not affect usage.  PART NO.: A reference to the part number in Inparts.dat file for the part used in this assembly.  QTY: Quantity of this part to include in this assembly. FG: Flag identifying this part as Piping or Instrumentation. The Piping parts are drawn from items in Inparts.dat with IDs of 1,000 or less. Their material of construction matches the material on the process side (component or pipe). These parts are the ones eliminated when you turn off the process connection when defining modifications to a loop. The Instrumentation parts are drawn from the remaining items in Inparts.dat, which includes specifications for their materials of construction. 2 Defining the Project Basis 253 Note: When you create/edit an InAsmbly.Dat file, and you are specifying a loop, you have the option to set the FLAG column field to A instead of the default which is blank (Or P). For loops that you've created an A version of, the system expects you to also have defined a primary (default) version. Then by selecting A instead of P in the project (at the design basis on the loop) you can cause it to pick your A version instead of the usual selection of P. Important: The A vs. P choice is not about selecting the internal default or the Instrument Assembly.Dat loop definition. It is about choosing between two loop definitions in the selected Instrument Assembly.Dat file, of you've picked one.  NOTE: Additional place for comments; does not affect usage. By changing the part types and quantities for each, you change the results developed for the field hook-ups. You can:  delete the parts of a hook-up  revise each line  add parts to a particular field hook-up from Inparts.dat The Sample_Inparts.dat file is shown below: 254 2 Defining the Project Basis There are extensive instructions for use provided toward the top of the scrollable document. Please read these carefully before modifying the file, with the same limitations as described above. The field hook-up assembly parts are organized into the following columns:  ID: A unique, four-digit part number. This shows up as the PART No. in Inasmbly.dat.  COA: A valid Icarus instrumentation Code of Account (COA). You should use an Icarus COA even if you plan to redefine the COA sets (see Icarus Reference, Chapter 34, “Code of Accounts”).  QT: Quantity- must be set to 1.  UT: Unit of measure.  DIA I/P: Diameter (if applicable) in Inch-Pound (IP) units. This is included in the line item details print out to identify the item.  DIA MET: Same as above, but for Metric.  DESCRIPTION: Name for the line item to print in the details section of reports.  MATL: One of the valid Icarus materials of construction listed in the file.  BCOST (USD): Material cost of the part in USD for the YEAR indicated in the file. This will be automatically converted to the currency of the project. The currency units are not important- the USD symbol here is for reference purposes only. You may change the symbol and/or enter your own cost values. However, it is critical that you enter the conversions between this currency and the four country currencies known to Icarus. That is done using the four CURCONs listed in the file.  MH: Installation man-hours per indicated quantity (for example, per LF or M, EA, etc).  CREW: Select one of the available Icarus instrumentation crews to perform the work.  YEAR: The system will automatically escalate the user-entered material cost (see above, under BCOST) to the base year for the version of Aspen Capital Cost Estimator that is running the estimate. For example, if a cost is specified as being valid in 2002, and you are running a First Quarter 2004 (1Q ’04) version of the system, then the cost in this file will be escalated to 1Q ‘04 before 2 Defining the Project Basis 255 appearing in any report. It is important to note that the escalation index used is specific for the instrumentation account. This usually differs from the global system base indices listed in the Icarus Reference. The Release Notes provided with each cost release details the year-to-year changes by major account. Using the Plot Plan Layout Tool Note: To enable the Plot Plan Layout Tool, you must set Print Equipment Coordinates on the Equipment Specs sheet to Y (Print coordinates on datasheet). Default is N (Do not print coordinates on datasheet). To enable the Plot Plan Layout Tool: 1 On the Project Basis tab, click Basis for Capital Costs | Design Basis. 2 In the Design Basis folder, click Equipment Specs. The General Equipment Specs dialog box appears. 3 On the General Equipment Specs dialog box, set the Print Equipment Coordinates value to Y, as shown below: 256 2 Defining the Project Basis Note: This feature does not apply to ACCE Versions V7.0 or V7.1. Workflow for Plot Plan Layout Tool: 1 Open an Aspen Capital Cost Estimator project. Add areas and equipment in each area according to your project scope. If you want the system to calculate area size for any area, keep the length and width fields of that area blank. For structural areas, specify number of levels/floors. The system will not calculate area sizes for MODULE type areas; you must specify the area dimensions. For equipment on structure, you must specify the floor/level number of the structure on the equipment form as the location of equipment on the structure. 2 Defining the Project Basis 257 2 On the main tool bar, click Run | Evaluate Project for cost evaluation of the project. For areas without specifications of lengths and widths, the system will calculate lengths and widths from the equipment dimensions in the respective areas. 3 On the main tool bar, click Run | Export/Import From/To Basic Engineering to launch an Aspen Basic Engineering application. The Aspen Capital Cost Estimator application is put to sleep, and the costing interface to Aspen Basic Engineering is launched. All area dimensions and equipment footprints are exported to Aspen Basic Engineering. 4 Open the drawing editor and create a new plot plan document. 5 On the plot plan, place a scale symbol; the default scale is 100, but you can change the scale. Labels and a piperack symbol are available in the Aspen Basic Engineering plot plan drawing. No other symbols are available. All the exported equipment, open steel/concrete structure, building and area symbols are seen under the stockpile, in the plot plan tab. No other symbols (other than exported components, labels, and pipe rack) can be placed on the drawing. All areas and components may be placed in one drawing. 6 For a new project, all areas and equipment will be displayed in the Stockpile of Aspen Basic Engineering. Move areas and equipment from stockpile to the main drawing area. For an existing project with equipment and areas placed in the plot plan drawing, all old areas and equipment will be placed in the proper locations of the drawing area. 7 In the Plot Plan interface, all equipment in a single area must reside in the area. You can move areas in the main drawing area, but you can move equipment inside its parent area only. You cannot move any equipment from its parent area to other areas. No new equipment can be added to the plot plan other than those imported from Aspen Capital Cost Estimator. Equipment can be placed one above the other in an open steel structure, but then only the topmost equipment will be visible. All equipment located one above other or at different elevations in an open steel structure need to be differentiated by user specified elevation parameter (level or floor number). 258 2 Defining the Project Basis 8 Place all the areas and the equipment in each area in the desired locations (X, Y coordinate) of the Plot Plan area. 9 Close the Plot Plan interface in Aspen Basic Engineering. Area coordinates (bottom left corner X, Y) with respect to Plot Plan datum (0,0 coordinate of Plot Plan) and equipment coordinates (X, Y, Z) with respect to parent area coordinates (bottom left corner) will be passed to Aspen Capital Cost Estimator interface. Area sizes will be passed to Aspen Capital Cost Estimator from Aspen Basic Engineering. 10On the main tool bar, click Run | Interconnect Piping Lines to connect piping lines between equipment. 11Evaluate the project cost. All lengths for interconnected piping lines will be calculated using the relative equipment locations and the lines not connected will inherit default lengths from the system volumetric model. The connected piping line length will be derived from: (a) a function of the design parameters of equipment and (b) the coordinates of the equipment. This length will be divided equally between the equipment if they are in the same area. For equipment in different areas, the system assumes that the connected equipment piping line will run to the respective shortest area boundary and will be on a pipe rack along the boundary of the areas. The length along the pipe rack will be divided equally between the equipment. In addition, each line on a piece of equipment will have a height coordinate where it joins to the equipment nozzle (available internally) so that the vertical run length of piping can be calculated. 2 Defining the Project Basis 259 260 2 Defining the Project Basis 3 Loading and Mapping Simulation Data Note: Simulation data can be used in Aspen Capital Cost Estimator only if you are licensed to use Aspen Icarus Process Evaluator (Aspen Process Economic Analyzer) or Aspen Decision Analyzer. If you are licensed, you can select at startup to use Aspen Process Economic Analyzer or Analyzer in the Aspen Capital Cost Estimator environment. Overview If the process you wish to evaluate in Aspen Process Economic Analyzer is based on a simulator file report from a process simulator software program, the first step, after creating a project scenario and defining the Design Basis, is to load and map simulation data. Aspen Process Economic Analyzer supports reports from the following simulators:  AspenTech’s AspenPlus Version 12.1  Chemstations’ ChemCAD for Windows Version 5.3.2  Hyprotech’s HYSIM Version STD/C.271  Hyprotech’s HYSYS Version 2.4.1  SimSci’s PRO/II with PROVISION Version 5.61  Pacific Simulation’s WINGEMS 2.0  WinSim’s DESIGN II for Windows Version 8.17 3 Loading and Mapping Simulation Data 261 Preparing Simulation Reports For Aspen Process Economic Analyzer to load the simulation data, an appropriate ASCII output report needs to be generated from the simulator. Most simulators describe the various steps needed to generate ASCII reports. This section provides additional procedures to generate reports in an Analyzercompatible format. The procedures provided here start with the default report generation options. If changes have been made from the default report generation options, then it may be necessary to change them back to the default settings for creating an output report for Aspen Process Economic Analyzer. AspenPlus Report Generation AspenPlus provides a template containing the property sets that a project needs in order to generate an output report for Aspen Process Economic Analyzer. Note: If you use the template, the following component specification, if entered in AspenPlus, must be re-entered in Aspen Process Economic Analyzer: Block - CCD STAGE EFFICIENCY To use the template: 1 Open the project in AspenPlus. 2 On the File menu, click Import. 3 Navigate to: Program Files\AspenTech\Economic Evaluation V7.3\Program\Load Note: This is the default path; it may differ depending on where you installed Aspen Icarus. 4 Depending on the simulation units of measure, select the appropriate simulator directory (for example, AspenPlus) and then the corresponding template (.apt) file. 262 3 Loading and Mapping Simulation Data To create the required property steps in Aspen Plus without using a template: 1 On the Data menu, click Properties. This will open the data browser to the property specifications. 2 In the data browser tree structure, open the folder Prop-Sets located in the Properties folder. 3 Click New to create a new property set. 4 Type a name for the property set or use the default name. 5 Click OK. 6 In the Substream field, select All. 7 Scroll down the list of available properties, clicking those you wish to select. To start the scroll window, click in a physical properties cell: o MASSVFRA o MASSSFRA o MASSFLMX o VOLFLMX o MASSFLOW o TEMP o PRES o MWMX The specifications for this property set are complete as indicated by the check mark displayed on the tree view of the data browser. 8 Click the Prop-Sets folder. You will see the property set you just created in the object manager and the status should be Input Complete. 9 Create the second property set by once again clicking New. 10Type a name for the property set or use the default name. 11Click OK. 12Click the Qualifiers tab. 13In the Phase cell, click Total. 14Click the Properties tab. 15In the Substream field, click ALL. 16Now click the Units cell corresponding to the CPMX property and pick either of the following units: KJ/KG-K -or- 3 Loading and Mapping Simulation Data 263 BTU/LB-R The specifications for this property set are complete. 17Click the Prop-Sets folder. The newly created property set will appear in the object manager with an input complete status. 18Create the final property set needed by Aspen Process Economic Analyzer by clicking New. 19Type a name for the property set, or use the default name. 20Click OK. 21Click the Qualifiers tab. 22In the Phase cell, click Vapor. 23Click the Properties tab. 24Select the following properties for this property set: o VOLFLMX o MASSFLMX o KMX o MUMX o CPMX o MWMX 25Now click the Units cell corresponding to the CPMX property and pick either of the following units: o KJ/KG-K -oro BTU/LB-R The creation of property sets is complete. Now these property sets must be specified for use in the generation of a report. To specify these property sets for use in report generation: 1 If the Setup folder is not already expanded, expand it by clicking on the plus sign next to the folder symbol. 2 Click Report Options. 3 Click the Stream tab. 4 Click the Property Sets button. 5 Move the three property sets you just created to the Selected property sets box. 264 3 Loading and Mapping Simulation Data 6 Click the > button to move them to the Selected property sets box. 7 Click Close. The specifications required for loading an AspenPlus report file are now complete. You can close the data browser window. After running the simulation, you must create an output report. To create an output report: 1 On the File menu, click Export. 2 In the Save As dialog box, use the drop-down menu to select Report Files (*.rep) or XML files (*.xml). 3 Type a file name or accept the default value. 4 Click Save. This will create the ASCII report file needed to load into Aspen Process Economic Analyzer with the name given above. Note: The order on any of the tower models must be set to TOP-DOWN in order for the tray information to get loaded into Aspen Process Economic Analyzer correctly. This is the default setting. Aspen Plus Utilities If a unit operation block has a utility specified, the utility resource specifications and usage data will be transferred into Aspen Process Economic Analyzer. After loading the simulator data, a preference screen will appear. Specify any missing data for the Aspen Plus utilities in order for the Aspen Plus utility to be properly handled. The Aspen Plus utilities will appear as new utility resources. The appropriate project components will use the specified utility resource, based on the Aspen Plus utility used in the simulation. A message box will appear if utility resources are modified or deleted from the Aspen Plus simulation prior to a reload of data into Aspen Process Economic Analyzer. You can choose to delete the old imported Aspen Plus utility resources in Aspen Process Economic Analyzer, or just add/update existing imported utilities in Aspen Plus. 3 Loading and Mapping Simulation Data 265 AspenPlus – Aspen Process Economic Analyzer Simulator link A link from AspenPlus to Aspen Process Economic Analyzer lets you load changes into Aspen Process Economic Analyzer when simulation settings are changed in AspenPlus. To load process simulator data through the Aspen Icarus link into a new Aspen Process Economic Analyzer project scenario: 1 Run the simulation in AspenPlus. 2 On the File menu, click Send To and click Aspen Icarus. When the prompt appears, the Aspen Process Economic Analyzer project name will be designated to be the name of the simulation file from AspenPlus. AspenPlus will designate the scenario name. If the scenario name is changed, any future attempts to run the link for the same project will result in a new Aspen Process Economic Analyzer project being created. It is recommended that the scenario name designated by AspenPlus be left as it is for maximum usability. 3 Click OK. The Project Properties dialog box appears. 4 Specify the Project Description, Remarks, and the Units of Measure. 5 Click OK. The Input Units of Measure Specifications dialog box appears. 6 Verify the Input Units of Measure Specifications; then click OK. The General Project Data dialog box appears. 7 Verify the General Project Data; then click OK. Aspen Process Economic Analyzer displays a prompt to load the Simulator Data. 8 Click OK. If the simulation has specified units that are undefined, a prompt will appear to do so. Define all AspenPlus units with those available in Aspen Process Economic Analyzer. 266 3 Loading and Mapping Simulation Data To load process simulator data through the Aspen Icarus link into an existing project scenario: 1 Run the simulation in AspenPlus 2 On the File menu, click Send To and click Aspen Icarus. Aspen Process Economic Analyzer displays a prompt to load simulator data. 3 Click OK. Because all other project basis settings have been specified, mapping and sizing can be performed at this time. ChemCAD Report Generation These instructions apply to both ChemCAD for Windows, Version 5.3.2, and for previous versions of ChemCAD. The specifications are the same for all versions. 1 On the main menu, on the Output menu, click Report. Note: In ChemCAD for Windows, just click the Output menu from the menu bar. 2 Specify the following for report options:  Select Streams  Print All Streams: Y   Note: Check box in ChemCAD for Windows Select Unit Operations Print All Unit Operations: Y Note: Check box in ChemCAD for Windows.  Stream Properties 3 Select or deselect the following stream properties as indicated below: Property Select De-Select OVERALL PROPERTIES Mass flow rate X Mole flow rate X Temperature X Pressure X Mole Vap frac X Enthalpy X Molecular wt. X Total act.dens X 3 Loading and Mapping Simulation Data 267 Property Select De-Select VAPOR PROPERTIES Mass flow rate X Mole flow rate X Molecular wt. X Vap. Act. Dens X Vap. Viscosity X Vap. Cp X Vap. Thrm. Cond X Liq. Surf. Tens. X LIQUID PROPERTIES Mole flow rate X Molecular wt. X Liq. act. Dens X Liq. Viscosity X Liq. Cp X Liq. Thrm. Cond. X SOLID PROPERTIES* Mass flow rate X Molecular wt. X Density X PSD X DISTILLATION OPTIONS Tray profile X Tray properties X Tray sizing X Packed column sizing X TRAY COMPOSITIONS Mass flow rate X * Solid properties are located on Page 2 of Stream Properties in ChemCAD for Windows. The component mass flow rates for individual streams must be included in the output report. 4 Navigate to the Stream Flowrate/Composition menu under the Reports/Output menu. 5 Pick Mass Flowrate. If you want Aspen Process Economic Analyzer to use tray sizing information from the simulator, then you must include the appropriate sizing information. 268 3 Loading and Mapping Simulation Data 6 To do this, go to Distillation Summaries under the Reports/Output menu; then select the appropriate sizing section (packed or trayed). 7 After the completion of all these specifications, generate the output report by selecting Calculate and Give Results. This should generate an output report. You can rename it if you wish. This is the file to be used as input for Aspen Process Economic Analyzer. HYSIM Report Generation 1 Copy the following .spc files from the \Program\Load\Hysim directory to your HYSIM working directory before generating output inside the simulator.  MIXER.SPC  TEE.SPC  HTXRATE.SPC  BALANCE.SPC  CALC.SPC  MASSBAL.SPC  MOLEBAL.SPC For all other operations, use the default .spc files provided by Hyprotech. 2 For HYSIM version 386|C2.12 or earlier, copy the stream format file STRSUM.FMT located in the /Aspen Process Economic Analyzer/Docs directory of your HYSIM working directory. If you have HYSIM version STD:C2.63 and above, copy the stream format file STRSUM2.FMT located in the /Aspen Process Economic Analyzer/Docs directory to your HYSIM working directory and rename it STRSUM.FMT. You must either delete or rename the existing STRSUM.FMT file to perform this. The output report generated from HYSIM should contain operation output (defined as spec_sheet in HYSIM) and the complete stream summary. Both of these outputs must be saved under the same file name. The information is appended to the file and does not get overwritten. To generate the operation output and stream summary (Required): 1 Load the desired project inside HYSIM (*.sim). 3 Loading and Mapping Simulation Data 269 2 3 4 5 6 7 8 o operation output o stream summary On the main menu, click Print. On the print option, click File; then press Enter. Select the same file (file_name) as above; then press Enter. Click the Print option; then press Enter. Select the Stream option; then press Enter. Inside the Stream option, select Summary; then press Enter. The list of streams present in the current project is displayed. Click the <-> option for all the streams to be written in file_name. The procedure creates the required report (file_name), which can be loaded into Aspen Process Economic Analyzer and used for project evaluation. If sizing operations are performed inside the simulator and you want the information to be carried over to Aspen Process Economic Analyzer, the following steps must be performed in addition to the above procedure: 1 Load the desired project inside HYSIM (*.sim). sizing summary 2 On the main menu, click Size. 3 Inside the size option, choose the unit operation desired; then press Enter. 4 Select the particular equipment (for example, col-101) ; then press Enter. 5 Select auto_section or user_section; then press Enter. 6 After the sizing calculations are performed, select Print. 7 Select File; then press Enter. 8 Select the same file name (file_name) ; then press Enter. 9 Click Summary; then press Enter. Important:  The operation names and stream names can not contain the following characters:  270 +, -, *, or spaces The ASCII report has to be created in the default units specified by HYSIM for the ENGLISH and the SI modes of 3 Loading and Mapping Simulation Data  operation. You can run a simulation in any simulator-provided units. However, prior to creating the report file, you must convert the units to the default specifications provided by HYSIM. During the sizing procedure for the column operation, if user_section is chosen, care should be taken to check that the stage numbers are not repeated in the different sections of the same column operation. The following two examples demonstrate the correct and incorrect specifications. Correct Incorrect user_section_1 : (start stage) 1 user_section_2: (start stage) 11 user_section_1 : (start stage) 1 user_section_2 : (start stage) 3 (end stage) 10 (end stage) 10 (end stage) 15    (end stage) 15 The user_section name should not contain the following characters: +, -, * The report format should be such that the width of the report should be less than or equal to 4 streams wide. This can be accomplished from the format option provided in HYSIM. Stream summary should follow the operation output in the report, that is, the order should be maintained. HYSYS Report Generation Aspen Process Economic Analyzer’s External Simulation Import Tool imports HYSYS simulator data into Icarus database files, which you can then load into Aspen Process Economic Analyzer. To import HYSYS simulation data for loading into Aspen Process Economic Analyzer: 1 On the Tools menu, click External Simulation Import Tool. 3 Loading and Mapping Simulation Data 271 The Simulator Link dialog box appears. 2 Click the Browse button for the Simulator File field. 3 Select the process simulator project you created; then click Open. 4 Click the Browse button for the Export File field. The Export File will contain the exported simulation results data from the selected HYSYS project. Do not include any file extensions for this file. The import tool will automatically assign a d01 extension to this file. 5 Select the location and enter the file name you want to be used to contain the exported data. You can also select an existing file. 6 Click Save. 272 3 Loading and Mapping Simulation Data 7 On the Tools menu, click Connect. HYSYS will automatically start with the selected project. The following figure shows the file Cheplant.hsc in the HYSYS interface. 8 Click Export on the Simulator Link dialog box to start the process of exporting the simulation data from the selected HYSYS project into the Export File. Once finished, you will see five files with the name you gave to the Export File. These files contain the exported data. Note: These files should always go together, in case you want to copy them to another location. D:\test\cheplantn.d01  Icarus database file D:\test\cheplantn.d02 D:\test\cheplantn.d03 D:\test\cheplantn.d04 9 On the Simulator Link dialog box, click Disconnect. The tool will close HYSYS. If you want to keep HYSYS running and make changes to your simulation, you can use the Export Again button to export the data again into the Export File. 10Exit the import tool. 11Start Aspen Process Economic Analyzer and create a new project. 12Select Hyprotech’s HYSYS as the Simulator Type. 13When selecting the simulator report file, select the Export File (the file with the extension .d01) created using the import tool 3 Loading and Mapping Simulation Data 273 14To load, map, and size this project, continue as described in this guide. SimSci’s PRO/II with PROVISION Report Generation Two methods can be used for generating reports from PRO/II with PROVISION.  You can change the input keyword file (*.inp) to include the required print options using keywords for those using PRO/II directly -or You can change the print options from within the PROVISION user interface. For either method, the operation names and stream names should not contain the following characters:  +  * Note: When specifying sidestrippers, each sidestripper must be identified by a unique four-character name. Currently, sidestrippers are not always identified by their full user-given names in PRO/II with PROVISION report files. Sometimes, they are identified by only the first four characters of the user-given names. Therefore, to properly load sidestripper information into Aspen Process Economic Analyzer, sidestripper Unit identifiers (UID’s) must be used, which are only four characters long. To prepare the SimSci report in PROVISION: 1 On the Input menu, select Problem Description. Make sure that the Problem Identifier field is not blank; something must be entered. 2 On the Output menu, select Report Format. 3 On the Report Format menu, select Miscellaneous Data. 4 Set the Report Width field to 80 Columns (the PROVISION default value). 5 On the Report Format menu, select Stream Properties. 6 Select Molar Flowrate and Weight Fraction. 7 On the Report Format menu select Unit Operations. 8 For each column unit operation: 274 3 Loading and Mapping Simulation Data A On the Unit Operations list, select Column. B Click the Print Options button while unit is highlighted. C Select Molar Basis from the Column Summary list. D From their respective column print options window, select: o Molecular Weights o Actual Densities o Actual Volumetric Flowrates o Transport Properties o Flowing Enthalpies o Standard Liquid Densities E Click OK. F Repeat for each remaining COLUMN unit operation in list. Note: See the note in the KEYWORD section regarding COLUMN sidestripper’s UID’s. 9 Click Close to finish. 10Use the default options for remaining unit operations. Using Keywords For General Print Options, use the following keywords: Print INPUT STREAM = ALL = ALL RATE = M WIDTH = 80 For COLUMN operations, use the following keyword: Print PROPTABLES = PART or ALL Loading Simulation Data The following loading procedure translates the specified process simulator report file into Aspen Process Economic Analyzer. To load process simulator data: 1 In Project Explorer, Project Basis view, right-click Simulator Type in the Process Design folder; then click Edit. 3 Loading and Mapping Simulation Data 275 The Select Simulator Type dialog box appears. 2 Select one type from the list; then click OK. Aspen Process Economic Analyzer displays a message saying what the new simulator type is. 3 Click OK. 4 In the Process Design folder, Right-click Simulator File Name; then click Edit. The Open dialog box appears, showing all simulator files in the Report folder. You can browse other drives and folders as well. 276 3 Loading and Mapping Simulation Data 5 Select a file; then click Open. Note: The List view now displays the pathname of the selected simulator file when you select Simulator File Name in Project Explorer. 6 Do one of the following:  Click on the toolbar. -or On the Run menu, click Load Data. A confirmation window appears. 7 Click Yes. Aspen Process Economic Analyzer loads the simulator data. When the loading of the data is finished, the Process view of Project Explorer is populated with simulator areas and simulator blocks. 3 Loading and Mapping Simulation Data 277 Viewing Data Derived from Simulator To access simulator-derived data (read-only): 1 Right-click a block, and on the menu that appears, click Modify. 2 Click Cancel to close. 278 3 Loading and Mapping Simulation Data Working with Block Flow Diagrams Aspen Process Economic Analyzer automatically generates a Block Flow Diagram (BFD) from a loaded simulator report. Providing a graphical representation of the process, the BFD displays computational blocks and their connections. The blocks in the diagram correspond to tree items displayed in the Project Explorer’s Process view. Color-coding of the blocks in both the Process view and the BFD agree; mapped items are displayed green and unmapped items are displayed yellow. Displaying the Block Flow Diagram To display the Block Flow Diagram:  On the View menu, click Block Flow Diagram. 3 Loading and Mapping Simulation Data 279 The BFD appears in the Main Window. Note: A block can be moved by clicking on the center of the block and dragging it to the desired location. Doing so will also move the streams connected to the block. If the simulator data is reloaded, the block and stream locations will be regenerated by Aspen Process Economic Analyzer. In addition to the blocks displayed in the Process view, the BFD displays streams, direction of stream flows, inlets, and outlets. The commands on the View menu change when the BFD is active. (See Block Flow Diagram View Menu on page 279 more information.) X X The Drag & Find Feature There is a quick and easy way to find a block on the BFD. Drag the block from the Project Explorer’s Process view and drop it anywhere in the BFD. The part of the BFD displayed changes so that the block you want to find appears in the upper-left corner of the Main Window. 280 3 Loading and Mapping Simulation Data Drag a block from Project Explorer (Process view) to the BFD Aspen Process Economic Analyzer finds the block on the diagram Accessing Commands in the Block Flow Diagram Right-clicking on blocks in the BFD accesses the same commands available when you right-click a block in Project Explorer’s Process view. Block commands Clicking View accesses simulator-derived data (read-only), as shown on page 278. X X The Map command and Delete Mappings command are explained in the next section, Mapping Simulator Items to Icarus 3 Loading and Mapping Simulation Data 281 Project Components, starting on page 285. Alteration of mapping will alter the blocks' color based on its status. X X Stream commands You can double-click a stream to access the Develop Stream specifications form. This form is explained on page 229. X X Zooming You can use the Zoom In and Zoom Out buttons to increase or decrease the magnification by degrees: You can also select an exact magnification by using the Zoom dialog box. To use the Zoom dialog box: 1 On the View menu, click Zoom. The Zoom dialog box appears. 2 Click the desired magnification, or click Custom and type a percentage between 10 and 1,000. 3 Click OK to change magnification and close the dialog box. -orClick Cancel to close the dialog box without changing magnification. The Zoom dialog box also has two options that affect printing: Fit into one page Mark this box to have Aspen Capital Cost Estimator re-size the BFD to fit onto one page when printed. This automatically selects the next option, What-You-See-Is-What-You-Get, since the 282 3 Loading and Mapping Simulation Data screen image will reflect the size required to fit on one printed page. What-You-See-Is-What-You-Get (WYSIWYG) When WYSIWYG is cleared, zooming in or out will only affect the magnification factor on the screen, while the printer always prints at 100%. However, if WYSIWYG is selected, the magnification factor on the printer will be changed so that the printed image will have the same size as the image appearing on the screen. BlockFlow Diagram View Menu The View menu contains some options that are only displayed when the Block Flow Diagram is active Use this to Toolbar View or hide the toolbar. See page 48 for descriptions of toolbar buttons. Status Bar View or hide the status bar. See page 32 for description of the status bar. 3 Loading and Mapping Simulation Data X X X X 283 Project Explorer View or hide Project Explorer. See page 34 for description of Project Explorer. X X Palette View or hide the Palette. See page 40 for description of the Palette Properties Window View or hide the Properties Window. See page 44 for a description of the Properties Window. X X Workbook Mode X Turn Workbook Mode on and off. See page 36 for an explanation of Workbook Mode. X Capital Costs View X Launch Aspen Icarus Reporter for interactive reports (on-screen, HTML, or Excel) or Icarus Editor for evaluation reports (.ccp). The Project Evaluation needs to have already been run. See page 619 and page 609 for details. X Investment Analysis View X X X X Display Investment Analysis spreadsheets. See Reviewing Investment Analysis on page 653 for instructions. X X Block Flow Diagram Display Block Flow Diagram of the loaded simulator data. Process Flow Diagram Display Process Flow Diagram. This command is not active until you have mapped the simulator items. Streams List Display a read-only list of all simulatorderived stream properties in a spreadsheet. You can customize some of the features of the spreadsheet (which stream properties to display, whether to display names of the properties, and the display style of the property values) by editing the stream list template file: ...\Economic Evaluation V7.3\Data\ICS\strlist.fil 284 Grid Visible View or hide grid lines. Snap to Grid Move blocks in increments corresponding to the grid lines when dragging to new location. Show Page Bounds View or hide page separation lines. When displayed, you can see where page breaks will be when printing. Ports Visible View or hide ports in the Process Flow Diagram. Does not apply to Block Flow Diagram. Zoom Access Zoom dialog box. See page 282. X X 3 Loading and Mapping Simulation Data Mapping Simulator Items to Icarus Project Components Mapping is the process of converting each simulator block (that is, model or unit operation) into one or more Icarus project components. To map simulator items: 1 If you want to map all items, access the Map dialog box by doing one of the following:  Click on the toolbar. -or On the Run menu, click Map Items. 2 If you want to map a single block or all blocks in an area, do one of the following:  In Process view, right-click a block or area; then click Map on the menu that appears. -or In the Block Flow Diagram, right-click a block then click Map on the menu that appears. 3 Loading and Mapping Simulation Data 285 The Map dialog box appears. Note: If you clicked the Map button on the toolbar or clicked Map Items on the Run menu, only the Map All Items check box is available in the Source section. If you clicked Map on a pop-up menu, both Map Selected Item(s) – the default choice – and Map All Items are available. Select the desired mapping options. Option Description Source Map Selected Item(s) Map the selected simulator block or the simulator blocks in the selected simulator area. This option is available only if you selected Map from a pop-up menu. Map All Items Map all simulator items in the project. Basis Last Mapping Map a block according to the last time it was mapped. This option retains only the type of Icarus project component(s) to which the block was last mapped. Default Use the Component Map Specs file for the basis. Default and Simulator Data Use the Component Map Specs file for the basis, but override the mapping using specific data in the simulator. For example, if you select this option and a reboiler type is specified in the simulator report, an equivalent reboiler type will be used in the mapping. Further, if the "Preferences>Process>Use Automatic Mapping Selection when Available" was selected, then additional engineering rules of thumb will be used for a selected category of equipments (for example, pumps, compressors, and heat exchangers) to come up the 286 3 Loading and Mapping Simulation Data Option Description mapping recommendations. (Note: Currently this mode is active only when blocks are mapped one at a time.) Users are encouraged to review these recommendations and either accept them or select a different equipment type based on their knowledge of their processes and practices. Options Size Icarus Project Component(s) Size the mapped Icarus project component(s). If you are mapping a single item to a single component that can be sized using the interactive Sizing Expert (see list on page 377), the Interactive Sizing form will appear after mapping. X X Otherwise, Aspen Process Economic Analyzer uses its automatic sizing. Although the Sizing Expert is unavailable when sizing multiple components, you can still use it later (assuming the component is one of those that can be sized interactively). Just right-click on the mapped component and click Re-Size on the pop-up menu. Note: See Chapter 6 for instructions on using the Sizing Expert. 3 Click OK. The Project Component Map Preview dialog box appears. Note: All simulator items are displayed because Map all Items was selected at the previous dialog box. Those components being mapped have asterisks next to them. 3 Loading and Mapping Simulation Data 287 If you selected Map Selected Item(s) on the Map dialog box, the Simulator Items list displays just the selected simulator block(s). If you selected Map all Items, the Simulator Items list displays all simulator blocks. The Current Map List displays any components that are already mapped to the simulator block highlighted on the Simulation List. The Configuration option box is active only for blocks representing column models. (In the sample project, Block B7 represents a column model.) You must use the arrow scroll buttons to see all ten possible configurations. Selecting a configuration type automatically fills in the Current Map List with the components required for that configuration type. See Tower Configurations on page 295 for more information. 4 Click New Mapping to map a block highlighted on the Simulator Items list to an Icarus project component. X X If the simulator block represents a column model that does not yet have all its required mappings, the Select a Suffix dialog box appears, listing the types of components (indicated by suffixes that appear at the end of Item Descriptions on the List view) that still need to be mapped to the block. Note: See Tower Configurations on page 295 for more information. X 288 X 3 Loading and Mapping Simulation Data Suffix To indicate bottoms split bottoms splitter bot exchanger bottoms exchanger bottoms pump bottoms pump Cond condenser for the tower cond acc condenser accumulator ovhd exchanger Overhead exchanger Overhead split Overhead splitter ovhd pump Overhead pump precooler first heat exchanger in “split” configuration” Reb reboiler for the tower reflux pump reflux pump Tower main tower Trim second heat exchanger in “split” configuration” Other user-selectable. spray cond Spray condenser spray cond exit pump Pump for recirculating the spray condenser exit sc tot recycle splitter Splitter in Spray Condenser Configuration that generates the total recycle stream sc cooler Heat exchanger in the Spray Condenser Configuration that cools the entire total recycle stream sc tot recycle trim splitter Trim splitter in Spray Condenser Configuration 2 (page 302) X sc trim X Heat exchanger in the Spray Condenser Configuration that cools the entire total recycle stream 5 Select a suffix; then click OK. 3 Loading and Mapping Simulation Data 289 The Icarus Project Component Selection dialog box appears. 6 Select a component. The Project Component Map Preview dialog box now displays the component category's item symbol (for example, AG) and the component type (for example, DIRECT) in the Current Map List. More component details are displayed in the Icarus Project Component Description section. 290 3 Loading and Mapping Simulation Data By default, the Component Name field contains the block name. You may want to modify it to be more descriptive and to distinguish the component from others to which the block has also been mapped. This can be as simple as adding a descriptor at the end. Each component mapped from the block must have a unique name; if another component already has the default component name, Aspen Process Economic Analyzer prompts you to enter a unique name after you select another component. 7 Click OK to complete the mapping. If you selected to size the mapped component(s), Aspen Process Economic Analyzer also performs automatic sizing or, in cases in which a single item is being mapped to a single component for which interactive sizing is available, the Interactive Sizing form appears. See Chapter 6, Sizing Project Components, for information on this feature. With the block now mapped, the List view displays the components mapped from the simulator block. Component Status You may notice a "?" in the Status column of a project component mapped from the simulator block. This indicates that 3 Loading and Mapping Simulation Data 291 there are still specifications that need to be entered for the component. To enter the specifications, right-click on the component and click Modify Item on the pop-up menu. Entering specifications in the required fields will change the status to OK. Required fields are indicated by color-coding explained on page 330, under Entering Component Specifications. X X If you do not enter the specifications and the "?" remains in the Status column, the item will not be included in the project evaluation and will have "0" cost associated with it. It will not cause SCAN messages. Deleting Mappings To delete mappings:  Right-click in the simulator area or simulator block in Process view; then, on the menu that appears, click Delete. Tower Configurations Because a column can be mapped to multiple pieces of equipment, Aspen Process Economic Analyzer requires that you select a tower configuration on the Project Component Map Preview dialog box. 292 3 Loading and Mapping Simulation Data You can select from among ten possible configurations:  Standard – Single  Standard – Total  Standard – Total w/Circ.  Standard – Split  Standard – Split Total  Standard – Split Total w/Circ.  Full – Single  Full – Single w.Circ.  Full – Split  Full – Split w/Circ. This term means Single Tower has one condenser. Split Tower has multiple condensers. Total the reflux pump handles the total outlet liquid flow from the accumulator. In such configurations, the splitting into a reflux and overhead liquid product occurs after the reflux pump. Circ. there is a pump between the bottoms splitter and the reboiler giving a forced circulation configuration around the reboiler. Note: Full configurations include the following equipment not found in Standard configurations:  overhead pump  overhead product heat exchanger  bottoms product pump  bottoms product heat exchanger Based on the tower configuration selected, Aspen Process Economic Analyzer automatically creates a model for each tower block and then maps the model to an Icarus project component. In addition, you can specify how the condenser requirements should be split between the Precooler and the Trim cooler on the Design Criteria specifications form. If subcooling is present, the precooler will completely condense the overhead vapor and the trim cooler will perform the subcooling; the split specification on the Design Criteria specifications form will be ignored when subcooling is present. 3 Loading and Mapping Simulation Data 293 The following figures display the ten possible configurations. The default item description suffixes (see page 289) are used to identify the configuration parts, each of which is mapped to an Icarus project component. X 294 X 3 Loading and Mapping Simulation Data Figure 1: Standard – Single Figure 2: Standard Total 3 Loading and Mapping Simulation Data 295 Figure 3: Standard Total w/Circ 296 3 Loading and Mapping Simulation Data Figure 4: Standard Split Figure 5: Standard Split Total 3 Loading and Mapping Simulation Data 297 Figure 6: Standard Split Total w/Circ. Figure 7: Full – Single 298 3 Loading and Mapping Simulation Data Figure 8: Full – Single w/Circ. Figure 9: Full – Split 3 Loading and Mapping Simulation Data 299 Figure 10: Full – Split w/Circ. 300 3 Loading and Mapping Simulation Data Figure 11: Spray Condenser Configuration 1 w/Circ. Note: Flow rate of the Spray Cond Total Recycle (SCTR) stream is calculated using Ratio of Recycle to (Ovhdliqprod + Reflux) Flowrates = mSCTR / (mOVH LIQ PROD+ mREFLUX). Ratio of Recycle to (Ovhdliqprod + Reflux) Flowrates is an input specified in the Design Criteria. mSCTR = mass flow rate of the SCTR stream. mOVH LIQ PROD = mass flow rate of the Overhead Liquid Product stream. mREFLUX = mass flow rate of the Reflux stream. 3 Loading and Mapping Simulation Data 301 Figure 12: Spray Condenser Configuration 2 w/Circ. The duty for the SC COOLER and SC TRIM exchangers are calculated using Ratio of SC Trim Duty to Overall Duty = QSCTRIM / QCONDENSER QCONDENSER = QSCTRIM + QSCCOOLER where: Ratio of SC Trim Duty to Overall Duty is an input specified in the Design Criteria QSCTRIM = Spray Condenser Cooler Duty QSCCOOLER = Spray Condenser Trim Duty QCONDENSER = Total Overhead Condenser Duty, obtained from Simulator Data Then the temperatures of the streams exiting the Spray Condenser Cooler and Spray Condenser Trim exchangers are calculated using: a Q = mCpDeltaT calculation. 302 3 Loading and Mapping Simulation Data Flow rate of the streams exiting the SC Tot Recycle Trim Splitter are determined using: SC Trim Splitter Flow Split Ratio = mSCRTSEx1 / mSCCEx mSCCEx = (mSCRTSEx1 + mSCRTSEx2) SC Trim Splitter Flow Split Ratio is an input specified in the Design Criteria mSCCE = mass flow rate of the SC Cooler Exit Stream mSCRTSEx1 = mass flow rate of the SC Rcy Trim Splitter Ex1 Stream (this is the one that subsequently goes through the SC TRIM exchanger) mSCRTSEx2 = mass flow rate of the SC Rcy Trim Splitter Ex2 Stream Sizing Selection This section outlines the workflow of the sizing selection feature available in Aspen Icarus Process Evaluator. Sizing selection is a mechanism that lets you pre-define and/or define sizing rules for project components. Specifically, you can set rules on equipment models or specific project components to be sized with one or more custom models. Project Sizing Selection Typically, you load data from a simulation and then choose to map the simulator unit operations. In the mapping screen that appears, there is a check box to Review Sizing Selection. If selected (the default is based on the Tools | Options | Preferences | Process | Sizing selection on the item-size menu), the sizing selection appears. You select any custom model for sizing the project components listed.  If an item is selected, the sizing preview screen appears during a size or re-size performed on one or more project component(s). 3 Loading and Mapping Simulation Data 303  If an item is not selected, the mapping preview screen does not appear for editing during these steps, but the sizing selection specifications is applied to the selected project component(s). Figure 13: Mapping with option to review sizing selection If selected, you will see the Sizing Selection preview after the mapping preview screen for a chance to edit how the project components are sized (see Figure 14). Figure 14: Sizing Selection preview for specified project components You can specify the sizing routines (System Sizing and custom models) for each project component (created by mapping from a 304 3 Loading and Mapping Simulation Data simulator or manual creation) that will be applied during the size-all step. If a custom model is specified in the current sizing list for a project component, the project component will be sized in the order shown in the Current Sizing List (see Figure 14). Any custom models listed will be sized using the custom model tool automatically without any user-interaction required. After sizing is complete, the system returns to a ready-state for you to perform additional project tasks. For Global Sizing Selection information, see page 372. X X Specifying Additional Components Icarus project components can be added to areas mapped from a simulator report. However, these project components must initially be added in a user-added area. You can later rearrange the components in Project Explorer’s Project view, drag components from a user-added area to an area mapped from the simulator report. Follow the instructions for adding a project component on page 324. X X If the component you add is process equipment, Aspen Process Economic Analyzer adds an icon representing the new equipment item in the upper left-hand corner of the Process Flow Diagram (PFD). The next section, Working with Process Flow Diagrams, includes instructions (under “Editing Connectivity” on page 310) for connecting an added component to a stream in PFD view. X X Working with Process Flow Diagrams Process Flow Diagrams (PFD) provide graphical representations of Icarus process equipment mapped from simulator blocks and the interconnecting streams. You can edit the layout and connectivity of the mapped items from PFD view. You can also add streams. Aspen Process Economic Analyzer provides intelligent port selection, so that when drawing a stream you see 3 Loading and Mapping Simulation Data 305 the candidate ports highlighted in green as the mouse is moved over them. To access PFD view: 1 On the View menu, click Process Flow Diagram. 2 Use the Drag-and-Find feature to locate any equipment item on the PFD. 3 Drag an equipment item from Project Explorer (Project view) and drop it on the PFD. The icon in the PFD that corresponds to the selected equipment will be positioned in the upper left-hand corner (regardless of magnification). Editing the Layout To change the position of an item:  Use your mouse to drag the item to its new position. Aspen Process Economic Analyzer reroutes any streams connected to the item. To change the route of a stream:  Click the stream; then drag the stream to straighten it or to create an elbow-bend. 306 3 Loading and Mapping Simulation Data Note: If you eventually select Reroute All Streams on the Run menu, Aspen Process Economic Analyzer chooses the most logical routes for all streams. Process Flow Diagram View Menu Note: The View menu contains some options that are displayed only when the Block Flow Diagram is active. Use this to Toolbar View or hide the toolbar. See page 48 for descriptions of toolbar buttons. X Status Bar X View or hide the status bar. See page 32 for a description of the status bar. X Project Explorer X View or hide Project Explorer. See page 34 for a description of Project Explorer. X 3 Loading and Mapping Simulation Data X 307 Palette View or hide the Palette. See page 40 for a description of the Palette. X Properties Window X View or hide the Properties window. See page 44 for a description of the Properties window. X Workbook Mode Turn Workbook Mode on and off. See page 36 for an explanation of Workbook Mode. X Capital Costs View X X Launch Aspen Icarus Reporter for interactive reports (on-screen, HTML, or Excel) or Icarus Editor for evaluation reports (.ccp). The Project Evaluation needs to have already been run. See page 619 and page 609 for details. X X X X Investment Analysis View Display Investment Analysis spreadsheets. See Reviewing Investment Analysis on page 653 for instructions. Block Flow Diagram Display Block Flow Diagram of the loaded simulator data. Process Flow Diagram Display Process Flow Diagram. This command is not active until you have mapped the simulator items. Streams List Display a read-only list of all simulator-derived stream properties in a spreadsheet. You can customize some of the features of the spreadsheet (which stream properties to display, whether to display names of the properties, and the display style of the property values) by editing the stream list template file: X X ...\Economic Evaluation V7.3\Data\ICS\strlist.fil 308 Grid Settings Access Grid Properties dialog box, where you can set the grid increments and select to view or hide grid lines. Snap to Grid Move blocks in increments corresponding to the grid lines when dragging to new location. Show Page Bounds View or hide page separation lines. When displayed, you can see where page breaks will be when printing. Ports Visible View or hide ports. Zoom Access Zoom tool. This is the same as in the Block Flow 3 Loading and Mapping Simulation Data Diagram (see page 282). X X Add Stream Access the Develop Streams dialog box. See Adding A Stream, page 312, for details. Draw Disconnected Stream Access the Disconnected Streams dialog box. See “Drawing a Disconnected Stream,” page 315, for details. X X X Edit Connectivity X Activate the Edit Connectivity feature. See “Editing Connectivity,” page 310, for details. X X Setting Grid Properties You can select to display grids of any increments. In addition, you can select the color of the grids and whether to be in Snap to Grid mode. To set grid properties: 1 On the View menu, click Grid Settings. The Grid Properties dialog box appears. 2 Set the Across and Down grid increments in the Increments section. Specify in the Units section whether the specified increments are in inches or centimeters. 3 Select the Snap to Grid check box to turn on Snap to Grid mode. When you drag a block in this mode, the block’s bounding outline moves in increments corresponding to the grid. 4 Click Color to select a grid color. 5 Finally, in the Visibility section, click whether to show or hide the grid. 3 Loading and Mapping Simulation Data 309 6 Click OK to apply the settings. Editing Connectivity The Edit Connectivity feature lets you make changes to the layout of items in the PFD. Because this involves connecting and disconnecting streams to ports, the Ports Visible option should be on, as it is by default. If the ports are not visible, click the Ports Visible button . Connecting a Stream to Different Inlet Port To connect a stream to a different inlet port: 1 Do one of the following:  On the toolbar, click the Edit Connectivity button -or On the View menu, click Edit Connectivity. 2 Place the cursor over the end of the stream you want to connect to a different inlet port. The cursor becomes an arrow. 3 Click the end of the stream. The cursor now appears as a crosshairs. 4 Move the cursor to another inlet port. When the cursor is in close proximity to a component, the component's available inlet ports display green. 310 3 Loading and Mapping Simulation Data 5 Click the new inlet port. Connecting an Added Project Component to a Stream Project components that you add to the project appear in the upper left-hand corner of the PFD and are not connected to any streams. To connect an added project component to a stream: 1 Do one of the following:  On the toolbar, click the Edit Connectivity button -or On the View menu, click Edit Connectivity. 2 Place the cursor over the added project component that you wish to insert into an existing stream. The cursor becomes a hand. 3 Click the component. A bounding outline, representing the component, appears around the cursor. 3 Loading and Mapping Simulation Data 311 4 Move the cursor over a stream. Click when you have placed the cursor over the desired stream. Aspen Process Economic Analyzer disconnects the Sink end of the stream from the inlet port on the current component, then automatically re-connects it to the inlet port on the inserted component. Aspen Process Economic Analyzer also creates a new stream, which appears white and has properties relative to the initial stream. Aspen Process Economic Analyzer connects the Source end of this new stream to the outlet port of the inserted item and the Sink and to the inlet port of the original. The added item can now be sized manually or using the Size Item option, which either automatically sizes the item or, if interactive sizing is available, accesses the Sizing Expert. The Sizing Expert, explained in Chapter 6, will utilize the newly connected streams. Adding a Stream From PFD view, you can create a new stream and specify its connectivity. The process of developing streams is explained in detail under Developing Streams, page 228. X X To add a stream: 1 Do one of the following: 312 3 Loading and Mapping Simulation Data  On the toolbar, click the Add Stream button . -or On the View menu, click Add Stream. The Develop Streams dialog box appears. 2 Do one of the following:  To create a stream from scratch, click Create and proceed to Step 3. -or To create a stream based on an existing stream, in the Base Stream section, click the existing stream; and then click a Basis: Absolute If the Basis Mode is Absolute, the data from the base stream is copied to the new stream at the time the new stream is created. If the data of the base stream is altered at any time after this point, the data of the new stream remains unchanged. Relative If the Basis Mode is Relative, the new stream’s data is dynamically linked to that of the stream on which it’s based. This means that alterations to the data of the base stream immediately affect the new stream. 3 Click Create. 3 Loading and Mapping Simulation Data 313 The Create Stream dialog box appears. 4 Type a name in the Stream Name field; then click OK. The Develop Streams specifications dialog box appears. 5 Make any desired modifications; then click OK. 6 Move the cursor, which appears as a square, to an outlet port. Aspen Process Economic Analyzer provides intelligent port selection, highlighting the candidate ports in green. 7 Click when you have placed the cursor over the desired outlet port. 8 Move the cursor, which now appears as crosshairs, to an inlet port. 9 Click when you have placed the cursor over the desired inlet port. 314 3 Loading and Mapping Simulation Data Drawing a Disconnected Stream To draw a disconnected stream: 1 Do one of the following:  On the toolbar, click the Draw Disconnected Stream button . -or On the View menu, click Draw Disconnected Stream. The Disconnected Streams dialog box appears. 2 Click a stream; then click OK. 3 Draw the stream as described in the previous instructions for Adding a Stream. Working with Streams Right-clicking on a stream accesses a pop-up menu with the following commands. Use this to Modify Access the Develop Stream dialog box listing the stream’s 3 Loading and Mapping Simulation Data 315 specifications, which you can modify. Disconnect Erase the stream from the screen and store it, so that you can select it when using the Draw Disconnected Stream feature (see page 315). Reconnect Source Reconnect the stream to a new outlet port. Reconnect Sink Reconnect the stream to a new inlet port. Delete Delete the stream. X 316 X 3 Loading and Mapping Simulation Data 4 Defining Report Groups, Areas, and Project Components When developing a Aspen Capital Cost Estimator project, you can add project components to areas in Project Explorer’s Project view. Project components are the pieces of the process plant (or mill) that, when linked together, complete a process. Components are categorized as follows: Note: See Icarus Reference for information on individual components. Category To define Process Equipment Equipment for gas, liquids and solids handling and off-site/packaged systems. Plant Bulks Material commodities that service a section of the plant or the whole plant. Plant bulks are divided into categories: Piping, Civil, Steel, Instrumentation, Electrical, Insulation and Paint. Site Development Modifications that must be done to the site. Site development items are divided into categories: Demolition, Drainage, Earthwork, Fencing, Landscaping, Roads-Slabs-Paving, Piling and Railroads. Buildings Civil structures directly involved in the process or for off-site use. Quoted Equipment A way to enter special equipment not found in Process Equipment above. Unit Cost Library Items from a Unit Cost Library. See Chapter 7. Equipment Model Library Items from an Equipment Model Library. See Chapter 7. 4 Defining Report Groups, Areas, and Project Components 317 Adding a Report Group Areas in Aspen Capital Cost Estimator are divided into report groups. Some reports summarize costs by report group. A report group is a user-defined category that can contain any number of areas. Note: Show Report Group in Aspen Capital Cost Estimator must be marked in Preferences, General tab view, to see report groups displayed in Project Explorer. This Preferences option is marked by default. (See page 58 for information on Preferences.) X X New projects include one default report group, with the name Main Area. You can rename the report group by right-clicking and clicking Rename Report Group on the pop-up menu. To add a report group: 1 Right-click Main Project and, on the pop-up menu, click Add Report Group. Aspen Capital Cost Estimator adds a report group with the default name New Report Group. 2 Right-click on New Report Group and click Rename Report Group. 3 Type a name for the report group and press enter. To delete a report group:  Right-click the report group; then click Delete Report Group. 318 4 Defining Report Groups, Areas, and Project Components Adding an Area To add an area: 1 In Project Explorer’s Project view, right-click a Report Group folder; then click Add Area on the pop-up menu. The Area Information dialog box appears. 2 Define the area, including name, type, and dimensions. The area type determines the default area specifications. For example, Aspen Capital Cost Estimator generates an open steel structure for the area type OPEN, but does not generate one for the area type EXOPEN. See page 36-4 of Icarus Reference for details on which specifications Aspen Capital Cost Estimator generates for each area type. You do not have to use all the default area specifications. The following section explains how to define area specifications. Area Types:  EXOPEN 4 Defining Report Groups, Areas, and Project Components 319  FLOOR  GRADE (Default)  MODULE  OPEN  PAD 3 Click OK. Project Explorer now displays the new area. Copying a Report Area over another Report Area To copy a Report Area over another Report Area: 1. Right-click on a Report Group (for example, Battery limit). 2. Click Copy All. 3. Right-click the report group you want to replace. 4. Click Copy specs. 5. Right-click project node. 6. Click Paste. The target Report Area now contains the same information as the source Report Area. Defining Area Specifications You can define mechanical design and cost basis specifications for the newly added area. You can define or modify area specifications in two ways:  using the Project view  using the Spreadsheet view Method 1: Defining area specifications using Project View To define area specifications using Project view: 1 Right-click on the area in Project Explorer’s Project view and then click Modify on the pop-up menu. 320 4 Defining Report Groups, Areas, and Project Components Aspen Capital Cost Estimator displays the Area Specifications dialog box. 2 Select the specification category you want to define: Select To do this Area Title Info Change the area title. Area Equipment Define standards and procedures applying to this area only. Overrides specifications entered at the project level for this area only. Includes:  Design allowance  Weld efficiency  Wind design required  Design deflection  Stress relief option  Diameter option  Rotating equipment spares  Shop fab maximum diameter Area , Piping, Civil, Steel, Define standards and procedures applying to this area only. Instrumentation, Overrides specifications entered at the project level for this Electrical, and Paint area only. Area Specs Define area’s type, dimensions, and average high/low ambient temperatures. Area Insulation For Hot Insulation Schedule: If you have not selected an 4 Defining Report Groups, Areas, and Project Components 321 Select To do this external Hot Insulation Schedule, select:  L-Light ave low ambient > 40DEG F (4 DEG C)  M-Medium ave low ambient > 20DEG F (-6 DEG C)  H-High- ave low ambient < 20DEG F (-6 DEG C) OR  One or more hot insulation libraries selected from external files For Cold Insulation Schedule:  C-Cold OR  One or more cold insulation libraries selected from external files Area Modules Define module type (default is SKID: flat base structural module); beam, column, and bracing options; structure costs; shipping costs; and impact loads. Material Index Info Adjust area’s system-generated material costs by a percentage. Overrides specifications entered at the project level for this area only. Man Hour Index Info Adjust area’s system-generated man-hours by a percentage. Overrides specifications entered at the project level for this area only. 3 Click Modify to access the selected area specifications. The Area Equipment Specs dialog box appears. 322 4 Defining Report Groups, Areas, and Project Components 4 Defining Report Groups, Areas, and Project Components 323 4 Enter area specifications; then click OK. Method 2: Defining area specifications using Spreadsheet View To define or modify area specifications using Spreadsheet view: 1 On the main menu bar, click View | Spreadsheet View | Areas. The Areas spreadsheet view appears. 2 On the Areas spreadsheet view, click Options. 3 On the menu that appears, select the specification category you want to define/modify. Select To do this Area Title Info Change the area title. Area Equipment, Piping, Civil, Steel, Instrumentation, Electrical, Insulation and Paint Define standards and procedures applying to this area only. Overrides specifications entered at the project level for this area only. Area Specs Define area’s type, dimensions, and average high/low ambient temperatures. Area Modules Define module type (default is SKID: flat base structural module); beam, column, and bracing options; structure costs; shipping costs; and impact loads. Material Index Info Adjust area’s system-generated material costs by a percentage. Overrides specifications entered at the project level for this area only. Man Hour Index Info Adjust area’s system-generated man-hours by a percentage. Overrides specifications entered at the project level for this area only. 4 On the spreadsheet, make your modifications. 5 When you are satisfied with your modifications, click Apply. 6 Click OK. Your modifications are made in the project. Note: You cannot use this feature if a component specs form is open that would let you edit data that would also be editable in the spreadsheet view. 324 4 Defining Report Groups, Areas, and Project Components Adding and Defining Pipeline Areas If you selected Allow Pipeline Areas when creating the project (see page 28), there will be a default report group with the name Pipeline Area. You can rename the report group by right-clicking and clicking Rename Report Group on the pop-up menu. The default report group contains one area called Pipeline Area. X X To add a pipeline area: 1 Right-click on the pipeline report group and click Add Pipeline Area. The Pipeline Area specifications form appears. 2 Select a pipeline title, fluid type (oil, gas, or water; default is oil), main-line length (used for productivity adjustment in various work items), whether to have double-jointed piping (default is double-jointed for pipe diameter equal to or greater than 20 IN [500 MM]), length of delivered pipe section (default is 80 FT [24 M] if double-jointed and 40 FT [12 M] if not double-jointed), and internal lining type (fusionbonded epoxy, cement, or none; default is none). 3 Click OK. 4 Defining Report Groups, Areas, and Project Components 325 You can now add pipeline segments to the area. 4 When adding a component (explained in next section), click Plant Bulks | Piping. Pipeline segments are at the bottom of the list of piping plant bulks. To edit a pipeline area:  Right-click the pipeline area; then click Modify. Adding a Project Component Aspen Capital Cost Estimator provides two methods for adding a project component:  Drag-and-drop Drag a component from the Palette to an area on Project Explorer’s Project view and enter an item description. This adds the component to the area without displaying the Component Specifications form; the specifications are left to be entered at your convenience.  Pop-up menu Right-click on an area and click Add Project Component from the pop-up menu, then select a component from the Project Component Selection dialog box and enter an item description. This adds the component and also displays the Component Specifications form, where you can complete the component definition right away. Method 1: Dragging a Component from the Palette To add a component using the drag-and-drop method: 1 With the Palette (Components view) and Project Explorer (Project view) displayed, drag a component from the components list to an area on the Project Explorer. 326 4 Defining Report Groups, Areas, and Project Components Note: The Recent Items folder in the Components view stores the last 10 project component selections. 2 To drag, click on the component and hold down the mouse button, move the cursor until over an area, and release the mouse button. The New Component Information dialog box appears. 3 Enter an item description (required) and User Tag Number (optional), and then click OK. The component is added. Project Explorer displays a block for the component under the selected area. The List view displays 4 Defining Report Groups, Areas, and Project Components 327 general information. You may notice a question mark (?) in the Status column on the List view. This indicates that there are still specifications that need to be entered for the component. To enter the specifications, follow the instructions under “Entering Component Specifications” on page 329. X X Method 2: Using the Pop-up Menu To add a component using the pop-up menu: 1 In Project Explorer, Project view, right-click on a non-simulator area and click Add Project Component on the pop-up menu. 328 4 Defining Report Groups, Areas, and Project Components The Project Component Selection dialog box appears. 2 Enter the Project Component Name. 3 Highlight the category to which the desired equipment belongs (process equipment, plant bulks, site development, buildings, quoted equipment) and click OK. Aspen Capital Cost Estimator displays a list of sub-categories. Continue to narrow down the selection to a specific component. Then click OK. The component is added to the area. The Component Specifications form is automatically displayed. You can either complete the definition of the equipment item now or later. Entering Component Specifications After adding a component, you still need to enter at least some component specifications to complete the component’s definition. Many component specifications have default values used when no value is entered, but most component specifications require further input. If a component added still has any specifications requiring input, a question mark (?) 4 Defining Report Groups, Areas, and Project Components 329 appears in the status column of the List view for that component. You do not have to enter specifications immediately upon adding a component; you may wish to wait until more information about a project becomes available. As more information about a project becomes available, you may also wish to modify previously entered component specifications. The following instructions apply as well to modifying previously entered specifications. To enter or modify component specifications: 1 If the Component Specifications form is not already displayed in the Main window, display the form by right-clicking on the component and clicking Modify Item on the pop-up menu. You can right-click on the component in either Project Explorer (Project view) or List view (Area level) Double-clicking the component will also display the Specifications form. Color coding  Red Border: An entry must be made in the field. All specifications forms have at least one required entry field. 330 4 Defining Report Groups, Areas, and Project Components  Green Borders and Thick Gray Borders: An entry must be made in either the field with the thick gray border or in the two fields with the green borders. The field with the thick gray borders and the fields with the green borders are mutually exclusive. In the form pictured to the right, either the pump size must be selected or the fluid head and liquid flow rate must be entered. The Properties Window notes this in the Description. Enter the specifications. Note: While on either the component or installation bulks specifications form, you can quickly determine the net effect of all your changes by clicking the Evaluate button reviewing the resulting report. See page 678 for more information. X and X To define installation bulks for the component, click the Options drop-down and select the type of bulks to define. See “Defining Installation Bulks” on page 332 for a complete description of installation bulks. X 4 Defining Report Groups, Areas, and Project Components X 331 2 After defining the component and installation bulks, save the specifications form by clicking OK. Defining Installation Bulks Installation bulks are items directly associated with the component being defined and are used to complete the installation of the item, for example, a foundation for a vessel. The difference between an installation bulk and a plant bulk is that an installation bulk is associated with a component, whereas a plant bulk services the whole plant or mill. You can define Installation bulks when entering or modifying equipment or plant bulk specifications. To access installation bulk specifications: 1 Display the Component Specifications form. 2 Click the down-arrow on the Options button. Note: An asterisk (*) next to an installation bulk indicates that it has been edited. On the menu pictured below, asterisks indicate that the Pipe - Item Details and Civil installation bulks have been edited. 332 4 Defining Report Groups, Areas, and Project Components 3 Click the type of installation bulks you wish to view or define. Aspen Capital Cost Estimator displays the specifications form for the selected installation bulk items. See the subsections that follow for descriptions of the different types of installation bulks. 4 When you are done defining the installation bulk, save your changes in either of two ways, depending on what you intend to do next: o If you want to continue modifying this component’s installation bulks or component specifications, click Apply to save the changes. You can now select either Project Component or another type of installation bulks from the Options menu. o If you are done making changes to the installation bulks and to the component specifications, click OK to save the changes and close the specifications window. Mat’l/Man-hours Adjustments Using Mat’l/Man-hours Adjustments, you can specify percent adjustments of system-calculated values as follows: 4 Defining Report Groups, Areas, and Project Components 333 Category Percent adjustment for Equipment Material cost (COA 100-299) Setting Man-hours (COA 100-299) Piping Material costs and/or man-hours (COA 300-399) Civil Material costs and/or man-hours (COA 400-499) Steel Material costs and/or man-hours (COA 500-599) Instrumentation Material costs and/or man-hours (COA 600-699) Electrical Material costs and/or man-hours (COA 700-799) Insulation Material costs and/or man-hours (COA 800-899) Paint Material costs and/or man-hours. (COA 900-999) These adjustments compound material and man-hour indexing applied to the same COA’s. User-entered material costs and man-hours (entered using either Quoted Equipment or Mat’l/Man-hours % Additions) are not affected by these adjustments. The Special Options section at the bottom of the Mat’l/Manhour Adjustments form lets you specify that the component is a spare, supplied by owner, or existing. Aspen Capital Cost Estimator adjusts the component costs accordingly. In addition, the Special Options section lets you select demolition (that is, dismantlement) of the component and its installation bulks. To demolish a component item: 1 Click Mat’l/Man-hours Adjustments on the Options menu of the Component Specifications form. 2 Scroll down to the Special Options section and, from the Installation Option scroll list, select DEML. 334 4 Defining Report Groups, Areas, and Project Components For example, selecting the demolition (DEML) option causes the following changes to the component:  Material costs are set to zero.  Man-hours and labor costs are charged to demolition COAs (for example, 109, 309, 409, and so on.)  Piping and civil man-hours are down-adjusted:  Shop fab man-hours are removed from piping man-hours.  Civil formwork/bracing man-hours are removed. 3 Go back through the Mat’l/Man-hour Adjustments form and make the proper adjustments to account for the relative difficulty of demolition versus new build. For example, if you know unsetting the component is 15% easier than initially setting it, then enter 85% in the Setting labor adjustment field. 4 Save your changes in either of two ways, depending on what you intend to do next: o If you want to continue modifying this component’s installation bulk or component specifications, click Apply to save the changes to the Mat’l/Man-hour Adjustments. You can now select either Project 4 Defining Report Groups, Areas, and Project Components 335 Component or another installation bulk from the Options menu. o If you are done making changes to the installation bulks and to the component specifications, click OK to save the changes and close the specifications window. Mat’l/Man-hours Additions Using Mat’l/Man-hours Additions, you can add lump sum material costs and/or man-hours to a specified COA. All additions are reported “as is.” Additions are neither indexed nor adjusted by Mat’l/Man-hours Adjustments. Up to 20 additions may be defined per component. Example: in the Mat’l/Man-hour Additions form for the CLAD TECHNOCAL STORAGE TANK component, 20 labor hours have been added to COA 304 and 30 labor hours have been added to COA 604. Pipe – General Specs Use Pipe – General Specs to define the rules for developing all installation piping on the selected component. You can use many fields to define general piping specifications, such as:  Material  Pressure  Temperature  Installation - above or below grade 336 4 Defining Report Groups, Areas, and Project Components       Fluid or electric tracing Flange class and type Stress relief Insulation type Insulation jacket type Paint treatment Note: In Aspen Kbase Version 2004.2, under General Piping specs, there was a field called fitting spec filename to use to select the fitting spec filename to use for the project. In newer Kbase and Aspen Capital Cost Estimator versions, the fitting specification is moved a Customer External file. To access this file: 1 Right-click the Fitting external file. 2 Click Select. A selection dialog box appears in which you can select which external fitting specs file to use. Pipe – Item Details Use Pipe – Item Details to specify individual runs of piping and associated fittings, tracing, paint and insulation. The line is developed using the rules defined in Pipe – General Specs unless they are re-defined with Pipe – Item Details. Up to 40 lines may be defined/adjusted for each component. Note: To reduce the time required to retrieve data when multiple items have been added, select in Preferences to not display all items. If Display P&I Installation Items is unmarked on the Preference dialog box (General tab view), selecting Pipe – Item Details will display a dialog box from which you can select the item you wish to edit or select to add a new item. See page 58 for instructions on entering Preferences. X X The component starts with piping depicted in the Piping and Instrumentation Drawings manual. You can also display the component’s piping and instrumentation drawing by clicking the P&ID button on the Component Specifications form. It displays the piping you are adjusting on the Pipe Details Installation Bulk form. You can revise the pipe volumetric model for a component lineby-line. Specifications on the Pipe – Item Details Installation 4 Defining Report Groups, Areas, and Project Components 337 Bulk form override the project, area- and component-level specifications that otherwise determine the design of all lines of pipe. For example, area dimensions determine the lengths of lines generated by volumetric models, except those lines for which you enter a specific length. The Piping Volumetric Model field offers the following options:  “blank” - Specified pipe only, no volume. model  This option should rarely be used. It is a rapid way to discard the complete piping model for this item; however, in addition to discarding all of the automatically generated lines of pipe, this also discards all the associated drains/vents and pipeassociated instrumentation. The system now generates only piping, drains/vents and on-/in-line instrumentation for those lines that you subsequently define. Once you have used this option, the other options below cannot be used because the model is already discarded. If you subsequently re-create a line that the volumetric model would have automatically created, the associated on-/in-line instrumentation is automatically “re-created.” A - Add line to pipe volumetric model This option is used to add a new line of pipe to a component. The number of the new line must be higher than any other automatically created or user-defined line. For example, if a 338 4 Defining Report Groups, Areas, and Project Components  component generates lines 1 to 6, then an added line may have the number 7 to 40. The area dimensions will have no effect on the length of these lines. It is not necessary to add line numbers in numeric order; however, they will be generated and reported in numeric order. To associate instrumentation with a new line, specify that a sensor or control element location is this line number. Line 40 is reserved for drains/vents. C - Change lines on pipe volumetric model  This is a commonly used option. It is used to modify automatically generated lines of pipe; user-specified lines are not changed. The line is generated exactly at it would have been in the absence of your specifications, except for the items which you change. You may use this to change only the metallurgy, diameter or length of a run, or only the valves and fittings (including setting the quantity to 0) or any combination of these. D - Delete line on pipe volumetric model  This option deletes a single line of automatically generated pipe and its associated drains/vents and instrumentation. R - Replace line on pipe volumetric model This option replaces the automatically generated line completely with the exact line that you specify. If you do not define something for this line, you do not get it. For example, if you specify a line of fixed length containing no valves or fittings, then you only get the straight-run of pipe. To make more than one specification for Pipe – Item Details:  Click the Add button . This adds an item specs column to this form. To delete any unwanted or unused column(s): 1 Click any cell in that column (or drag for a range of columns). 2 Click the Delete button . Note: Incompletely specified columns must be either completed or deleted before saving. 4 Defining Report Groups, Areas, and Project Components 339 Duct Duct installation bulk items specify individual runs of process ductwork and associated fittings and insulation. Up to five duct lines may be specified for each component. Use the same methods described for multiple lines of pipe. Civil Civil installation bulk items specify bulk excavation and up to three different foundation types/sizes. The available foundation types are listed in the Icarus Reference. From the specified foundation types and volumes, Aspen Capital Cost Estimator calculates:  Excavation and backfill  Form work (plywood/backup lumber with reuse)  Rebar  Sand mat (or ring wall foundation types only)  Grout  Anchor bolts/embedments Steel The Steel installation bulk specifies the following:  Ladders  Stairs  Platforms In addition, up to three different steel items may be specified. Instrumentation Instrument installation bulk items specify individual instrumentation loops or parts of loops with associated sensors, transmitters and signal cabling. Up to 50 loops may be defined for each component. 340 4 Defining Report Groups, Areas, and Project Components Note: To reduce the time required to retrieve data when multiple instrument items have been added, select in Preferences to not display all items. If Display P&I Installation Items is unmarked on the Preference dialog box (General tab view), selecting Instrumentation will display a dialog box from which you can select the item you wish to edit or select to add a new item. See page 58 for instructions on accessing and entering Preferences. X X The component starts with instrumentation depicted in the Piping and Instrumentation Drawings manual. You can also display the component’s piping and instrumentation drawing by clicking the P&ID button on the Component Specifications form. It displays the instrumentation you are adjusting on the Instrumentation Installation Bulk form. You can revise the instrument volumetric model for a component loop-by-loop. Specifications entered on the Instrumentation Installation Bulk form override the project-, area- and component-level specifications that otherwise determine the design of all instrument loops. The Instrument Volumetric Model field offers the following options:  “blank” - Specified loop only, no volume. model This option should rarely be used; it is a rapid way to discard the complete instrument model for this item. The system now 4 Defining Report Groups, Areas, and Project Components 341  generates instrumentation for those loops that you subsequently define. To define new loops, you continue to use this “blank” option for each successive loop. Once you have used this option, the other options below cannot be used because the model is already discarded. A - Add loop to instr. volum. model  This option is used to add a new loop to a component. The number of the new loop must be higher than any other automatically created or user-defined loop. It is not necessary to add loop numbers in numeric order; however, they will be generated and reported in numeric order. For example, if a component generates loops 1 to 6, then an added loop may have the number 7 to 50. D - Delete loop on instr. volum. model  This option deletes a single loop, including sensor, transmitter, cable, control center connections and final control element. R - Replace loop on instr. volum. model  This option replaces the automatically generated loop completely with the exact loop that you specify. If you do not define something for this loop, or you selectively delete a part, you do not get it. For example, if you specify a sensor and transmitter only, then you only get the signal generated and sent to the control center. “+” - Append to previous loop w/same no. This option is used to append extra sensors or control valves to the immediately preceding, user-defined loop (you must also correctly specify the loop number of the preceding loop). It may not be used to append items to automatically generated loops; to do this, you should first use the replace option to redefine the loop, then use the “+” option. Whether you are appending a sensor or control element, you should make entries for both the sensor and control valve locations. To define more than one adjustment:  Use the same methods described earlier for Pipe – Item Details (page 339). X 342 X 4 Defining Report Groups, Areas, and Project Components Instrument Loop Adjustment On the Instrumentation Installation Bulk form, there are eight Loop Modification fields, which allow you to remove different elements of the instrument loop from the project. Select “-” from the drop-down menu to remove an element. Two of the elements, sensor and control valve, can also be specified as quoted (“Q”) or vendor-provided (“V”) equipment. When either “Q” or “V” is selected, the system includes installation manhours for the element but not material costs. Deleting the process connection removes all of the instrument piping. The indicating signal and control signal runs are reported together, so removing one would decrease the amount of cable and supports by half. The following diagram shows how the eight adjustable loop elements fit into the loop design: Notes: (A) Junction boxes can be found under PLANT BULKS, INSTRUMENTATION, JUNC-BOX. (B) Multi-core runs can be found under PLANT BULKS, INSTRUMENTATION, ELECTRONIC SIGNAL WIRE. You can specify it with or without the junction box. (C) Control centers can be found under PLANT BULKS, INSTRUMENTATION, MULTIFUNCTION CONTROLLERS (electronic) or PLANT BULKS, INSTRUMENTATION, INSTRUMENT PANEL – ANALOG (pneumatic). 4 Defining Report Groups, Areas, and Project Components 343 Electrical The Electrical installation bulk specifies local equipment lighting, control wiring and power/cable and motor starters for up to three different types of electrical loads. Insulation The Insulation installation bulk specifies insulation and fireproofing for component and installation bulk steel. For components, the insulation type, jacket type, thickness and area may be specified. For component and steel fireproofing, type, rating and area may be specified. Paint The Paint installation bulk specifies surface preparation and painting of component and installation bulk steel. Paint for pipe is specified under piping. Entry field specifications include:  Size of area to be painted  Number of prime and final coats  Percent of painted area to be sandblasted  Galvanizing (for steel) 344 4 Defining Report Groups, Areas, and Project Components Importing Areas and Components Aspen Capital Cost Estimator lets you import entire areas or individual components from other project scenarios. You can select in Tools| Options | Preferences | Process whether to also include installation bulks and/or connected streams (see Chapter 1. Getting Started.Preferences. Process). By default, installation bulks are included and connected streams are not. To import an area or component: 1 In the Palette’s Projects view, double click the project scenario from which you wish to import. This displays the project areas in the scenario. 2 Expand an area folder to display the components in it.   To import a component: o Drag the component to the desired area in Project Explorer, Project view. Aspen Capital Cost Estimator adds the component to the area. To import an area and its components: o Drag the area to Main Project in Project Explorer. 4 Defining Report Groups, Areas, and Project Components 345  Aspen Capital Cost Estimator adds the area and its components. To import all the components in an area to an existing area in the current project scenario: o Drag the area from the Palette to the desired area in Project Explorer. Aspen Capital Cost Estimator adds the components to the area without creating a new area. Importing an Entire Scenario As well as allowing you to import individual areas or components, Aspen Capital Cost Estimator lets you import an entire scenario using a drag-and-drop operation. This imports all the areas and components in the selected scenario. You can select in Tools | Options | Preferences | Process whether to also include installation bulks and/or connected streams (see Chapter 1. Getting Started.Preferences.Process). By default, installation bulks are included and connected streams are not. To import an entire scenario: 1 Have Project Explorer’s Project view open, since you will drag the scenario there. 2 Click on the scenario in the Palette’s Projects view. 3 Drag the scenario from the Palette to Project Explorer’s Project view. Aspen Capital Cost Estimator displays a confirmation window. 346 4 Defining Report Groups, Areas, and Project Components Note: You can only import scenarios that have the same units of measure as the current scenario. If the units of measure are not the same, a dialog box will inform you of this when you try to import. 4 Click Yes. The areas and components of the selected scenario are imported. Copying Components The Copy command copies a selected component and all of its associated installation bulks. This is useful if you want to add a component that is similar to an existing item. The item can be copied and modified with less effort than creating a new item. Remember to change the Item Description when copying components to distinguish the copy from the original. To copy and paste a component: 1 Right-click the component in either Project Explorer or the List window (at area level, so that components are listed), and then click Copy on the pop-up menu. You can also copy multiple components at once: select the desired components on the list window, right-click on one of the components, and click Copy on the pop-up menu. 2 Right-click on the area to which you want to add the component(s) and click Paste on the pop-up menu. The component is added to the area. Note: If the area contains a component with the same name as the one being pasted, Aspen Capital Cost Estimator changes the new component’s name so that “#1#” appears at the beginning. 4 Defining Report Groups, Areas, and Project Components 347 Cut and Paste If you want to delete (cut) a component from one area and add (paste) it in another area, use the same procedure as above, except click Cut instead of Copy on the pop-up menu. Drag and Drop You can also move a component from one area to another by dragging it. Modifying Components You can modify the following components using Spreadsheet View:  Vessels  Towers  Heat Exchangers  Pumps  Quoted Components To modify a component using Spreadsheet View: 1 On the main menu bar, click View | Spreadsheet View | <the type of component to modify>. The <the type of component to modify> spreadsheet view appears. 2 On the <the type of component to modify>spreadsheet view, click Options. 3 On the menu that appears, click the option you want to modify. 4 On the spreadsheet, make your modifications. 5 When you are satisfied with your modifications, click Apply. 6 Click OK. Your modifications are made in the project. Note: You cannot use this feature if a component specs form is open that would let you edit data that would also be editable in the spreadsheet view. 348 4 Defining Report Groups, Areas, and Project Components Copying Areas Aspen Capital Cost Estimator's Area Cut-and-Paste operations let you:  Create a new Report Group with the same Area and Components as an existing Report Group  Replace an Area and its components with another Area and its components To create a new Report Group with the same Area and Components as an existing Report Group: 1 On the Project View tab, right click Main Project. 2 On the menu that appears, click Add Report Group. A Report Group named New Report Group appears on the tree. 3 Right-click New Report Group; then click Rename Report Group. 4 Type the new name for the Report Group; then click ENTER. 5 Right-click the area you want to copy to the new Report Group. 6 On the menu that appears, click Copy Specs. 7 Right-click the new Report Group. 8 On the menu that appears, click Paste. The area and its components are copied into the new Report Group. To replace an Area and Components with another Area and Components: 1 On the Project View tab, right-click the area you want to copy. 2 On the menu that appears, click Copy Specs. 3 Right-click the area you want to overwrite with the copied area information. 4 On the menu that appears, click Paste. 5 A warning message appears, telling you that performing this action may overwrite some data. If you are sure you want to overwrite the area with the copied area information, click Yes. The target Area and its components are replaced with the data from the source Area and the source Area's components. 4 Defining Report Groups, Areas, and Project Components 349 Deleting Components The Delete command removes a component and all associated installation bulks from the project. To delete a component: 1 Right-click on the component in either Project Explorer or the List view and click Delete on the pop-up menu. A confirmation dialog box appears. Note: You can select in Preferences not to have this prompt appear (see page 58). 2 Click Yes to delete the component or click No to retain the component. X X You can also delete multiple components at one time: select the components on the list window, right-click on one of the components, and click Delete on the pop-up menu. Re-numbering Components After deleting components, you may wish to re-number the remaining components so that the numbering contains no gaps and reflects the order in which components were added. For example, if you add components A, B, C, D, and E in that order, the automatically generated Order Numbers would be 1, 2, 3, 4, 5, respectively (the Order Number appears on the List view). If you then delete components B and C and re-number, components A, D, and E would have Order Numbers 1, 2, 3, respectively. The order in which they were created would still determine the Order Numbers. To re-number components: 1 On the Run menu, click Re-number. 2 On the menu that appears, click Project Components. 350 4 Defining Report Groups, Areas, and Project Components Deleting Areas The Delete Area command removes the selected area and all of its components. To delete an area: 1. Right-click on the area in Project Explorer and click Delete Area on the pop-up menu. A confirmation dialog box appears. Note: You can select in Preferences not to have this prompt appear (see page 58). 3 Click Yes to delete the area. X X -orClick No to retain the area. Re-numbering Areas Areas have reference numbers that are internally stored and then used by the Evaluation Engine. They are not visible in the current version of Aspen Capital Cost Estimator. Just as with components, re-numbering is intended to close gaps in the numbering after deletion. To re-number areas: 1 On the Run menu, click Re-number. 2 On the sub-menu that appears,. click Project Areas. Using the Custom Model Tool Aspen Process Economic Analyzer’s Custom Model tool lets you base component specifications on formulas or fixed data stored in Excel. Use the tool to send a component’s specification values, connection stream values, and specified bulk information (pipeitem details, material and man-hour adjustments) to an Aspendesigned Excel workbook, where you can enter new specification 4 Defining Report Groups, Areas, and Project Components 351 values based on your own data or formulas. Then, use the tool to send the new data back to Aspen Capital Cost Estimator. For instance, you could use the Custom Model tool to calculate a pump driver power based on a flow rate and pump head or to calculate project component costs using your own custom method in Excel. The specifications rules remain stored in Excel, so that you can change the specifications in Aspen Process Economic Analyzer and then revert back to the Excel specifications by re-running the tool (if the values are fixed). Once the tool has been used with a project component, Aspen Process Economic Analyzer associates the customized project component with the last Excel spreadsheet used. Running the tool at the project level updates all components for which the tool has already been run. The tool provides template files for mixers and pumps, as well as a general template to use as the starting point for creating files for other components. However, for components other than pumps and mixers, you must first copy the general template file (or use Save As) and enter the slot names for the component specifications you wish to input, as explained below. To use the Custom Model tool on a project component: Note: Before using this tool, you must select the Activate Custom Model option on the Process tab in Preferences. See page 58 for information on accessing Preferences. 1 In Project Explorer, Project view, right-click the pump or mixer component that you wish to customize. 2 On the menu that appears, click Custom Model. X 352 X 4 Defining Report Groups, Areas, and Project Components The User Custom Model dialog box appears. It displays the name of the project, scenario, and project component selected for the operation. It also displays available Microsoft Excel (.xls) template files. 3 Click the Excel template file that you have created for the selected project component. 4 Defining Report Groups, Areas, and Project Components 353 4 Click Run. Excel displays the workbook, with tabs for:  Input  Custom Rules  Output The Input worksheet displays the original Icarus system values from Aspen Capital Cost Estimator.  Item information is provided at the top of the worksheet. The item information is from the Component Specifications form.  Stream information, if available, is shown toward the bottom.  Below the stream information is information on the installation bulks for Material and Man-hour Adjustments and Pipe Item Detail. The Custom Rules worksheet is provided for storing any data that you may wish to use in the output formulas. 354 4 Defining Report Groups, Areas, and Project Components Input specs have been placed on the Custom Rules along with sample alterations for the following:  Mixer with three inlet streams and one exit stream  Pump with connection streams, material and man-hour adjustments  Pipe item details The Output worksheet displays the same component specification slots as on the Input worksheet. However, you can customize the values on the Output worksheet. 4 Defining Report Groups, Areas, and Project Components 355 The values are in the same column-row position as on the Input worksheet, so that you can easily reference the Input data when entering formulas. You send the entries on the Output worksheet to Aspen Process Economic Analyzer by clicking Apply or OK on the Custom Model tool. The following include customized values based on the sample alterations on the Custom Rules worksheet:  Mixer with three inlet streams and one exit stream  Pump with connection streams, material and man-hour adjustments  Pipe item details These customizations have been entered solely for example purposes. 5 Enter new specifications on the Output worksheet. For example, if you want to double the Input flow rate value provided on Row 10, Column C, enter the following formula: =Input!C10*2 6 Go to the Custom Model tool; then click OK to send the output to Aspen Process Economic Analyzer and close the tool. When you display the specifications form of the component, you will see the values from the Output worksheet. Creating a Template To create a template for a component: 1 Open GeneralModelTemplate.xls; then save it as another file. The folder in which you store Custom Model files is specified on the Locations tab in Preferences (APICustomModelDir). The default is: AspenTech\ Economic Evaluation V7.3\Program\API Custom Models 2 Starting on Row 6, Column B for item information, enter the slot names for the specifications that you want to have sent from Aspen Process Economic Analyzer when the file is run for a component. 356 4 Defining Report Groups, Areas, and Project Components Slot names for every equipment and plant bulk item are provided in Icarus Technology Object Definitions (API.pdf). For example, to have the tool send Shell Design Temperature to Excel when the file is run for Fixed Tube Heat Exchangers, you would need to enter CPDesignTemperatureShell. 3 For connection stream information, enter slot names starting on Row 43, Column B. 4 For material and man-hour adjustments, enter slot names starting on row 70, column B. 5 For the pipe-item details, enter slot names starting on row 101, column B. Running the Custom Model Tool at Project-Level for Batch Update The batch update process for the Custom Model can be done one of two ways.  The first method is for a batch update of custom model operations performed on project components that are already linked to a custom model template.  The second method is for a batch update of all selected components. After using the Custom Model tool for any number of components, you can continue to experiment with different specifications and easily revert back to the custom specifications by running the tool at the project level. Simply right-click Main 4 Defining Report Groups, Areas, and Project Components 357 Project or Project Area in Project Explorer’s Project view; then click Custom Model. If more than one project component has been selected for the custom model (for example, multi-selection, area selection, project selection), a message box will appear asking you to specify the mode of operation. If you click Yes, you will be able to specify a custom model template and all of the selected project components will be processed with the one chosen template. If you click No, only project components with a link to a custom model template will be processed with their associated template. Note: the output will be based on the values in the Output workbook in Excel. If the Output workbook contains formulas based on input, changes in input since originally running the Custom Model will affect the output when the Custom Model is re-run. This re-runs all custom models stored in the Custom Model tool. 358 4 Defining Report Groups, Areas, and Project Components 5 Sizing Project Components Note: Sizing is only available in Aspen Capital Cost Estimator if you are licensed to use Aspen Icarus Process Evaluator (Aspen Process Economic Analyzer) or Aspen Decision Analyzer and you select at startup to use one of them in the Aspen Capital Cost Estimator environment. Overview Sizing for Project Components Mapped from Simulator Items Operating conditions for the project components mapped from simulator models are obtained from the information loaded into Aspen Capital Cost Estimator from the simulator report. Any Design Data in the simulator report is also loaded and used during sizing. The information consists of a unit operation model and the streams connected to it. You can size a mapped project component in either of two ways:  Right-click the component in Project Explorer and click Size Item on the pop-up menu. 5 Sizing Project Components 359  Click the Size button on the Component Specifications form: Interactive Sizing Expert For the following components, Aspen Capital Cost Estimator provides the Interactive Sizing form that lets you adjust sizing specifications. The Interactive Sizing form appears when you size the component. Heat Exchangers DHE FIXED-T-S DHE FLOAT-HEAD DHE U-TUBE DRB KETTLE DRB THERMOSIPH DRB U-TUBE Compressors DCP CENTRIF DCP GEN-SERV DGC CENTRIF DGC CENTRIF-IG DGC RECIP-MOTR EGC RECIP-GAS DCP ANSI DCP ANSI-PLAST DCP API 610 DCP API 610-IL DCP CANNED DCP TURBINE DCP PULP STOCK DCP NAG DRIVE Pumps DCP ANSI DCP ANSI-PLAST DCP API 610 DCP API 610-IL DCP CANNED DCP TURBINE DCP PULP STOCK DCP NAG DRIVE Vessels DHT HORIZ-DRUM DVT CYLINDER 360 5 Sizing Project Components DVT SPHERE DVT SPHEROID DVT STORAGE If interactive sizing is not available, Aspen Capital Cost Estimator sizes the item automatically using the simulator data. Sizing for Project Components Not Mapped from Simulator Items Project components not mapped from simulator items can be sized if they are connected to streams. See “Creating Streams to Connect to Components” on page 362 for instructions on creating inlet and outlet streams. If the component is one of those for which interactive sizing is available (see list on page 377), the Interactive Sizing form is displayed during sizing. See “Using the Interactive Sizing Form” for instructions on connecting a component to streams during sizing. X X X X If sizing is not available for a component, the Size option is unavailable. Resizing Project Components If the process conditions associated with a component change, then use the Re-Size command on the project component pop-up menu to update all equipment sizing information. The Re-Size command will clear all the previous sizing results and then size the equipment based on the current process conditions (those that you have entered and those available from the currently loaded simulator file). Therefore, if the component 5 Sizing Project Components 361 being re-sized is one of those for which interactive sizing is available, the Interactive Sizing form that appears is blank. If you would like to keep some of your component specifications (that is,, not have them replaced by those calculated by the Sizing Expert), do not use the Re-size command. Instead, use the Size command or the Size button to access the Interactive Sizing form with current specifications retained, rather than cleared. Then, clear all fields except those you want to retain and click OK to execute sizing. Aspen Capital Cost Estimator will re-calculate only the blank fields. Creating Streams to Connect to Equipment Items For most components, the interactive Sizing Expert requires selection of an inlet stream (that is, a stream carrying fluid to the equipment item) and an outlet stream (that is, a stream carrying fluid from the equipment item). The set of instructions below show how to create streams to connect to an item. In the example, inlet and outlet streams are created to carry 49 DEF F water to a heat exchanger and an outlet stream is created to carry 200 DEG F water from the heat exchanger. In the example used in the set of instructions following these, a heat exchanger is sized to heat water from 40 DEG F to 200 DEG F, using the streams created in the first examples. To create an inlet stream and an outlet stream: 1 In Project Explorer’s Project Basis view, right-click Streams; then click Edit. 362 5 Sizing Project Components The Develop Streams dialog box appears. 2 On the Develop Streams dialog box, click the Create tab. 3 In the Streams tree structure, click User. Leave the Basis as Absolute, since you are creating a completely new process stream. 4 Click Create. The Create Stream dialog box appears. 5 On the Create Stream dialog box, enter a stream name, such as Process-IN. 6 Click OK. 7 On the Develop Stream specifications form, specify: o a primary fluid component o temperature o pressure o liquid mass flow Example:  In the Primary Fluid Component field, click Water. 5 Sizing Project Components and click 363  In the Temperature (DEG F) field, enter 40.  In the Pressure (PSIA) field, enter 90.  In the Liquid Mass Flow (LB/H) field, enter 50,000. 8 Click Apply. Aspen Capital Cost Estimator fills in the rest of the fields in the Liquid Information section. 9 Click OK to return to the Develop Streams dialog box, where you now need to create an outlet stream. 10In the tree structure, click User. Notice that the inlet stream that you just created is now displayed under User. 364 5 Sizing Project Components 11Click that stream and, in the Basis group, click Relative. The new outlet stream will be based upon the inlet stream. 12On the Create Stream dialog box, enter a stream name, such as Process-OUT. 13Click OK. The Develop Stream specifications form appears. Specifications that appear gray are the same as those of the base stream. Any modifications made will appear black. 14Enter an outlet stream temperature that corresponds to temperature to which the heat exchanger will be heating the fluid. In the example above, the temperature has been entered as 200 DEG F and the pressure has been entered as 80 PSIA. The other specifications are the same as the base stream’s. 5 Sizing Project Components 365 15Click OK to apply the changes and return to the Develop Streams dialog box, which you can now close. Using the Interactive Sizing Form With the necessary streams created, you are ready to perform sizing. To size an equipment item: 1 Add an equipment item for which interactive sizing is available (see list below) and display the Component Specifications form. If you are following the example, add a floating head shell and tube exchanger. (See page 324 for instructions on adding components.) X 366 X 5 Sizing Project Components It is not necessary to enter any values on the specifications form before starting the Sizing Expert. However, all applicable sizing parameters that are entered in the component specifications form will be carried over automatically to the sizing expert and used in calculations. 2 Click the Size button. The Interactive Sizing form appears. Note: In order for the Sizing Expert to run, you must select process fluid streams (one at Inlet and one at Outlet conditions) for at least one side (hot or cold side). Any other data you provide (for example,, Duty, Overall heat transfer coefficient, LMTD, and so on) helps the Expert do its job better, but is not necessary. 5 Sizing Project Components 367 3 Click on the Hot Inlet Stream field and then click to access a drop-down list that includes all utility resources and user-created streams. Note: “fluid” refers to liquid or gas. 4 If you are heating a fluid, as in the example, select a utility resource to use as the heating source. The tables on the following page provide definitions of the utility resources. To heat a fluid from 40 DEG F to 200 DEG F, as in the example, the utility Steam @100PSI-Aspen Process Economic Analyzer UTILITY is appropriate. -orIf you are cooling a fluid, select the stream carrying the fluid to be cooled. Utility Resources If you specify a utility resource as a stream, the Sizing Expert will estimate the actual utility rate required for the heat transfer and use this rate to create utility streams as though they were user-specified. The utility stream names are prefixed by “ICU” and are present under the Utility category in the Develop Streams dialog box. These utility streams differ from utility resources in that they have an actual flow rate whereas a resource is a “reservoir” that can provide utility streams at any required flow rate. Default Utility Resources Available for I-P Projects Steam @100PSI 368 Inlet temperature Exit temperature Operating Pressure (DEG F) (DEG F) (PSIA) 327 327 100 Utility type Heat source 5 Sizing Project Components Default Utility Resources Available for I-P Projects Inlet temperature Exit temperature Operating Pressure (DEG F) (DEG F) (PSIA) Steam @165PSI 363 363 165 Heat source Steam @400PSI 444 444 400 Heat source Low Temp Heating Oil 600 550 25 Heat source High Temp Heating Oil 725 675 25 Heat source Refrigerant – Freon 12 -21 -21 15.5 Heat sink Refrigerant – Ethylene -150 -150 15.5 Heat sink Refrigerant – Ethane -130 -130 15.5 Heat sink Refrigerant – Propylene -50 -50 15.5 Heat sink Refrigerant – Propane -40 -40 15.5 Heat sink Cooling Water 95 75 50 Heat sink Utility type Default Utility Resources Available for METRIC Projects Inlet temperature Exit temperature Operating Pressure (DEG C) (DEG C) (KPA) Steam @2760KPA 229.2 229.2 2760 Heat source Steam @1135KPA 184 184 1135 Heat source Steam @690KPA 164 164 690 Heat source Low Temp Heating Oil 315 287 2523 Heat source High Temp Heating Oil 385 357 2523 Heat source Refrigerant – Freon 12 -29.8 -29.8 105 Heat sink Refrigerant – Ethylene -101 -101 105 Heat sink Refrigerant – Ethane -90 -90 105 Heat sink Refrigerant – Propylene -45 -45 105 Heat sink Refrigerant – Propane -40 -40 105 Heat sink Cooling Water 35 24 105 Heat sink 5 Sizing Project Components Utility type 369 5 Click on the Hot Outlet Stream field and then click to access the drop-down list of utility resources and user-created streams. 6 If you are heating a fluid, select again the utility to use as the heating source. -orIf you are cooling a fluid, select the stream carrying the cooled fluid from the exchanger. 7 Click on the Cold Inlet Stream field and then click to access the drop-down list of utility resources and user-created streams. 8 If you are heating a fluid, select the stream carrying the fluid to be heated. 9 A If you are following the example, select the Process-IN stream that you created in the previous set of instructions (see “Creating Streams,” pages 362 through 366). X X X X B If you are cooling a fluid, select a heat sink utility to use as a cooling medium. Click on the Cold Outlet Stream field and then click to access the drop-down list of utility resources and user-created streams. If you are heating a fluid, select the stream carrying the heated fluid from the exchanger.  If you are following the example, select the Process-OUT stream that you created in the previous set of instructions (see “Creating Streams,” pages 362 through 366). X X X X If you are cooling a fluid, select again the heat sink utility to use as the cooling medium. Click Apply. Aspen Capital Cost Estimator fills in the other fields on the Interactive Sizing form. 370 5 Sizing Project Components Note: results are not transferred to the Component Specifications form until you click OK and the sizing is successfully completed (that is,, without generating error messages). 10Click OK. Aspen Capital Cost Estimator provides a message informing you of the overdesign factor. 11Click OK to accept this message. The values obtained from Interactive Sizing now appear on the Component Specifications form. 5 Sizing Project Components 371 12Click OK to save. You can now run an item evaluation and see the values generated by the Sizing Expert in the item report. Global Sizing Selection You can define and/or select a sizing selection library to predefine the sizing selection for a project scenario. For each type of component, you can specify custom models that will be applied in the sizing phase. These rules can also be modified on a component-by-component basis when working on a specific project scenario. For example, if you want to have all DCP CENTRIF based equipment models within a project scenario sized with a specific custom model, you can edit or create a 372 5 Sizing Project Components Sizing Selection library (see Figure 1) to be used. These libraries must be edited/created outside of a project. Figure 1: Library tab in palette To edit the library: 1 Double-click the library name (for example, my sizing). The Sizing Selection dialog box appears. 2 To view or edit the sizing selection, click on the equipment model. All equipment models default to “System Sizing” (see Figure 2). 5 Sizing Project Components 373 Figure 2: Sizing Selection dialog box 3 To add or remove a custom model to the sizing selection list, click New Sizing; then click your choice on the list of available custom models (see Figure 3). Figure 3: Add new sizing with custom model The current sizing list for the equipment model is order dependent (see Figure 4). 374 5 Sizing Project Components Figure 4: Current Sizing List with System sizing and two custom models Once this library has been specified, it must be selected in the project (see Figure 5). Figure 5: Selecting the Sizing Selection library for a project scenario Sizing Areas The Area sizing feature in Aspen Capital Cost Estimator develops length and width of an area from the equipment in the area. When actual area dimensions are not available, you can get a better estimate of area length and width from the system when these parameters are not specified in the area specs form. The system calculated area length and width is used in the design of all area bulks. You can use the system calculated area parameters as the area specs. To have Aspen Capital Cost Estimator calculate the area: 1 Open the Aspen Capital Cost Estimator project. 2 Modify an area spec by right-clicking the area; then, on the menu that appears, clicking Modify. 3 Click Specification | Area Specs; then, on the menu that appears, click Modify. 4 Clear the values for Area length and Area width. 5 Click OK; then click Close. 6 Evaluate the project. In the report, the system-calculated length and width for each area appear in:  AREA BULK REPORT  AREA DATA SHEET 5 Sizing Project Components 375 To specify the area yourself: 1 Open the Aspen Capital Cost Estimator project. 2 Modify an area spec by right-clicking the area; then, on the menu that appears, clicking Modify. 3 Click Specification | Area Specs; then, on the menu that appears, click Modify. 4 Enter values for Area length and Area width. 5 Click Area Piping; then enter data for the piping envelope. 6 Click Area Electrical; then enter data for Distance equipment to panel/DB. 7 Click OK; then click Close. 8 Evaluate the project. In the report, the system-calculated length and width for each area appear in:  AREA BULK REPORT  AREA DATA SHEET To Develop Area Utility Piping and Pipe Racks – system calculated area length and width: 1 Open the Aspen Capital Cost Estimator project. 2 Modify an area spec by right-clicking the area; then, on the menu that appears, clicking Modify. 3 Click Specification | Area Piping; then, on the menu that appears, click Modify. 4 Clear the data in the Utility length parameter (0) and Utility stations (-) fields. 5 Click OK. 6 Click Area Steel; then, on the menu that appears, click Modify. 7 Clear the data in the Pipe rack length (0) field; then click OK. 8 Close the Area Specification menu. 9 Evaluate the project. Some areas generate utility headers, utility stations. and pipe rack bulks. This information appears in:  AREA BULK REPORT 376 5 Sizing Project Components Sizing Requirements, Calculations, and Defaults Certain types of components have minimum input requirements for sizing. Those requirements are provided in the following sections, along with explanations of how the sizing is calculated for different component types. Air Coolers Minimum Input Requirements   Inlet Stream Exit Stream Sizing Procedure The air cooler thermal and detailed mechanical design equations are given below: For thermal design: Q = U*A*MTD MTD = f*LMTD For mechanical design: A = pi*D_tube*N_tubeRows*N_tubesPerRow* Tube_length where: Q = Heat Duty U = Heat transfer coefficient A = Bare tube surface area MTD = Mean Temperature difference LMTD = Log mean temperature difference, based on purely countercurrent flow f = Temperature correction factor N_bays = Number of bays N_tube_rows = Number of tube rows N_tubesPerRow = Number of tubes per row (takes into account the presence of a fan shaft) Tube_length = Length of tubes 5 Sizing Project Components 377 The process fluid properties (temperature, pressure, and specific heat capacity) are assumed to be constant throughout the air cooler and are estimated as the mean of the inlet and outlet stream properties. The required heat duty is calculated from the inlet and outlet process stream conditions if it is not specified. The process fluid stream temperatures, inlet and exit, are used along with the temperatures specified for the air stream (Design Criteria specifications) to calculate the LMTD. The temperature correction factor is then used to calculate the MTD. If the process fluid temperatures and air temperatures are appropriate, meaning that there is no temperature crossover and the temperature approach at the ends is reasonable, then the surface area required for the given heat duty is estimated using the thermal design equation. The air flow rate needed to realize this heat duty is then calculated using the specified ambient and outlet air conditions. An iterative algorithm has been developed to size the air cooler. The sizing routine calculates the heat duty that can be realized using the specified tube bundle geometry (bay width, number of tube rows, and tube length). It assumes defaults for parameters that you have not specified. If the computed heat duty is larger than the heat duty actually required, the iterative procedure terminates. The tube bundle arrangement used represents the specification of the air cooler selected. If the calculated heat duty does not meet the required heat duty then a bigger air cooler is chosen (that is, parameter values are increased) and the above procedure is repeated. The iterative procedure terminates either when a tube bundle geometry that can meet the heat duty requirements is found, or when even the largest available air cooler does not meet the process requirements. Air-side heat transfer coefficients are calculated using the relations that take into account the tube bundle geometry. The work of Young, Briggs, and Robinson, as summarized in [6] is being used to evaluate the heat transfer and pressure drop of air across the tube bundle. The pressure drop thus calculated is used in estimating the fan power required. The number of fans required is calculated based on the aspect ratio (tube length/bay width). For any aspect ratio of up to 1.5, only one fan is selected. Defaults 378 Tube pitch = 2.5 INCHES Tube thickness = 0.125 INCHES 5 Sizing Project Components Bay width = 4 ft to 20 ft Tube rows = 3 to 6 Maximum Tube length = 3*Bay width Inlet air temperature (from Design Criteria specifications) Outlet air temperature (from Design Criteria specifications) Agitated Tanks Minimum Input Requirements   Inlet stream Exit stream Sizing Procedure The capacity of the agitated tank is determined by the following equation: C = Q * (T_r / 60.0) where: C = Capacity , CF Q = Liquid volumetric flowrate, CFH T_r = Liquid residence time, MINUTES The diameter of the agitated tank is determined using L/D and geometry: C = (/4) * D^2 * L where: D = Diameter of vessel, FEET L = Fluid height, FEET Vessel height is obtained by the following: H = L + h_d where: H = Vessel height, FEET 5 Sizing Project Components 379 h_d = Vapor disengagement height, FEET Design parameters are based on the current Design Criteria specifications if available: Length/Diameter Ratio: Default = 3 Vapor disengagement height: Default = 1 FEET Agitator type: Default = = = ANCHOR Driver type: Default Impeller type: Default STD T6FB Operating pressure is obtained from the simulator report. If the report does not have a value, then the pressure of the inlet stream having the maximum value is chosen as the operating pressure. The operating pressure is used to obtain the L/D ratio (if user specification is absent). If P <= 250 PSIA, then L/D = 3 If 250 < P <= 500 PSIA, then L/D = If P > 500 PSIA, then L/D = 5 4 where: P = Pressure, PSI L = Fluid height, FEET D = Diameter of vessel, FEET The project component must have at least one process stream connected to the inlet and exit. Also, since the sizing procedure is based on the liquid holding period, at least one of the streams should have liquid phase. The design pressure and temperature are based on the operating pressure and temperature as modified by your entries on the Design Criteria specifications form. Compressors Minimum Input Requirements  380 Inlet and Exit stream information 5 Sizing Project Components  Driver Power (for Reciprocating Compressors) Sizing Procedure The capacity requirement for the compressor is calculated from the inlet stream information. The inlet stream flow rate and density are used to estimate the total volumetric flow rate through the compressor. The compression ratio (exit to inlet pressure) is obtained from the operating pressures of the inlet and exit stream. The compressibility factor (inlet and exit) is based on user-specified information, if available, or estimated by the sizing expert based on the Primary Fluid Component. The Icarus Evaluation Engine estimates the driver power if it is neither user-specified nor provided in the simulator report. The engine currently uses a mechanical efficiency of 100% to arrive at the brake horsepower. The brake horsepower, thus calculated, is compared against a table of available standard motor sizes. If the calculated brake horsepower is not found in the table, then the motor with the next higher horsepower is selected. If the driver horsepower is either user-specified or provided in the simulator report, the engine uses this value. However for pricing the compressor, the table of available standard motor sizes is referred. If the specified horsepower is not found in the table, then the price of the motor with the next higher horsepower is used. In the case of simulator inputs, different simulators provide information that may be slightly different. For instance, in the case of AspenPlus, the compressor calculations take into account any mechanical efficiency specified during the simulation run. So the “brake horsepower” reported in the case of AspenPlus already takes into account the mechanical efficiency. However, other simulators, such as SimSci (“Actual Work”); HYSIM and HYSYS (“Energy Required”), and ChemCAD ( “Actual Power”); do not account for mechanical efficiency. Keep this in mind and be aware of what has been accounted for in the simulation side when using simulator information as inputs. Defaults Minimum inlet pressure for air compressors is 14.696 PSIA 5 Sizing Project Components 381 Crushers Minimum Input Requirement   Inlet and Exit stream information Final product size. Sizing Procedure The sizing expert estimates the solid flow rate from the inlet stream information. The crushing ratio (feed to product size) is set at 4. Work index is the total energy in KWH/TONS, needed to reduce the feed to a size so that 80% of the product will pass through a 100 micron screen. The sizing expert in Aspen Capital Cost Estimator assumes a default value of 13.81 for the material work index. The total driver power required for the crusher is calculated using material work index and the value of the product size. The following equation is used to estimate the driver power: P = 1.46 (T_m) (W_i) ( 1/(d_p ^ 0.5) - 1/(d_r ^0.5)) where: P = Driver power, HP T_m = Crusher capacity, TPM W_i = Material work index d_p = Product size, FEET d_r = Feed size, FEET Defaults   Material Work Index: 13.8 KWh/ton Size Reduction Ratio: 4 Crystallizers Minimum Information Required Inlet and Exit Stream information 382 5 Sizing Project Components Additional Information Final Product size Sizing Procedure The sizing program calculates the crystallizer capacity based on the inlet and exit stream information. Default value of 0.83 MM is used as final product size if the user-specified value is not available from the simulator report. In addition, the following defaults values are used for the design parameters: Growth rate = 0.36 MM/H The residence time in hours for a batch crystallizer is determined by the following relation: Residence time = d_p / (3 * R_g where: d_p = Product size, MM R_g = Growth rate, MM/H Based on the minimum and maximum values for the required fields in the component specification form, the number of additional crystallizers are estimated. Dryers Minimum Input Requirement Inlet and Exit stream information Sizing Procedure The sizing program calculates the dryer capacity based on the total evaporation rate for the drying process. For tray and drum dryers, an average depth of 2.25 FEET is used to determine the total dryer requirements. For vacuum and jacketed rotary vacuum dryers, the dryer capacity is determined by obtaining value of the drying time and the average percentage utilization of the dryer capacity. 5 Sizing Project Components 383 The system defaults are as follows: Drying time = 0.75 HOUR Average percentage utilization = 25 The number of additional items required for the given drying operation is determined from the knowledge-based engine in Aspen Capital Cost Estimator, which analyzes minimum and maximum values for the required fields in the specification form. Dust Collectors Minimum Input Requirement Inlet and Exit stream information Sizing Procedure The sizing program estimates the vapor volume flowing through the dust collector using the exit stream information available from the simulator report. In case of cyclones, the sizing program assumes a default linear velocity of 150 FPS. The height to width ratio is fixed at 2.5. Using the above defaults, the volumetric rate through the separator is obtained using Zenz correlation represented by the following equation: Q = 2.5 (D ^ 2) V / 16 where: Q = Vapor volumetric rate, CFS D = Cyclone separator diameter, FEET V = Linear velocity, FPS In case of baghouse dust collectors, the sizing program uses Nylon as the default filter cloth material to determine the air to media ratio which then determines the diameter of the separator. 384 5 Sizing Project Components Air to media ratio is the flow rate of air (at 70 DEG F) in CFM. The default ratio results in a pressure drop of 0.5 INCHES of water when passed through 1 SF of clean fabric. The sizing program uses a default air to media ratio of 10 CFM. The minimum and maximum values of the required field(s) shown in the component specification form are used to determine the number of identical equipment items. Filters Minimum Input Requirement   Inlet stream Exit stream Sizing Procedure The sizing program calculates the total amount of filtration product rate based on the exit stream information. Based on the type of filter selected, the average dimension of the filter equipment is selected and the filter size is then optimized for the given operation such that the dimensions selected for the equipment are within the minimum and maximum values as specified by the knowledge-based engine. In case of batch filtration, a default batch time of 0.25 HOUR is used. In case of plate and frame filters, default value of cake thickness of 0.3 FEET is used. In the case of continuous operation, the cycle time default is 0.08 HOUR. Based on the actual capacity requirement and the maximum and minimum sizes provided by the knowledge-based engine, the number of identical items is determined. Heat Exchangers The heat exchanger sizing program estimates the heat transfer area required for the given operating conditions. The model also performs detail estimation of the number of tubes, tube length, and other internal components of the heat exchanger based on either user-defined specifications (from the process simulator report or the Design Criteria specifications form) or system defaults. 5 Sizing Project Components 385 Minimum Input Requirements Inlet and Exit Process Stream Information Sizing Procedure The process stream(s) are classified into various categories. The Primary Fluid Component class that you specify for the process fluid(s) flowing through the heat exchanger is used to estimate the following design parameters:  Latent heats (vaporization and condensation)  Fouling resistance  Specific heat capacity of the fluid  Liquid film resistance  Overall heat transfer coefficient Duty requirement for the heat exchanger is either directly obtained from the simulator report or estimated based on the inlet and exit process stream information for the process model. In case the fluid undergoes phase change, a boiling point temperature, Tb, is estimated that would lie between the inlet and exit stream temperature. The estimated Tb is then used in the calculation of the sensible and latent heats based on the Primary Fluid Component. The sensible heat of any solids present in the stream is also accounted for in the duty calculation. In estimating the design pressure on shell and tube heat exchangers, the 2/3rd Rule is applied if it has been selected on the Design Criteria specifications form (see page 195). X X If only the process fluid conditions are specified by the simulator model, the heat exchanger sizing program determines the appropriate utility from the list of utilities that you specify using the Utility Specifications accessed from Project Basis view (see page 210). If multiple utilities are available for heat transfer, then the sizing expert uses the utility fluid with a temperature approach closest to the process fluid. This minimizes the heat transfer losses. However, a minimum of 1 degree Fahrenheit difference in the final temperature of the process fluid and the utility fluid must exist for the utility fluid to be selected for the process. If an appropriate utility fluid is not available for the heat transfer process, the heat exchanger sizing program will terminate without estimating the heat exchanger size requirements. X 386 X 5 Sizing Project Components The mean temperature difference (MTD) is estimated based on the fluid temperature for both the shell and the tube side. It also depends on the flow configuration for shell and tube heat exchangers, which is specified by the number of shell and tube passes. For reasons of compactness of equipment, the paths of both fluids may require several reversals in direction. Mean temperature differences in such cases can be obtained by applying a factor (called the F-factor) to the terminal temperature difference. The logarithmic mean temperature difference (based on purely counter current flow) is multiplied by the F-factor to obtain the mean temperature difference. If the temperatures are not properly entered then appropriate warning messages are displayed. In such cases it recommended that you check the inlet and outlet temperatures of the shell and tube side streams and verify that they are realistic. The overall heat transfer coefficient is either directly obtained from the simulator report or evaluated based on the shell and tube fluid properties (film resistance, fouling tendency present for the various processes in the system database). The heat exchanger sizing program determines the position of the fluids in the shell and tube heat exchanger. The position depends on both the process and utility fluid class. If duty is provided by the simulator report, then you can override the value only through interactive sizing. The final heat transfer area is obtained by multiplying the heat transfer area, calculated based on the duty required, with the Heat Exchanger Minimum Overdesign Factor. If you do not specify an overdesign factor then the default value is used from the Design Criteria specifications. If the duty generates a surface area less than minimum required for practical design, the item report will give the appropriate warning message. FLOAT HEAD or U-TUBE heat exchangers have an even number of tube passes. If you enter an odd number for the number of tube passes for any of these heat exchanger types, Aspen Capital Cost Estimator generates warning messages. The shell and tube design pressure and temperature are based on the maximum operating conditions of the fluid flowing through the shell and tube respectively. The Design Criteria specifications form lets you change them according to individual project requirements. 5 Sizing Project Components 387 Heat Exchanger Internals The final heat transfer area is determined by the actual number of tubes chosen for the equipment. The least surface area of the combination of numbered tubes and shells is changed for final design. A default tube length of 20 FEET is used for calculating the number of tubes. System default values for tube diameter, tube thickness, tube pitch and baffle distances are used if user specifications are not available. General Information The utility requirement is estimated only when the system determines the utility fluid. If both shell and tube side fluid stream information is specified in the simulator report, then the system assumes that both of the fluid streams are process streams and that no utility fluid is expended. Presently, the model defaults are used for determining the material of construction. For shell and tube heat exchangers, if the heat transfer surface area calculated by the sizing program is greater than the largest heat exchanger designed by the design and cost engine, then the heat exchanger is divided into multiple shells with identical configurations. The capital cost estimation is then calculated based on the complete heat exchanger. Note: When mapping a rigorous heat exchanger model (HXRIG) from SimSci, the number of shells in parallel is used to determine the number of shells in Aspen Capital Cost Estimator. For Aspen Capital Cost Estimator, the maximum number of shells in series is 1. Double Pipe Heat Exchanger The sizing program in Aspen Capital Cost Estimator estimates the total surface area required for the given duty. During the capital cost estimation, detailed design for the heat exchanger is developed based on the values for tube length and number of tubes per shell obtained from the simulator report or from the user. 388 5 Sizing Project Components Fin Tube Heat Exchanger The sizing program estimates the total surface area required for the given duty. During the capital cost estimation, detailed design for the heat exchanger is developed based on the tube length and number of fins per tube obtained either from the simulator report or from the user. Spiral Plate Heat Exchanger The sizing program estimates the total surface area required for the given duty. During the capital cost estimation, detailed design for the heat exchanger is developed based on the tube length and number of fins per tube obtained either from the simulator report or from the user. Pumps Minimum Input Requirements Inlet and Exit stream information Sizing Procedure The sizing program calculates the total capacity requirements for the selected pump based on the total flow rate of the inlet fluid stream(s) obtained from the simulator. Flow Rate/Capacity Pump flow rate is obtained from the simulator information. If the information does not exist, then pump flow rate is calculated based on the stream flow rates. The stream is assumed to be completely liquid phase and no check is made for presence of vapor phase. The pump flow rate obtained from the simulator information is multiplied by the pump overdesign factor, also referred as the capacity over-design factor, present in the Design Criteria specifications file. 5 Sizing Project Components 389 Pump% Efficiency Pump efficiency is directly obtained from the simulator. If the value is not present in the simulator report, then the default value of 70% is used. Pump Overdesign You can modify the pump overdesign factor either on the Design Criteria specifications form or the Interactive Sizing form. Modifying the overdesign factor using the Design Criteria specifications form (page 195) will applies the new factor to all the pumps in the project. Modifying the overdesign factor for a pump using the Interactive Sizing form (page 366) applies the factor only to that particular pump. This lets you either specify the factor for all pumps or specify the factor individually for each pump. X X X X Driver Power If you specify a driver power in the component specification form then this value is used. If the user does not provide the value then it is calculated by the cost engine. The Icarus Evaluation Engine calculates the hydraulic horsepower based on the capacity, viscosity and head, and then uses the pump efficiency to estimate the brake horsepower. The brake horsepower is compared against a set of standard available motor sizes to estimate the pump driver power. If multiple inlet streams are present, the minimum value of pressure is used for determining the operating pressure of the equipment. Defaults (if they are not obtained from the simulators):   Operating pressure: 14.696 PSIA Operating temperature: 77 DEG F Calculating Pump Head The total head developed by the pump is composed of the difference between the static, pressure, and velocity heads. Additionally, friction at the suction and discharge sides would also contribute to some head loss. The pump head is calculated using the following relation: 390 5 Sizing Project Components Head, FEET = h_d – h_s where: H = total pump head, FEET h_d = = discharge head, FEET h_s suction head, FEET Assumptions:  No friction losses at the entrance and exit.  No static head on suction and discharge sides.  Velocity heads are not included in estimating the suction and discharge heads. Head in feet is estimated by the following relations: Head, FEET = (Pressure, PSIA) * (2.31)/(Fluid specific gravity) The specific gravity of the fluid is based on inlet streams conditions. The discharge pressure for the pump is based on the maximum value for the exit stream(s). The suction pressure is based on the minimum value for the inlet streams(s). Screens Minimum Input Requirement   Inlet stream information Screen opening size (or average product size) Sizing Procedure The sizing program determines the capacity of the screen based on the inlet flow rate estimated from the stream information. The screen opening size is used to determine the final product size. The feed material for the vibrating screen is obtained from the Design Criteria specifications. The following choices are available:  Sand and Gravel  Limestone/Crushed Stones  Coal  Cinders  Coke 5 Sizing Project Components 391  Wood The material type affects the screen unit capacity which is defined as the amount of solid (in tons per hour) flowing through one square foot of screen cloth based on material, having 6 to 8% moisture, screen cloth having 50% or more open area; 85% screen efficiency. Based on the material selected and the screen opening size, the screen unit capacity is chosen. Further, the sizing program assumes that five layers of particles are present on the screen. The surface area required for the vibrating screen is obtained. Based on the maximum and minimum values specified by the knowledge base for the screen capacity, additional items required by the operations are determined. Towers Minimum Input Requirements     Stage temperature, pressure, flowrates Number of stages Inlet stream Exit stream Sizing Procedure The distillation column sizing module can be used to size the following Icarus process equipment:  DDT TRAYED  DDT PACKED  TW TRAYED  TW PACKED  DC HE TW The following simulator models can be used to generate the necessary process information required for successfully executing the application: 392 Simulator Models used AspenPlus ABSBR, DISTWU, DISTL, RADFRAC HYSIM/HYSYS COLUMN Pro/II COLUMN, IO, SURE, CHEMDIST, SHORTCUT 5 Sizing Project Components Loading Column Model from Simulator In Aspen Capital Cost Estimator, the rigorous column unit operations loaded from the simulator report (that is, COLUMN UNITS model in PRO/II) are developed in great detail, including all pieces attached to the main column unit. Typically, the simulator model develops stage information for the main tower and duties for an associated condenser and reboiler. These duties are used along with the specified fluid conditions available from the stage information tables to generate all of the input specifications required for the equipment. Sidestrippers and pumparounds are separated from the main tower if necessary during the loading process after all the relevant information is collected for the models. Once the report is loaded, these units are treated as separate simulator models which can be mapped and sized independently of the main tower design. Sidestrippers Sidestrippers attached to tower models are separated from the main tower model during the loading process. Sidestrippers load information from the same tables in the report from which the main tower information is discerned. For example, the typical information loaded for sidestrippers in Pro/II are: SIDESTRIPPER ABC COLUMN SUMMARY TRAY TEMP PRESSURE DEG C KPA ————— ————— ———————— 1/ 10 200.3 600.50 2/ 11 202.2 601.53 —————— NET FLOW RATES —————— HEATER LIQUID VAPOR FEED PRODUCT DUTIES KG-MOL/HR M*KJ/HR —————— —————— ————— ——————— ——————— 22. 7.8 20.0L 5.0V 8.5V 20.1L SIDESTRIPPER ABC TYPE STREAM PHASE FROM TRAY ————— —————— —————— ————— FEED ABCDRW LIQUID FEED ABCSTM VAPOR PROD ABCSRVP VAPOR 10 PROD ABCPRD LIQUID 11 TO TRAY ——— 10 11 LIQUID FRAC —————— 1.0000 .0000 FLOW RATES KG-MOL/HR —————————— 23.00 5.55 8.46 20.09 HEAT RATES M*KJ/HR ——————————— 1.3216 .2785 .5325 1.0678 Information is obtained for the sidestrippers in the same manner as for the main tower unit (Refer to information for obtaining process data for main tower unit). 5 Sizing Project Components 393 Pumparounds The inlet and outlet fluid conditions for pumparounds are obtained from the stage information to which the unit is connected. Additionally, the duty associated with each pumparound is loaded into the unit. This unit is then separated during the loading process and is treated as an independent simulator model which can be mapped and sized on its own. For example, the information required by pumparound units in PRO/II are obtained from the following part of the column report: COLUMN SUMMARY ————— NET FLOW TRAY TEMP DEG F ———— ————— . . . 40R 355.9 RATES ————— PRESSURE LIQUID PSIG ———————— —————— 33.00 HEATER VAPOR FEED PRODUCT LB-MOL/HR ————— ————— ——————— 5618.9 4301.4L DUTIES MM BTU/HR ————————— 94.6551 PUMPAROUNDS TRAY TEMP, FROM TO FROM —— —— —————— 40 40 355.9 DEG F LIQUID FRACTION ——————————— RATES ——————————— TO FROM TO LB-MOL/HR M LB/HR STD BBL/HR ————— —————— ————— ————————— ———————— —————————— 416.1 1.0000 .4108 7273.09 995.238 3569.48 Mapping the Tower Model Typically, column models in simulators do not include the ancillary equipment attached to the main tower. For example, a tower unit may really consist of the following equipment:  Main tower  Overhead condenser  Condenser accumulator  Overhead split  Reflux pump  Overhead pump  Overhead product sub-cooler  Reboiler  Bottoms split  Bottoms product pump  Bottoms product heat exchanger Both overhead and bottoms split are process stream splitters and therefore do not represent any project component. In Aspen Capital Cost Estimator, during mapping and sizing process, they are typically mapped as a quoted cost item with zero cost. 394 5 Sizing Project Components In addition, the equipment design could involve splitting the units into more than one actual piece for reasons of economy. For example, in many applications, condensers are split into a precooler (which is typically an air cooler but also can be any other type of heat exchanger) and a trim cooler (typically a shell and tube heat exchanger). Tower models (such as RADFRAC model in AspenPlus, COLUMN UNIT in PRO/II and COLUMN in HYSIM/HYSYS) can be mapped into any of the following ten Aspen Capital Cost Estimator configurations:  Standard - Single or Standard - Total Tower Condenser Condenser accumulator Overhead split Reflux pump Bottoms split Reboiler.  Full - Single Tower Condenser Condenser accumulator Overhead split Reflux pump Overhead pump Overhead product heat exchanger Bottoms split Reboiler Bottoms product pump Bottoms product heat exchanger  Standard - Split or Standard – Split Total Tower Precooler Trimcooler Condenser accumulator Overhead split Reflux pump Bottoms split 5 Sizing Project Components 395 Reboiler  Full - Split Tower Precooler Trimcoooler Condenser accumulator Overhead split Reflux pump Overhead pump Overhead product heat exchanger Bottoms split Reboiler Bottoms product pump Bottoms product heat exchanger  Standard - Total w/Circ. Tower Condenser Condenser accumulator Overhead split Reflux pump Bottoms split Reboiler Circulation pump  Full - Single w/Circ. Tower Condenser Condenser accumulator Overhead split Reflux pump Overhead pump Overhead product heat exchanger Bottoms split Reboiler Bottoms product pump Bottoms product heat exchanger Circulation pump  Standard – Split Total w/Circ. 396 5 Sizing Project Components Tower Precooler Trimcooler Condenser accumulator Overhead split Reflux pump Bottoms split Reboiler Circulation pump  Full - Split w/Circ. Tower Precooler Trimcoooler Condenser accumulator Overhead split Reflux pump Overhead pump Overhead product heat exchanger Bottoms split Reboiler Bottoms product pump Bottoms product heat exchanger Circulation pump Refer to Tower Configurations in Chapter 4 for detailed flow diagrams. These configurations should be regarded as the “maximum” model with all potentialities satisfied The components actually developed depend upon the process conditions. For example, if the main tower model does not have a condenser and a reboiler, then only the tower model is mapped. If the overhead product is cooler than the temperature of the fluid from the condenser outlet, then an overhead exchanger is mapped. A bottoms product exchanger is mapped only when the bottoms product stream has a different temperature from the temperature of the bottom stage of the tower. 5 Sizing Project Components 397 In the case of split models, where the condenser duty is split into precooler and trimcooler duties, the ratio of the duty split is obtained from the Design Criteria specifications form. The overhead vapor stream flowing to the precooler is assumed to be at dew point if the condensation temperature is not provided. Loading Tower Input Information From the tower results in the report, the tables consisting of stage temperatures, stage pressures, stage molar vapor flow rates and stage molar liquid flow rates are loaded in the mapping process. For example, in the case of AspenPlus, the following tables in the RADFRAC block are loaded by Aspen Capital Cost Estimator in the mapping process: Table 1: Stage temperature and Stage Pressures are loaded (Column 1 and 2) ENTHALPY STAGE 1 2 3 4 5 6 7 8 9 10 TEMP. F PRESSURE PSI 149.27 223.45 227.79 230.39 232.06 233.25 234.18 234.98 235.72 236.74 20.000 22.000 22.100 22.200 22.300 22.400 22.500 22.600 22.700 22.800 BTU/LBMOL LIQUID VAPOR -0.12156E+06 -0.11895E+06 -0.11909E+06 -0.11918E+06 -0.11925E+06 -0.11931E+06 -0.11935E+06 -0.11939E+06 -0.11942E+06 -0.11941E+06 HEAT DUTY BTU/HR -42602. -.23509+08 -87138. -92519. -95701. -97662. -98970. -99924. -0.10068E+06 -0.10135E+06 -0.10196E+06 45802+08 Table 2: Stage molar liquid flowrates and Stage molar vapor flowrates are loaded. (Column 1 and 2) STAGE FLOW RATE FEED RATE PRODUCT RATE LBMOL/HR LBMOL/HR LBMOL/HR LIQUID VAPOR LIQUID VAPOR MIXED LIQUID VAPOR 1 2 3 4 5 6 7 8 9 10 1239. 0.2571E+05 0.2586E+05 0.2595E+05 0.2602E+05 0.2606E+05 0.2610E+05 0.2614E+05 0.2617E+05 0.2357E+05 430.0 .57657-01 1669. .24001+05 2140. 2286. 2380. 2444. 2493. 2532. 2568. 2604. 430.0000 .23571+05 Inlet and exit streams (and their stage numbers) are loaded in the mapping step. 398 5 Sizing Project Components For example, in the case of a RADFRAC model for AspenPlus, the following portion of the report is loaded in Aspen Capital Cost Estimator: INLETS7 OUTLETS - 8 9 STAGE 2 STAGE 1 STAGE 10 When sizing information is present in the report, the mapping program loads all the relevant information present in the sizing sections. For example, in the case of a RADFRAC model for AspenPlus, the following portion of the sizing report is loaded in Aspen Capital Cost Estimator for every section: Case : Tray tower sizing section STARTING STAGE NUMBER ENDING STAGE NUMBER TRAY SPECIFICATIONS — — — — — — — — — TRAY TYPE TRAY SPACING 2 29 METER SIEVE 0.60960 ***** SIZING RESULTS @ STAGE WITH MAXIMUM DIAMETER ***** COLUMN DIAMETER METER 4.00228 Case : Packed tower sizing section STARTING STAGE NUMBER ENDING STAGE NUMBER PACKING — — — — PACKING HETP PACKING 2 9 SPECIFICATIONS — — — — — — — TYPE HEIGHT FT FT BERL-SADDLE 2.00000 16.0000 Determining Tower Process Conditions  Operating Temperature The maximum temperature value for all the stages (given by column 1) is used as the operating temperature for the tower.  Operating Pressure The maximum pressure value for all the stages (given by column 2) is used as the operating pressure for the tower.  Minimum Operating Pressure The minimum pressure value for all the stages (given by column 2) is used as the minimum operating pressure for the tower.  Design Pressure 5 Sizing Project Components 399 The maximum value from the stage pressure profile is used for calculating the design pressure of the tower (that is, after applying the user-defineddesign value from the design criteria file). When stage pressures are not available, the maximum value of pressure from all the inlet streams is used.  Design Temperature The maximum value from the stage temperature profile is used for calculating the design temperature of the tower (that is, after applying the user-defined design value from the design criteria file). When stage temperatures are not available, the maximum value of temperature from all the inlet streams is used.  Number of Stages The number of theoretical stages is provided by the number of rows in Table 1. The final number is determined by taking into account condenser and reboiler (if they are provided). Also, the number of stages is affected by the reboiler type depending on whether the reboiler simulated in the report is kettle or thermosiphon. For example, in the case of RADFRAC model for AspenPlus, consider the following table: STAGE 1 2 3 4 5 6 7 8 9 10 TEMP. F 149.27 223.45 227.79 230.39 232.06 233.25 234.18 234.98 235.72 236.74 PRESSURE PSI 20.000 22.000 22.100 22.200 22.300 22.400 22.500 22.600 22.700 22.800 BTU/LBMOL LIQUID VAPOR -0.12156E+06 -0.11895E+06 -0.11909E+06 -0.11918E+06 -0.11925E+06 -0.11931E+06 -0.11935E+06 -0.11939E+06 -0.11942E+06 -0.11941E+06 HEAT DUTY BTU/HR -42602. -.23509+08 -87138. -92519. -95701. -97662. -98970. -99924. -0.10068E+06 -0.10135E+06 -0.10196E+06 .45802+08 If the reboiler is kettle, then the number of theoretical stages is eight. If the reboiler is thermosiphon (reboiler type is obtained from simulator), then the number of theoretical stages is nine.  Liquid Density  Density of liquid flowing inside the column is estimated from the density of the inlet streams and the exit streams. If liquid density cannot be obtained from the streams, the density of water is used as default. Vapor Density Density of vapor flowing inside the column is estimated from the density of the inlet streams and the exit streams. If vapor density cannot be obtained from the streams, the vapor 400 5 Sizing Project Components  density is estimated based on gas law. The vapor density is estimated at the minimum operating pressure and operating temperature. Average Molecular Weight of Vapor Inside Tower  Average vapor molecular weight is estimated from the inlet and exit streams. The lowest molecular weight of the streams is assigned as the vapor molecular weight. Average Molecular Weight of Liquid Inside Tower Average liquid molecular weight is the maximum molecular weight for the inlet and exit streams. Sizing Procedure The sizing procedure varies depending on the type of internals desired and the simulator model used for the operation. The procedure described below gives a description of the actual steps used by the sizing module to estimate the sizes for the different types of trayed and packed towers. Trayed Tower Sizing General Procedure (Followed for all tray internals): The type (class) of the fluid in the column is used to estimate some of the properties in designing the tray internals, such as surface tension, foaming tendency, deration factor if they are not specified in the simulation output report or on the Design Criteria specifications form. You can specify the overall column tray efficiency in the Tray Efficiency box on the Design Criteria specifications form (see pages 196). If the value is not provided, then it is estimated using Lockett’s modification of the O’Connell Correlation. This correlation is based on tests on actual plant columns and has been the standard of the industry. X X The tray efficiency is used to calculate the actual number of stages required for the separation. EOC = 0.492 ( L ) -0.245 where: EOC = efficiency, O’Connell Correlation L = viscosity of liquid, CPOISE  = relative volatility of key component 5 Sizing Project Components 401 A default value of 1.5 is used for the relative volatility of key components that you can modify on the Design Criteria specifications form. The liquid viscosity is either directly obtained from the report or estimated from the fluid classification.  Once the internal height of the column is estimated (based on the actual number of trays), additional height for vapor disengagement and liquid return is based on your Design Criteria specifications.  In general, the number of stages provided by the simulator report represent the theoretical number of stages. However, if detailed design of the tower has been done by the simulator using tray efficiency, then the number of trays are actual trays. If Aspen Capital Cost Estimator finds that the number of trays are actual, then it uses the value to estimate the height and does not add any additional tray efficiency. Using Tower Sizing Information When a simulator report provides sizing information, Aspen Capital Cost Estimator tries to use as much of the information as possible in the final design. When multiple sections are present in the report, the information used by Aspen Capital Cost Estimator depends on the equipment to which the model is mapped. Single Diameter Trayed Tower (TW TRAYED) If multiple sections are present with different diameters and tray spacings, then the largest values of the diameters and tray spacings are used for the actual design of the tower. Double Diameter Trayed Tower (DTT TRAYED) For double diameter trayed tower, the two largest diameters in the sectional report are used in the design. Once the tower is divided into two sections (based on diameter), the value of the tray spacing for each section is based on the stage numbers present in each section. The largest values of tray spacing for each section are used to estimate the tower height. For example, for AspenPlus, assume the following sizing information is obtained from the report after completing the loading process. 402 5 Sizing Project Components Section 1: Diameter = 5 FEET Tray Spacing = 24 INCHES Stages = 2 to 4 = 6 FEET Section 2: Diameter Tray Spacing = 30 INCHES Stages = 5 to 7 = 8 FEET Section 3: Diameter Tray Spacing = 18 INCHES Stages = 8 to 10 The sizing program will design a double diameter tower with the following dimensions: Top Section Diameter = 6 FEET Top Section Tray Spacing = 30 INCHES Top Section Stages = = 2 to 7 Bottom Section Tray Spacing = 18 INCHES Bottom Section Stages = 8 to 10 Bottom Section Diameter 8 FEET The program estimates the cross sectional area for each stage. Then, the maximum value is used to design the single diameter tower. In case of double diameter tower, the program estimates the diameter for the bottom section and the top section based on the cross sectional area estimated for each stage. Sieve Tray Design The capacity factor, CSB, is evaluated based on the correlation developed for entrainment flooding by Kister and Haas. Jeronimo et. al correlation is used to estimate the clear liquid height in the spray regime. Strictly, the Jeronimo and Swistowski correlation predicts the clear liquid height at the transition from the froth to the spray regime. However, empirical evidence has shown that 5 Sizing Project Components 403 clear liquid height in the spray regime is much the same as clear liquid height at that transition. The CSB estimated at the flooding point is used to evaluate the flooding vapor velocity. The bubbling area is calculated based on flood velocity, the derating factor and the safety factor. (Column default design is 90% of flood.) Downcomer liquid velocity is based on the foaming tendency of the fluid and tray spacing. Foaming tendency can be specified on the Design Criteria specifications form. The downcomer cross-sectional area is based on the downcomer velocity and the maximum liquid flow inside the tower. The total tower cross-sectional area is calculated by adding the bubbling area and the downcomer area. The diameter of the tower is obtained from the cross-sectional area by rounding the area up to the next half foot. The minimum diameter for the tower is 1.5 FEET. Valve Tray Design Valve tray sizing is based on the V-type Ballast trays produced by Glitsch. The system factors are estimated based on the fluid classification performed on the fluid flowing through the column. The tray diameter is evaluated for either single pass trays or two pass trays. It is based on 24 INCHES tray spacing and 80% of flood. Bibliography “Distillation Design”, by Henry Z. Kister. “Applied Process Design For Chemical And Petrochemical Plant”, Volumes 1 and 3, by Ernest E. Ludvig. “Standard Handbook of Engineering Calculations”, by Tyler G. Hicks “Chemical Engineers HandBook”, by Perry and Chilton, 6th Edition. Bubble-Cap Tray Design The allowable vapor velocity and the corresponding diameter for bubble-cap trays have been represented by the Jersey Critical 404 5 Sizing Project Components formula which corresponds to the work by Souder and Brown for column flooding.  D  0.0956 Wv / K  L  v  12 where: D = Diameter, FEET Wv = vapor flow rate, LB/H L = liquid density, LB/CF v = vapor density, LB/CF The factor K depends on the tray spacing as follows: Tray Spacing, INCHES K 18 3.4 24 4.2 30 4.7 30+ 5.0 Packed Tower Design Packed tower design is accomplished for both random and structured packings. The various types of packings supported by the system are described in the Icarus Reference. Kister and Gill flood point correlation is used to estimate pressure drop at the flood point as a function of packing factor alone. FL = .155 (Fp0.7) where: FL Fp = Pressure drop at flood point Packing factor Note: You can provide the value for the packing factor on the Design Criteria specifications form. The system defaults are used for each of the different types of packings if you do not enter a value. Once this pressure drop is known, the flood velocity is calculated using the latest version of GPDC (Generalized Pressure Drop Correlation) charts for both random and structured packings. HETP Prediction You can provide the HETP value on the Design Criteria specifications form. If the value is not specified, rules of thumb prediction reported in literature are used to predict the packed tower efficiency. 5 Sizing Project Components 405 For random packing columns, the following rules are used for estimating HETP (FEET): HETP dp 1.5 dp = = Packing diameter, INCHES HETP > DT for DT < 2 FEET For estimating the structured packing efficiency, the following rule of thumb is used: HETP, = INCHES 1200 /ap + 4 ap Packing surface area per unit volume, SF/CF = System Defaults The following system default values may be modified on the Design Criteria specifications form and Component Specifications form: Trayed Tower Defaults Tray Type = Sieve Tray Spacing = 24 inches Flooding Factor = 80 % Foaming Tendency = Moderate Packed Tower Defaults Packing Type = Random Packing Material = 1.0PPR Specific area per unit volume for the packing = 0.75 SF/CF General Defaults Top vapor disengagement height = 4 FEET Bottom sump height = 6 FEET SimSci’s SHORTCUT Column Operation In case of SHORTCUT column operation, the simulator provides only the minimum reflux ratio for the distillation process. To design the tower, the ratio of the operating reflux ratio and minimum reflux ratio has to be provided. The system uses the 406 5 Sizing Project Components default value of 2.0 for the ratio. The ratio can be changed on the Design Criteria specifications form (see page 196). If the simulator report does not contain information (number of trays) for the operating reflux ratio, the tower sizing program returns to the system without performing sizing for the tower. X X Vessels Horizontal Vessels The following graphic shows a typical horizontal vessel. The following design variables are specified on the Design Criteria specifications form:  Residence Time  Process Vessel Height to Diameter Ratio  Minimum Vessel Diameter  Vapor/Liquid Separator Sizing Method  Average Liquid Particle Diameter  Design factor multiplier for disengagement velocity  Separation Factor  Vapor area /cross sectional area  Separation Factor Multiplier  Minimum Boot Length (used in Horizontal Vessel Design)  Minimum Boot diameter  Boot Leg Liquid Velocity 5 Sizing Project Components 407 Design Requirements The maximum number of exit streams is three; two of the streams can be liquid. Calculating Diameter Vessel diameter is based on the maximum allowable vapor velocity inside the separator, to reduce the liquid entrainment in the vapor. The following two methods are available in Aspen Capital Cost Estimator (chosen from the Design Criteria specifications) to obtain vapor velocity.  Liquid Entrainment Method  Particle size separation method. Calculating Vapor Velocity Liquid Entrainment Method The maximum allowable vapor velocity, to reduce liquid entrainment is obtained as a function of liquid and vapor density and the Separation Factor, which itself is a polynomial function of vapor and liquid density and vapor and liquid flowrates. The polynomial equation was based on 5% of liquid entrained in the vapor and is valid for the range (defined below) of 0.006 to 5.0. Aspen Capital Cost Estimator lets you override the computed value of Separation Factor. W = l_mfr/v_mfr * sqrt (v_rho/l_rho) X = ln (SF) k_v = EXP(A + BX + CX^2 + DX^3 + EX^4) K = k_v * k_vm v_m = K * sqrt ((l_rho - v_rho)/v_rho) where: l_mfr 408 = Light Liquid Mass Flow rate v_mfr = Vapor Mass Flow rate l_rho = Light Liquid Density v_rho = Vapor Density K = System Factor SF = Separation Factor k_v = Polynomial Function of SF k_vm = Separation Factor Multiplier A = -1.877478097 B = -0.8145804597 5 Sizing Project Components C = -0.1870744085 D = -0.0145228667 E = -0.0010148518 The above relation for Separation Factor is valid for a “W”(SF) between 0.006 and 5.0. If “W” falls outside the range, the sizing program gives a warning message and the limiting value of W is used to estimate Separation Factor. For example, if calculated value of W is 0.001, then the value used in the correlation is 0.006. If the calculated value of W is 10.0, then the value used in the correlation is 6.0. Particle Size Separation Method This method estimates the disengagement velocity of liquid bubble in the vapor space. The maximum allowable vapor velocity is determined as a percentage of the disengagement velocity. Liquid drops falling in gases appear to be spherical up to a Reynolds number of 100. Large drops (greater than 0.3125 INCHES) will deform, with a resulting increase in drag, and in some cases shatter. For estimating vapor velocity, the liquid bubbles are assumed to remain in spherical shape. The terminal settling velocity can be obtained for different flow conditions. For laminar flow (K < 3): v = g * (rho_l - rho_v) *(dp^ 2)/ (18.0 * mu_v) and for turbulent region: v = 1.74 (g * dp * (rho_l - rho_v) / rho_v)^0.5 where: K = dp * (g * rho_v * (rho_l - rho_v)/ (mu_v^2) )^0.33 v = disengagement velocity g = gravitational constan rho_l = liquid density rho_v = vapor density dp = liquid bubble diameter mu_v = gas viscosity (assumed to be 0.05 LB/FT/H) 5 Sizing Project Components 409 The design velocity is then estimated by the following equation: v_m = v*f where: v_m = disengagement velocity f = design factor multiplier for disengagement velocity v = disengagement Calculating vessel cross-sectional area Vapor cross sectional area is estimated based on the vapor velocity and the vapor volumetric flow. The vapor cross sectional area is divided by the ratio of vapor area/cross sectional area to get the total required cross sectional area. v_csa = v_vol/v_m t_csa v_csa/r_vc = where: v_csa = Vapor area v_vol Vapor volumetric flow = r_vc = Vapor area/cross sectional area t_csa = Vessel cross sectional area Estimate Vessel diameter based on vapor flow: D_v = sqrt ((t_csa * 4) /) where: D_v =  = Vessel Diameter based on vapor flow 3.14 Estimate vessel diameter based on liquid holdup volume and user-specified value of L/D ratio. The maximum value of diameter calculated using vapor velocity and liquid holdup is used for final design. 410 5 Sizing Project Components Calculating Length Vessel liquid holdup volume is obtained based on the light liquid flowrate and the residence time. The vessel length is then calculated as given below: l_vol = l_vfr * r_t L = (l_vol * 4) / ( * D^2 * (1 - r_vc)) where: l_vol = Liquid holdup volume L = Length l_vfr = = = Light liquid volumetric flowrate r_t r_vc Residence time r_vc Checking L/D Ratio For all liquid vessels L/D is calculated as follows: If If 250 < If P <= 250 PSIA, P <= 500 PSIA, then L/D = 500 then L/D= P> then L/D= PSIA, 3 4 5 After estimating the length (L) and diameter (D) of the vessel, the ratio of L/D is compared with the Process Vessel Height to Diameter Ratio specified on the Design Criteria specifications form. Estimating Boot Dimensions Boot dimensions will be estimated only if the exit streams contain a heavier liquid phase. Boot diameter is based on the heavier liquid phase volume and boot liquid velocity. Boot volume (bt_vol) = hl_vfr * r_t Boot cross section area (bt_csa) = bt_vol / hl_vel Boot diameter (d) = = sqrt (4.0 * bt_csa /) Boot length (l) (bt_vol * 4)/( * d^2) where: hl_vfr = heavy liquid volumetric flow rate hl_vel = heavy liquid velocity l = boot length d = boot diameter 5 Sizing Project Components 411 Vertical Vessels The following graphic shows a typical vertical vessel. The following design variables are specified on the Design Criteria specifications form:  Residence Time  Process Vessel Height to Diameter Ratio  Minimum Vessel Diameter  Vapor/Liquid Separator Sizing Method  Average liquid particle diameter  Design factor multiplier for disengagement velocity  Separation Factor 412 5 Sizing Project Components    Minimum Disengagement Height Minimum height above the mist eliminator Height of Mist Eliminator Vessel diameter is calculated in the same manner as for horizontal vessels. The default value of Separation Factor Multiplier is available in the Design Criteria specifications. Calculating Vessel Height Vessel liquid holdup volume is based on the light liquid flowrate and the residence time. The liquid height in the vessel is then calculated and the additional height is added to obtain the overall vessel height. l_vol = l_vfr * r_t l_ht = (l_vol * 4) / ( * D^2) h = LLLTap_ht + l_ht+ HLLTap_ht + d_ht + me_ht + mea_ht where: l_vol l_vfr = liquid holdup volume = light liquid volumetric flowrate r_t = residence time l_ht liquid height based on residence time LLLTap_ht = = ddHLLTap_ht = height between inlet nozzle and high liquid level tap (desig criteria) d_ht = = = disengagement height me_ht mea_ht minimum height between low liquid level tap and tangent line (design criteria) mist eliminator height Height above the mist eliminator If the calculated l_ht is less than the minimum height between the taps, specified in the design criteria, then the minimum height is used. Checking L/D ratio For all liquid After estimating the length (L) and diameter (D) of the vessel, the ratio of L/D is compared with the Process Vessel Height to Diameter Ratio specified on the Design Criteria specifications form. 5 Sizing Project Components 413 414 5 Sizing Project Components 6 Piping and Instrumentation Models Overview Icarus provides hundreds of default piping and instrumentation drawings (P&ID’s), each associated with a process equipment item. If a process equipment item has a P&ID, the P&ID button is active on the Component Specifications form. Using the P&ID Editor Features of P&IDs          Functionality equivalent to Icarus 2000 added to Aspen Capital Cost Estimator Uses Intergraph RAD technology as drawing engine Intelligent P&ID for single component only Port based system with Piping, Electronic, Pneumatic, Thermocouple and Process Connection ports Piping and Process Connection ports are uni-directional; others are bi-directional Administrator mode for building components or user P&ID models for system library User mode selects system default models or alternate user P&ID models User can modify some characteristics of P&ID in a project Uses Aspen Capital Cost Estimator line diameter and length calculations or user supplied calculations using Line Sizing Equation Editor 6 Piping and Instrumentation Models 415 P&ID Modes You can work with P&IDs in two ways:  If you are not in a specific project, you are in Administrator mode. Use Administrator mode to build components or to build user P&IDs for the System Library.  If you are in a specific project, you are in User mode. In User mode, you can select system default models or user P&ID models. You can also modify some P&ID characteristics. P&ID Layout and Structure To access the P&ID user interface: 1 On the palette, click the Libraries tab. 2 On the Libraries tab, double-click the P&IDs icon . The P&ID User Interface appears. 416 6 Piping and Instrumentation Models The left pane contains the User P&IDs. This is where you can create customized drawings and manage your library. The right pane contains the System P&IDs. This is where you view the system PIDs. In the User P&ID Libraries area, you can add  categories  files You can create folders to organize your custom drawings. The system PIDs are organized by equipment type. You cannot add or remove PID files and folders cannot be added or removed from the system area, but you can customize a system drawing by copying and pasting or dragging and dropping into the Users PIDs area. Each PID file can only be used for a specific equipment type, such as a horizontal tank. A file can be further limited to an application of that equipment type, such as Batch operations. You specify this when you initial create your initial PID. To add a new category to the User P&ID Libraries area: 1 Right-click User P&ID Libraries. 2 On the menu that appears, click New | Category. The rename dialog box appears. 3 In the rename dialog box, type the name for your new category. 4 Click OK. Your new category appears in under User P&ID Libraries. To add a new User P&ID file: 1 Right-click User P&ID Libraries or the category under which you want to insert the new file.. 2 On the menu that appears, click New | File. 6 Piping and Instrumentation Models 417 The New File dialog box appears. 3 On the New File dialog box, type: the Name for the P&ID file (required) a Description of the P&ID file (optional) Note: Each PID file can only be used for certain equipment types the Item Symbol (type of equipment) this new drawing will apply to (for example, VT). You can browse for the Item Symbol by clicking the More button . the Item Type (optional) to further restrict the drawing to an individual application (for example, Storage only). You can browse for the Item Type by clicking the More button . Note: If you leave the Item Type field blank, the P&ID will apply to all applications of the selected Item Symbol (for example, all VTs). 4 When you are satisfied with the details of the new file,  Click OK to insert the new file. -or Click Cancel to abandon adding the new file. Note: If you click OK in Step 4 above, this will be a blank drawing where you must draw the desired drawing. To Delete (Remove) a User P&ID category or file: 1 Right-click the category or file you want to remove. 2 Click Remove. 418 6 Piping and Instrumentation Models Your category or file is removed. The Aspen Capital Cost Estimator PID Layout: Radpfs Interface This second user interface is the Radpfs drawing tool. This application lets you view a PID and make changes to it. The main area of the interface is the drawing area. The symbol menu is on the left side of the screen and the labels are at the bottom. The drawing area contains the PID objects and the labels. The labels include:  PID title  number  date  company name Use the toolbars at the top for:  drawing  zooming  labeling  and so on Note: You can remove the toolbars at the top to give you more drawing space. 6 Piping and Instrumentation Models 419 Symbol Menu The symbol menu is where you can select objects to add to the drawing. These objects include:  equipment symbols  instrument bubbles  piping lines  valves and fittings Symbol Menu – Details The illustrations below show the details of the Symbol menu. Symbol menu categories The Line types section of the Symbol menu includes:  Electronic 420 6 Piping and Instrumentation Models    Pneumatic Thermocouple Process connections When you select a line type in the Symbol menu, all of the ports of this type on the PID appear. The Piping section of the Symbol menu contains all of the valves and fittings that have graphical representations. Here are some example Piping objects: Under the Instrumentation heading of the Symbol menu you will find the control valves, which can be connected to piping lines and instrument bubbles to form loops. Here you will also find the instrument bubbles, which can be connected to equipment symbols or piping lines using process connections ports; the bubbles are connected to each other and control valves using electronic and pneumatic ports to form loops. Here are some example Instrumentation objects: The last two headings of the Symbol menu contain the equipment symbols:  Equipment contains the system default equipment symbols.  Custom Equipment contains any customized equipment symbols. 6 Piping and Instrumentation Models 421 Working with Ports The RadPfs PID editor is a port based system. Ports:  let you connect piping and instrumentation lines to objects in your PID  appear on the PID as arrows  display the port name if the cursor is positioned over it Port Properties Every port has the following properties:  Name  Type – A port can be connected only to another of the same type Piping Process Connection Electrical Pneumatic Thermocouple  Direction In Out Bi-directional Making Ports Visible To make ports visible:  On the Symbol menu, under Line Types, click the type of line for which you want to make the ports visible. For example, if you want to make the Piping ports visible on your drawing, under Line Types, click Piping. The Piping ports are now visible, as shown below. 422 6 Piping and Instrumentation Models Forming Connections Using Ports To use ports to form connections (or draw a line) on the drawing: 1 On the Symbol menu, click the port type you want. Ports of that type are made visible. 2 In the drawing, left-click the port you want to use. A dotted red line showing the link moves as you move the mouse. 3 Left-click another port of the type you are using. A line will be drawn automatically between the two ports. You might use this technique for a branching pipe or instrument loops. 6 Piping and Instrumentation Models 423 -orIn the case of piping lines, drop the other end of the red dotted line onto a blank area on the drawing. This will also draw the line automatically, but it will represent a line coming from or traveling to an area outside of the drawing. Editing P&IDs You can make changes to a PID in radpfs, such as:  adding piping lines  adding valves and fittings  adding ing instrumentation  adding labels  deleting objects Adding Piping Lines Remember that at least one end of a line of pipe will be connected to a piping port on the equipment s symbol ymbol or another line of pipe. The other end of the piping line can be  connected d tto a piping port or it can be  dropped onto white space to represent originating from or traveling to a d destination outside of the PID The suggested order is to to: 1 Add dd the line of pipe pipe. 2 Supply pply a pipe number. 3 Add valves and fittings. To add a piping line: 1 On the Symbol menu, click the Piping line type. 424 6 Piping and Instrumentation Models 2 Click a port you want to use. As you move the mouse around the screen you will see a red dotted line. 3 Click to assign the other end of the line of pipe. A line will be drawn automatically for you. The next step is to supply a pipe number. To supply a pipe number: 1 Right-click on the newly created piping line. 2 On the menu that appears, click Number Piping Line. 3 Type a pipe number for the piping line number. 4 Click OK. The next step is to add valves and fittings. To add a valve or fitting: 1 In the left pane, expand Piping. 2 Click the name of the type of valve (or other fitting) you want to add. A graphical representation in the lower left pane. The example below is of a butterfly valve. 3 Click the location on the line of pipe where you want to add the valve or fitting. It is drawn and connected automatically. 6 Piping and Instrumentation Models 425 To display the line number or the description on the PID: 1 Right-click on a line. 2 On the menu that appears, click: o Display Piping Number o Display Piping description To display more information about this line of pipe 1 Right-click the line of pipe. 2 On the menu that appears, click select View Piping Properties. The Piping Line Properties dialog box appears.   426 Use the Description field to change the description of this line of pipe at the top of the screen. Use the fields in the Fitting group to add valves and fittings which do not have graphical representations, such as elbows or tee’s. You can see that the first two valves are grayed out – these have graphical representations, so they must be added or deleted on the PID itself. 6 Piping and Instrumentation Models   Use the remainder of the fields to select fittings to add. Use the fields in the Line Sizing group to specify line sizing details. The Aspen Capital Cost Estimator PID system lets you write line sizing rules that calculate diameter and length relative to aspects of the component, such as volume or flow rate. See Line Sizing Tutorial, page 440, for details about how to create a new rule. The Line Sizing area is where you can select a rule for use on this piping line. X X The Temperature and Pressure Type fields are for:  gas compressors  double diameter towers  heat exchangers Use these fields to tell the system where this line of pipe is connected to one of these pieces of equipment. The Connect to equipment location field is used for nozzle sizing for vessels and towers only. Adding Instrumentation Loops All instrumentation and control valves in the Aspen Capital Cost Estimator system are grouped as loops. If you are familiar with the Icarus system, especially the instrumentation installation bulks form, a helpful concept is that: By selecting bubbles and editing the Instrumentation Properties, you provide the exact same information you would find in the Installation Bulk – Instrumentation screen. The suggested workflow for adding an instrument loop is:  Add the desired bubbles to the PID.  Connect the loop together.  Provide a loop number. The instrument bubbles are found in the Symbol Menu. They are organized by location, then by process variable. Location is important because it will affect the pieces of equipment generated in your estimate: for instance, if you choose a local control bubble only, you will not get a run of instrument cable from the field to the control center. Control center bubbles will not have process connection ports, so choose bubbles which represent your process most accurately. 6 Piping and Instrumentation Models 427 To add instrument bubbles and control valves to the PID: Note: This example is a pressure loop with a control valve. 1 On the left pane, expand Instrumentation. 2 Click the instrumentation type you want to place. 3 Move the cursor into the drawing where you want to place the instrumentation bubble; then click. The bubble is placed in the drawing. 4 Add the next instrumentation bubbles one by one. 5 Add a control valve (Instrumentation | Control Valves | <name of control valve>) if necessary. Next, the process connection ports are used to connect the local bubbles to the piping line or equipment symbol. 6 In the left pane, click Line Types | Process Connection to display the Process Connection ports so you can attach the bubble to a line of pipe. 428 6 Piping and Instrumentation Models A dotted red line appears when you move the cursor, showing you where the line will be drawn. 7 Click again where you want the line to connect. 8 In the left pane, click Line Types | Electronic to display the Electronic ports so you can connect the rest of the loop. 9 Click an Electronic port. A dotted red line appears when you move the cursor, showing you where the line will be drawn. 10Click again where you want the line to connect. The line is connected. 11Continue connecting bubbles and ports until the loop is complete. 12Right-click anywhere on the loop. 13On the menu that appears, click Number Loop. 6 Piping and Instrumentation Models 429 You can modify the loop, by:  removing parts of the loop from the estimate  adding a Back of Panel Option  changing instrument quantity  and so on To modify the loop: 1 Right click the loop. 2 On the menu that appears, click View Loop Properties. The Loop Properties dialog box appears. 430 6 Piping and Instrumentation Models If you are familiar with the instrumentation installation bulk form, you will probably notice that this interface provides many of the same inputs. The following inputs are unavailable, because they are determined graphically by the PID loop bubbles: o Process Variable o Panel Action o Sensor Type o Instrument Location o Signal Type 3 Use the Loop Properties dialog box to customize: o Description: Loop name o Back of Panel Option o Quantity o Number of Solenoids o Loop Modifications  Remove specific pieces of the loop from the estimate 4 When you have finished customizing the loop, click OK. Adding or Editing P&ID Labels Each PID has space at the bottom for:  title  number  date  company name To add or edit P&ID labels: 1 At the bottom of the drawing, double click in the box you want to edit. The text in the box becomes red, indicating you can edit it. 2 Type your additions or edits. 3 Click anywhere else in the drawing. Adding Miscellaneous Labels You can add miscellaneous labels throughout the PID. 6 Piping and Instrumentation Models 431 To add a miscellaneous label: 1 On the Label toolbar, click the Label icon as shown below. Note: If the Label toolbar is not visible, A Click View | Toolbars. B Select Label Label. C Click OK. 2 Click in the drawing w where here you want to place the label, moving your cursor to make a box into which the label will go. 3 Type your label into the box. 4 Click anywhere else in the drawing. Deleting Pipe, Instrument Instrumentation, ation, and Valves To delete any objects from you your drawing: 1 Right-click click the object you want to delete. 2 On the menu that appears, click Delete. When deleting objects, one common situatio situation n that is created is a disconnected line of pipe because you delete a valve or fitting from the middle of it, as shown here. After deleting a valve To reconnect the line: 1 Delete elete one of the loose ends ends. 432 6 Piping and Instrumentation Instru Models 2 Right ight click the other loose end end. 3 On the menu that appears, click Reconnect Source or Reconnect Destination Destination,, depending on the direction of the pipe. Line reconnected Efficient PID Creation When you create a drawing from scratch, the recommended workflow is to add items in this order: 1 Equipment symbol 2 Lines of pipe 3 Pipe numbers 4 Valves and fittings 5 Instrument bubbles 6 Control valves 7 Instrument connections 8 Instrument loop numbers 9 Labels AspenTech has found that efficiency is improved by positioning the objects in the drawing before using ports to form connections. This is because moving the objects into position before making all the connections save saves s readjustment effort later. 6 Piping and Instrumentation Models 433 Cosmetic Tips You can adjust just the position of any lines on your PID by dragging and dropping, as shown here. When you move objects around, you may see that there are kinks in some lines. To straighten kinked lines: 1 Right-click click the line you want to straighten. 2 On the menu that appears, click Align. You can move all objects on the PID,, including line numbers, descriptions, and text boxes, by dragging g and dropping. 434 6 Piping and Instrumentation Models Adjusting line intersection points To adjust the position of connection points between two lines: 1 Position the mouse over the connection point. 2 When the arrow appears, click and hold to drag and drop the connection up and down the line. When you use branch or join ports to connect one piping line to another, the branch port is always on the top of the line, and the join port is on the bottom. Sometimes this isn’t what you want. To reverse the connection: 1 Position the mouse over the connection point. 2 Click and drag to reverse the connection. Radpfs toolbars The most often used toolbars are:  the Symbol menu  Label  Main  Draw To add or delete toolbars: 1 On the main menu click View | Toolbars. 6 Piping and Instrumentation Models 435 The Toolbars dialog box appears. 2 On the Toolbars dialog box, select or clear the check boxes for the toolbars until you are satisfied. 3 Click OK. You can shift toolbars around the screen (undock them), by dragging and dropping. Zooming Use the Zoom icons on the Main toolbar to control your view of your drawing. Use this icon Zoom Area Zoom In Zoom Out Fit Pan 436 to highlight an area to zoom in on zoom in zoom out fit the viewable area to the full drawing area move the drawing around in the drawing space 6 Piping and Instrumentation Models Custom Equipment Symbols In addition to using the system default equipment symbols, you can create custom symbols. You can:  customize the default symbols  import symbols  create your own symbols from scratch Getting Started with Custom Equipment Symbols To add a new symbol to the system: 1 Double-click a blank PID file to open Radpfs. Note: You can find a blank file by expanding List of All P&ID Library Files in the center pane. 2 On the Main menu bar, click File | Add Custom Equipment Model. The Add Custom Model dialog box appears. 3 In the Enter model name field, type a name for the new model. 4 If you want, in the Enter display name field, type a description for the new model. 6 Piping and Instrumentation Models 437 5 In the Select category field, tell the system where in the folder structure you want to keep this new symbol (this is where you will find it in the Symbol menu). We recommend adding new symbols to the Custom Equipment heading. Note: On this interface you can create new subfolders by double clicking on the New category items. Modifying a system equipment symbol To modify a system equipment symbol: 1 Click File | Add custom equipment symbol. 2 Click File | Open. 3 In the /AspenTech/RADPFS <version>/icons/AspenEQ/ directory, click a file. 4 Click the equipment symbol to highlight it. 5 Click Edit | Copy; then select Window | <your new symbol file>. 6 Right-click; then click Paste. 7 Drag and drop the symbol to position the symbol in the middle of the drawing area. Now you add ports to the system equipment symbol. When you are customizing a symbol, the Port menu is visible on the left-hand side of the Radpfs interface instead of the Symbol menu To add a port: 8 Right-click a type in the Port menu; then click add port. 9 Give the port a descriptive name that indicates the intended function of the port. 10Select a type; then click OK. 11You can now put this port into position by dragging and dropping onto the equipment symbol. 12Use right-click and rotate to adjust the orientation of the port. 13Repeat steps 1 through 5 to add all the ports you think you’ll need 14Save the ports in the CustomEQ folder for use in future PIDs 15Save the symbol file in the CustomEQ folder. This new symbol will now be available for use in future drawings. 438 6 Piping and Instrumentation Models Importing an equipment symbol In addition to customizing an Icarus equipment symbol, you can import a symbol image from an outside drawing package, such as AutoCad or Microstation, and add ports to it. To import a system equipment symbol: 1 Click File | Add custom equipment symbol. 2 Click File | Open. 3 Open an outside drawing instead of a symbol file from the AspenEQ folder. 4 Left-click the equipment symbol and copy it. 5 Use the Window menu to switch back to the screen where you are defining the customized symbol. 6 Right click and paste the symbol; drag and drop to position the symbol in the middle of the drawing area. Now you add ports to the system equipment symbol. When you are customizing a symbol, the Port menu is visible on the left-hand side of the Radpfs interface instead of the Symbol menu To add a port: 7 Right-click a type in the Port menu; then click add port. 8 Give the port a descriptive name that indicates the intended function of the port. 9 Select a type; then click OK. 10You can now put this port into position by dragging and dropping onto the equipment symbol. 11Use right-click and rotate to adjust the orientation of the port. 12Repeat steps 1 through 5 to add all the ports you think you’ll need 13Save the ports in the CustomEQ folder for use in future PIDs 14Save the symbol file in the CustomEQ folder. This imported symbol will now be available for use in future drawings. 6 Piping and Instrumentation Models 439 Creating an equipment symbol from scratch The third option for creating new equipment symbols is to draw your own using the Microsoft drawings tools, found on the Draw toolbar. To create a system equipment symbol from scratch: 1 Click File | Add custom equipment symbol. 2 Use the shapes in the drawing toolbar to create your symbol Now you add ports to the system equipment symbol. When you are customizing a symbol, the Port menu is visible on the left-hand side of the Radpfs interface instead of the Symbol menu To add a port: 3 Right-click a type in the Port menu; then click add port. 4 Give the port a descriptive name that indicates the intended function of the port. 5 Select a type; then click OK. 6 You can now put this port into position by dragging and dropping onto the equipment symbol. 7 Use right-click and rotate to adjust the orientation of the port. 8 Repeat steps 1 through 5 to add all the ports you think you’ll need 9 Save the ports in the CustomEQ folder for use in future PIDs 10Save the symbol file in /AspenTech/RADPFS <version>/icons/CustomEQ/. This new symbol will now be available for use in future drawings. Line sizing Tutorial Instead of using the system default rules for calculating pipe length and diameter, you can write your own. You can use the Line Sizing Equation Editor to create new rules which size the pipe according to equipment properties such as:  volume  height  flow rate 440 6 Piping and Instrumentation Models To access the line sizing Equation Editor:  Without a project open, on the Libraries tab in the right pane of the Aspen Capital Cost Estimator interface, double-click Line Sizing Equation. The Equation Editor dialog box appears. The main list box contains the equations which are part of the system at this time. When you are editing an individual equation, you will use the inputs at the bottom of the interface. Line Sizing Equations Each line sizing equation is either a rule for calculating the pipe length or diameter. Each equation:  is either a Length or Diameter rule (determines starting letter L or a D)  has a reference number (example: 1001)  has a Descriptor line (example: D1001D)  has a Equation line (example: D1001E) The first line in the definition of a rule is the Descriptor line. This contains the text description and the unit of measure basis. The second line contains the equation itself. Note: You can add as many comment lines as you want in the list box to describe an equation or section of equations. 6 Piping and Instrumentation Models 441 In the example above,  the unit of measure basis is IP  the length is calculated as the Diameter of the equipment component divided by 2 plus 10 feet To create a new line sizing equation: 1 Without a project open, on the Libraries tab in the right pane of the Aspen Capital Cost Estimator interface, click Line Sizing Equation. The Equation Editor dialog box appears. 2 On the Equation Editor dialog box, click the Add button three times to add three more lines. There are three steps to creating an Equation: Step 1: Add a comment or comments Step 2: Specify the Descriptor and Units of Measure Step 3: Specify the Equation itself Step 1 To add a comment or comments: 1 Click the first of the newly-added lines to highlight it. 2 Click Edit. 3 In the Comment field, type any comments you want to describe this equation/section. 4 Click Apply. Your comment appears in the main window. 442 6 Piping and Instrumentation Models Step 2: To specify the descriptor and Units of Measure: 1 Click the second of the newly-added lines to highlight it. 2 On the Card Type list, click Length or Diameter. The other fields in the row are now available. 3 In the Ref. No. field, type a unique Reference Number. 4 On the Data Type list, click Descriptor. 5 In the Description field, type a text description for this equation. 6 On the Units list, click the unit of measure basis for this equation. Note: The line sizing system has been constructed so that all quantities used in the equations are assumed to be in the selected unit of measure basis. o An I-P equation will result in a length in feet or diameter in inches. o A metric equation will calculate a length in meters or a diameter in mm’s. o All variables used in the equation will also be calculated in terms of the selected unit of measure basis. For this reason your equations can be used by both Metric and I-P projects with equivalent results. 7 Click Apply. Step 3: To specify the Equation itself: 1 Click the third of the newly-added lines to highlight it. This line will contain the equation used to calculate the Length or Diameter of the piping line. 2 Create an equation using: o real numbers o variables selected from the Symbols drop-down box o operator symbols from the Operators and Operands area 3 When you are satisfied with your equation, click Apply. 6 Piping and Instrumentation Models 443 4 Click Compile to add the new equation to your system. 5 If you are prompted as to whether to save your changes before compiling, click Yes. 6 Click Close. You can now use this new equation in any PID by selecting the equation in the Piping Line Properties screen – Length or Diameter drop-down boxes. To open the default drawing for a component:  Click the arrow of the P&ID button and, on the drop-down menu; then click Open Default. This opens the drawing in the P&ID Editor, where you can print the drawing (File | Print) or send the drawing through electronic mail (File | Send). 444 6 Piping and Instrumentation Models You can use the P&ID Editor to make modifications to the drawing. Modifications affect only the active project. You can also use the P&ID Editor to create your own P&ID’s and build a User P&ID Library. Then, when adding an equipment item in a project, you can select to use your custom P&ID instead of the default. The following sections explain how to create custom P&ID’s and how to use them in Aspen Capital Cost Estimator. Using Custom P&ID’s in Aspen Capital Cost Estimator There are several ways to use custom P&ID’s in Aspen Capital Cost Estimator:  Set a custom drawing as a component’s default P&ID. This will make your custom drawing the component’s default P&ID in all future projects, until the default is reset.  Attach a custom drawing to a single component added to a project.  Set a custom drawing as a component’s default P&ID for only the active project. Setting a Component’s Default P&ID You can make a custom drawing a component’s default P&ID. This must be done with no project open. 6 Piping and Instrumentation Models 445 To set a component’s default P&ID: 1 In Aspen Capital Cost Estimator, with no project open, click the Libraries tab in the Palette. 2 Double-click P&ID to open the P&ID Libraries. 3 Click the Components tab in the Palette. 4 Right-click on a component; then click Set Default P&ID on the pop-up menu. The Set Default P&ID dialog box appears. This dialog box displays the name, location, and application type of the default drawings for the selected equipment item. The Location column shows Sys for system drawings and User for custom user drawings in the user folder. 5 Click the default P&ID you want to change out; then click Default. 446 6 Piping and Instrumentation Models The Selection dialog box appears. 6 Click a P&ID file (it will display the complete path of the file at the bottom of the dialog box); then click OK. 7 Click OK to close the Set Default P&ID dialog box. Resetting the Default P&ID You can reset the default to the original system P&ID. To reset a component’s default P&ID: 1 In Aspen Capital Cost Estimator, with no project open, click the Libraries tab in the Palette. 2 Double-click P&ID to open the P&ID Libraries. 3 Click the Components tab in the Palette. 4 Right-click on the component. 5 On the menu that appears, click Set Default P&ID. 6 Piping and Instrumentation Models 447 The Set Default P&ID dialog box appears. 6 Click the P&ID file you want to change out; then click Reset. The original default file replaces the user-selected one. 7 Click OK. Attaching a Custom P&ID to a Component You can attach a custom P&ID to a component:  when adding a component to a project  when modifying a previously added component To attach a custom P&ID to a component: 1 On the Component Specifications form, click the P&ID button’s drop-down arrow and click Select and Open Alternate. 448 6 Piping and Instrumentation Models 2 On the Selection dialog box, click the custom drawing; then click OK. 3 After the drawing is displayed, on the File menu click Exit and click No in the Close dialog box for saving changes. Setting a Component’s Default P&ID in Active Project Only To set the default P&ID for an active project: 1 Attach a P&ID file to the component (see above). 2 Click the P&ID button’s arrow; then click Set as Default on the menu. Default P&ID Options: Always FULL or Determined by User Options When you open the default P&ID for an equipment item the system will open the FULL model if this is an option. This behavior is independent of your input in the Piping and Instrument Design fields at the Project or Area levels. (The options for these fields are STD (standard) or FULL). If you prefer to have the system to check these inputs when selecting the default P&ID, you can change the behavior of the system by navigating to the following directory: 6 Piping and Instrumentation Models 449 …/Program Files/Aspen Tech/Economic Evaluation V7.3/Program/Sys/Drawings/ The text file pnidcros.tbl determines this behavior. To have the system to consider the STD or FULL input: 1 Delete the existing pnidcros.tbl file. 2 Copy STDorFULLpnidcros.tbl; then rename the new copy pnidcros.tbl. To revert to the default behavior (default is always FULL): If you want to revert back to the default behavior (default is always “FULL”) repeat this process with the “ORIGINALpnidcros.tbl” file. Working with Non-Graphic P&ID Data Inside a Aspen Capital Cost Estimator project, you can open a component form with piping and instrumentation data, then save that information as non-graphical P&ID in a P&ID library file. You can also create non-graphical P&ID libraries outside a project from the Library tabs and save them in new or existing library files. Saving Component Information as NonGraphical P&ID To save component information as non-graphical P&ID: 1 Open a component form. 2 Add or modify piping and/or instrumentation data. 3 Save the information by clicking Apply. 4 On the toolbar, click the arrow to the right of Options. 5 On the menu that appears, click Non-graphical P&ID. 6 Click Save P&ID in a library. A list of existing library files along with an option to create a new library file appears. 7 Either create a new library file, or click a library file on the displayed list. 450 6 Piping and Instrumentation Models 8 Specify a unique name for the P&ID and save it in the library file. Note: P&ID information will be saved without diameter and length information for pipes. Creating Non-Graphical P&ID Libraries Outside a Project To create non-graphical P&ID libraries outside a project: 1 On the Library tab, click Non-graphical P&ID. A list of existing library files appears. You can also or create a new library file folder. 2 Click the desired library file folder; then right-click. 3 On the menu that appears, click Create New. 4 On the dialog box that appears, type the P&ID name; then click OK. A window appears similar to component form, with options only for piping and instrumentation installation bulks. 5 Specify information for lines and loops; then save the P&ID information in the library file. You can also copy an existing P&ID in a library file, assign it a new name, modify it, then save in the same or different library file. Importing External P&ID Data Generate project estimate by importing piping and instrumentation information from SPPID (Intergraph SmartPlant P&ID, an external P&ID drawing tool) in Aspen Capital Cost Estimator. Importing of P&ID Drawings generated in Intergraph SmartPlant P&ID into Aspen Capital Cost Estimator comprises of two steps: 1. Export the P&ID Drawing to an XML file through the Use of TEF. 2. Import the XML file using the Aspen Capital Cost Estimator framework. 6 Piping and Instrumentation Models 451 The import process generates piping and instrumentation installation bulk sets for all P&ID equipments in Aspen Capital Cost Estimator. No Graphical data is imported. Open a new or existing Aspen Capital Cost Estimator project, and add equipment components to the new project. Because the equipment data in a P&ID drawing is not sufficient to develop equipment components in Aspen Capital Cost Estimator, you must create the equipment components (present in P&ID drawings) in a Aspen Capital Cost Estimator project. Subsequently, the PID XML file is imported using the Import P&ID Drawing on the File menu. Browse to the location where the exported XML files are stored, and select the appropriate exported XML File. 452 6 Piping and Instrumentation Models Upon selecting the XML File:  PID Data (Equipment, Lines, and Loops) are imported into a Temporary Access Database.  A Preliminary Evaluation of the Project is performed to generate Volumetric (or Installation) Bulk Pipe Lines.  A Mapping GUI is Launched: The GUI displays Equipment and Lines from both the P&ID Drawing, and the Aspen Capital Cost Estimator Project.  You are expected to map SPPID Equipment to Aspen Capital Cost Estimator Equipment, and SPPID Pipe line to Aspen Capital Cost Estimator Installation bulk pipe.  Alternately, you can select Automap, and map equipment and lines by user tag and line tag. 6 Piping and Instrumentation Models 453 Select the desired SPPID Equipment to map:  Details about the selected equipment appear in the lower text area.  P&ID Lines connected to the Equipment are listed in the P&ID Line list.  Aspen Capital Cost Estimator Equipment that are similar or have the same tag are listed in the Aspen Capital Cost Estimator Equipment list.  When you hover over any item on any list, a tooltip lists details about the item.  Select the SPPID Equipment and an appropriate Aspen Capital Cost Estimator Equipment; then click the Map button. 454 6 Piping and Instrumentation Models Continue until all equipment are mapped to Aspen Capital Cost Estimator; then proceed to map the SPPID Lines to Aspen Capital Cost Estimator equipment or lines.  Select the desired SPPID line to map:  Details about the selected line appear in the lower text area 6 Piping and Instrumentation Models 455  When you hover over any line, a tooltip lists details about the line  A PID Pipe Line can be mapped to Aspen Capital Cost Estimator Equipment or to an individual Aspen Capital Cost Estimator pipe line Select a Aspen Capital Cost Estimator Equipment to map to Select a Aspen Capital Cost Estimator line to map Click the Map button Note: You can choose to map one long SPPID line to two Aspen Capital Cost Estimator lines. In this case, fittings are partitioned between the two Aspen Capital Cost Estimator lines. In the example given below, Line P-13802-4”-1S3984 is mapped to the centrifugal pump; if you wanted to map it to the centrifugal pump inlet, then the SPPID line can be mapped to DCP-2 Line 2. Continue mapping SPPID lines to Aspen Capital Cost Estimator Equipment or Lines until all the interconnecting lines are mapped. If a single SPPID line is mapped to two Aspen Capital Cost Estimator lines, the fittings on the line are distributed to both lines of Aspen Capital Cost Estimator. When All Equipment and Lines have been mapped, you can choose to do one of three things:  Save mapping and exit, for instance, to import more drawings (the Aspen Capital Cost Estimator Project not yet updated with lines and loops) 456 6 Piping and Instrumentation Models   Update the Aspen Capital Cost Estimator project with line/fittings and loop/instrument data Cancel and quit the mapping GUI. After all piping and equipment from one or more drawings have been imported and mapped, the project is updated. This results in piping and instrumentation installation bulk sets for all P&ID equipments in Aspen Capital Cost Estimator. No Graphical data is imported. Interconnecting Volumetric P&ID Lines Connect pipelines between components in a Aspen Capital Cost Estimator project, estimate the project, and create piping line list report for connected lines with the same line tag. Open a Aspen Capital Cost Estimator project Open a new or existing Aspen Capital Cost Estimator project, add equipment components to the new project. Run Interconnect Piping Lines To run interconnect piping lines: 1 On the main tool bar, click Run. 2 Click Interconnect Piping Lines to launch the GUI as shown below: 6 Piping and Instrumentation Models 457 The GUI displays five lists. All equipment and its associated pipelines in the project are displayed in two groups:  Connect From  Connect To The first two lists display equipment and piping lines in the Connect From group. The third list displays all connected lines. The fourth and fifth lists display piping lines and equipment in the Connect To group. 3 On the list in the Connect From and Connect To groups, click the desired equipment item. 458 6 Piping and Instrumentation Models The line lists will then display only the lines corresponding to the selected equipments. When the mouse hovers over an equipment or a line, the tooltip in the list provides additional information related to this item. The related additional information is also displayed in the bottom text area when clicking on an equipment or a line. Connecting Piping Lines To connect two lines: 1 Select the Auto Generate Line Tag check box, or, in the Line Tag field, type a unique line tag. 2 In the Connect From line list, click a piping line. 3 In the Connect To line list, click the desired line. 4 Click Connect. 5 Repeat Steps 1-4 above to connect all the desired lines between the equipment items. Note: Use Filter to display all disconnected equipment or all disconnected lines. 6 Piping and Instrumentation Models 459 Disconnecting Piping Lines To disconnect all existing pipeline connections between all equipments:  Click Disconnect All. All connected lines will be removed from middle list and will be displayed in the respective line list. To disconnect a specific line between the two equipments:  In the middle list, click a line item; then click Disconnect. Renaming a Line Tag To rename a line tag: 1 On the Connecting list, click the desired item. 2 In Line Tag field, edit the line tag. 3 Click Rename Line Tag. 460 6 Piping and Instrumentation Models Saving All Connections and (optionally) Updating the Project To save all the connections and update the project:  Click the Update Project. To save all the connections without updating the project:  Click the Save Mapping & Exit. All connections on the GUI are saved, but the project is not updated. Getting the Connected Line List Report To get the connected line list report: 1 Evaluate the above project. 2 Click View | Capital Cost View. The Select Report Type to View dialog box appears. 3 On the Select Report Type to View dialog box, click Interactive Reports; then click OK The reporter is active. 4 Click Excel reports. 6 Piping and Instrumentation Models 461 5 Click Other reports | Discipline | Pipe: o Connected Line List -oro Model Line List as shown below: 6 Click Run Report. The report is shown below: Connected Line List 462 6 Piping and Instrumentation Models Model Line List Mapping Streams to Piping Lines Note: For Aspen Capital Cost Estimator with Aspen Process Economic Analyzer Overlay project, see the Aspen Process Economic Analyzer user guide (AspenProcessEconAnalyzerV7_3Usr.pdf). In an existing or new Aspen Process Economic Analyzer (or Aspen Capital Cost Estimator with Aspen Process Economic Analyzer Overlay) project, you can assign stream physical properties to lines in order to size the line diameter. Importing 3D Piping and Structure Data Using the SmartPlant 3D–Aspen Icarus Interface Overview The process of using the SmartPlant 3D–Aspen Icarus Interface is composed of two steps: 1 Exporting data from SmartPlant 3D using a reporting feature. 2 Importing data to create components in an Aspen Icarus project. 6 Piping and Instrumentation Models 463 Step 1: Exporting Data from SmartPlant 3D The goal of the first step is to create spreadsheet reports containing the data exported from SmartPlant 3D. SmartPlant 3D can generate three types of reports.  Pipe Rack data  Open Steel Structure data  Pipe Run data To generate these reports: 1 On the SmartPlant 3D Tools menu, click Run Report. The Run Report dialog box appears. 2 On the Run Report dialog box, on the Catalog Reports tab, click the report that includes the desired data. 464 6 Piping and Instrumentation Models Pipe Racks: Structure: 6 Piping and Instrumentation Models 465 Pipe Runs: 3 In the File name field, type the output file name; then click Run. Step 2: Importing the data to Aspen Icarus The goal of the second step is to import the data in the spreadsheets generated in the first step into Aspen Icarus to generate components. During the import process, the spreadsheets being imported are broken into two types.  The Pipe Run and Pipe Fitting spreadsheets  The Non-Pipe Runs spreadsheets: o Pipe Rack spreadsheets o Steel Structure spreadsheets Note: All the spreadsheets to be imported in one run must be in the same folder. To import the spreadsheets generated in the first step, you follow these three steps: 1 Selecting the Non-Pipe Run spreadsheets to import 2 Selecting the Pipe Run and Pipe Fitting spreadsheets to import. 3 Loading the spreadsheets. 466 6 Piping and Instrumentation Models Step 1: Selecting the Pipe Runs and Fitting Spreadsheets to Import. To select the Pipe Run and Pipe Fitting spreadsheets to import: 1 Open a project in Aspen Icarus with the desired basis of design configured. 2 On the Aspen Capital Cost Estimator File menu, click Import SP 3D. 6 Piping and Instrumentation Models 467 The Add SP 3D Spread Sheets dialog box appears. 3 On the Non-Pipe Runs Sheets pane, click Add Sheet. The Select Non-Pipe Run file dialog box appears. 468 6 Piping and Instrumentation Models 4 On the Select Non-Pipe Run file dialog box, click a spreadsheet exported from SP 3D other than the Pipe Run and Pipe Fitting spreadsheets. 5 Repeat Step 4 above as many times as desired, typically once for Pipe Racks and once for Steel Structures. Step 2: Selecting the Pipe Runs and Fitting Spreadsheets for Import Importing Pipe Run data requires has two steps. A Selecting the Pipe Run data B Selecting the Pipe Fitting data that goes with the Pipe Run data selected. 6 Piping and Instrumentation Models 469 Step A: Selecting the Pipe Run spreadsheet 1 On the Add SP 3D Spread Sheets dialog box, on the Pipe Sheets with Fitting sheets pane, click Add Sheets. The Pipe Runs file dialog box appears. 2 On the Pipe Runs file dialog box, click a Pipe Runs spreadsheet. 470 6 Piping and Instrumentation Models Step B: Selecting the Pipe Fitting data The Select a Fitting file dialog box appears. 3 On the Select a Fitting file dialog box, click the corresponding file. 4 Repeat the Add Sheets process as many times as necessary. 6 Piping and Instrumentation Models 471 Step 3: Loading the Data 5 After selecting all the sheets to import, on the Add SP 3D Spread Sheets dialog box, click OK. The main Aspen Icarus interface is hidden and a progress dialog is displayed. When the process is complete, the Aspen Icarus interface is redisplayed and the components imported have been created. Adding or Updating Codes to this Interface In cases where undefined codes are specified in the spreadsheets published by Smart Plant 3D for different piping, fitting, or structural attributes (for example, materials, fittings type, pipe schedule, pipe rack type, and so on), Aspen Capital 472 6 Piping and Instrumentation Models Cost Estimator will generate a loading error log file (SP3Derr.log) detailing the incompatible/unrecognized codes. The current OOTB interface contains codes received from Intergraph mapped to an appropriate equivalent in Aspen Capital Cost Estimator. At times, there may be changes or updates to these codes or the inclusion of company specific codes which will not be present in the OOTB solution. The following procedure describes the steps necessary to account for such changes in the codes so the Aspen Capital Cost Estimator loading process can proceed without error: 1 Locate the following XML file (SP3DIConfig.xml) in (V7.3 location): \Program Files\AspenTech\Economic Evaluation 7.3\Program\Sys\loader. 2 Backup this file as this file contains all valid codes for both applications in the OOTB solution. 3 Edit this xml file (in a manner consistent with the existing xml format) to add the new or changed codes in the relevant SPAttribute section: Example: For new pipe material codes add the new code(s) under CpPipeMaterial, new fittings codes under SpFittingType, new pipe rack codes under CpPipeRackType, and so on. 4 Provide an appropriate mapping to the new codes for the desired Aspen Capital Cost Estimator attribute. The mappings need to be recognized by Aspen Capital Cost Estimator; otherwise an error will occur when loading the data. The existing xml file has many of the Aspen Capital Cost Estimator mapping codes available, so this can be used as a reference. In addition, you can refer to the Aspen Capital Cost Estimator GUI if certain attributes are not present in the XML file and are desired to be used (for example, pipe materials). 5 Save the changes, ensuring the file name is maintained as SP3DIConfig.xml. The new file with added codes will be used the next time a load is performed for new projects. 6 For existing projects where the old codes (that is, the old xml file) was used, you will not see the updated codes when reloading the data unless the following is performed: a. Open the old project b. Locate the iccache directory (OOTB V7.3 location: \Documents and Settings\UserName\Local 6 Piping and Instrumentation Models 473 Settings\Application Data\AspenTech\Economic Evaluation V7.3\Projects\Project Name c. In this location, delete the SP3DIConfig.xml file. d. Reload the SP3D spreadsheets, the new codes will be used. It is recommended that an administrator perform these changes/updates and distribute the new xml file to users as needed. In addition, in order to use this updated data with future versions of Economic Evaluation, this xml file will have to be copied to the appropriate location of the new installation version. In cases where Aspen Tech makes changes to this file, previous company specific changes should be merged with Aspen Tech changes if necessary. Note: It is highly recommended the installed version of the xml file be backed up and retained prior to making any changes in the event the original file is required. Known Issues Slab Thickness An issue with the Export of slab thickness export exists – Integraph is working to resolve the issue. Piping Design Pressure In Version 2004.2, an issue with the import of piping design pressure existed. This is resolved in Icarus 2006 and subsequent versions. Because we expect the pipe schedule data to be exported, the design pressure data is not required for the evaluation. 474 6 Piping and Instrumentation Models 7 Developing and Using Cost Libraries Overview The Libraries view on the Palette arranges libraries in a tree-structure. Most of the libraries listed access project specifications (explained in Chapter 3). The Cost Libraries are unique, however, in that they comprise collections of particular cost items that you can add as project components. The cost libraries are customizable; you can add items to the libraries provided, as well as add your own libraries. Aspen Capital Cost Estimator includes two types of cost libraries:  Equipment Model Library (EML)  Unit Cost Library (UCL) Each library type may include one or more library files, which in turn may contain one or more library items, each representing a particular type of cost item. Equipment Model Library (EML) Note: If you are interested in accessing data as Unit Cost Libraries from Aspen Richardson's WinRace or another third party data source, see Accessing External Unit Cost Data in Chapter 6, Developing and Using Cost Libraries, in Aspen InPlant Cost Estimator V7.3 User Guide (AspenInPlantCostEstimatorV7_3-Usr.pdf). The EML is intended to store custom equipment items, for which you create component specification forms. In a project, you can add an item from the EML as a component and fill out the form that you earlier created. 7 Developing and Using Cost Libraries 475 The library can store a generic equipment item that comes in discrete sizes, such as an extruder, or an equipment item that follows a continuous cost-capacity relationship such as linear, semi-log or log-log. Unit Cost Library (UCL) The UCL is intended to store and retrieve direct costs and installation man-hours, which are based on a simple unit of measure (for example, the cost of a material item or installation man-hours per unit of area, per unit of length, per item, and so on). Costs can also be stored in a library for indirect items such as project management man-hours per month, crane rental (plant hire) on a daily, weekly, monthly basis, and so on For one-of-a-kind cost items not worth storing in a library, the unit cost library may be used to create a dummy item for recall and modification in a project. The dummy item is stored in the library with as little data as possible. This can be retrieved and modified in as much detail as required whenever you need a one-time cost added into a project. Developing and Using an Equipment Model Library (EML) Creating an EML The instructions in this sub-section show you how to create an EML. The instructions in the sub-sections that follow this one, which show you how to add an item to an EML and then add the item to a project, use a single example that can be added either to an Inch-Pound EML that you created or to one of the two Inch-Pound EML’s provided. To create an EML: 1 With no project open, go to the Palette’s Libraries tab view. 2 Expand Cost Libraries in the tree-structure; then expand Equipment Model Library. The Cost Libraries are divided into Inch-Pound and Metric. 3 To create a library for use in projects with an Inch-Pound units of measure basis, as in the example used in these 476 7 Developing and Using Cost Libraries instructions, right-click on Inch-Pound, then on the menu that appears, click New. The New Equipment Model Library dialog box appears. 4 Type a file name (required) for the EML and a brief description (optional); then click OK. 7 Developing and Using Cost Libraries 477 An empty Library dialog box appears. You can now add items to the new library. Adding an Item to an EML The instructions below for defining and using an EML item follow a single example from item creation through the addition of the item to a project. Using the example provided will define the item in such a way that it automatically generates a foundation and/or electrical power supply bulks. To add an item to an EML: 1 If you just added a library, the Library dialog box is displayed, and you can skip to Step 2. If not, follow these steps: 2 Go to the Palette’s Libraries tab view. 3 Expand Cost Libraries, Equipment Libraries, and either Inch-Pound or Metric. (If following the example provided, select Inch-Pound.) 4 Right-click on the library to which you want to add an item, and then click Modify on the pop-up menu. 5 Click Add on the Library dialog box. 6 Enter a Reference ID for the item in the Add Item dialog box. The one- to six-character alphanumeric Reference ID uniquely identifies the library item being added. The ID is used to sort 478 7 Developing and Using Cost Libraries and search for library items. The first character must be a letter. 7 Click OK. 8 Enter the descriptive data for the item in the Develop Equipment Model Library form. If following the example, enter the data exactly as shown below. Be sure to correctly enter the sizing parameters, CAPFLOW and PWRDRVR; Aspen Capital Cost Estimator knows to use GPM (or L/S for METRIC) and HP, respectively, for these parameters. 7 Developing and Using Cost Libraries 479 Note: Sizing method: the data is in the form of either a continuous curve (linear, log-log or semi-log) or a set of discrete tabular values. When an equipment model library item is retrieved into a project, the specified size for the project component is used to develop the appropriate cost, man-hours and weight from the library data. 9 Click OK to save your specifications. The new item appears on the Library dialog box, which you can now close. Adding an EML Item as a Project Component To add an EML item as a project component: 1 Open the project to which you want to add the EML item. For the purposes of this example, you can use either an existing or newly created US/I-P based project. 2 In Project Explorer (Project view), right-click on the area in which to add the EML item, and then click Add Project Component on the pop-up menu. 3 On the Icarus Project Component Selection dialog box, specify a project component name for the item. 4 Click Equipment Model Library; then click OK. 5 On the Select an Equipment Model Library File dialog box, click the EML to which you added the item. 480 7 Developing and Using Cost Libraries 6 Click OK. 7 At the Select an Equipment Model Library Item dialog box, select the item you added and click OK. 8 Enter your specifications for the item at the Component Specifications form, as shown below. Note that the Size parameters CAPFLOW and PWRDRVR are included on the form. 7 Developing and Using Cost Libraries 481 9 Click OK to apply and save the specifications. The item will now be included in project evaluations. Note: If you want to use sizing parameters with the EML, you must use one of the sizing parameter symbols listed below: 482 Symbol Description AREA Heat Exchanger Area AREAH Area Height AREAL Area Length AREAW Area Width CAP Liquid Volume CAPACITY Liquid Volume CAPFLOW Liquid Flowrate CAPREF Refrigeration Capacity DENS Fluid Density DENSITY Fluid Density DIA Vessel Diameter DIAMETER Vessel Diameter DIA1 Bottom Diameter DIA2 Top Diameter DTMP Design Temperature DTMP2 Alt Design Temperature DUTY Heat Transfer FLOW2 Alt Gas Flow FLOWRATE Gas Flow HEAD Fluid Head 7 Developing and Using Cost Libraries HEIGHT Vessel T-T Height HGT Vessel T-T Height HGT1 Bottom Height HGT2 Top Height JPRES Jacket Pressure LENGTH Equipment Length LTH Equipment Length MWGT Molecular Weight NITEMS Multiple Items POWER Power PRES Pressure PRES2 Alt Pressure PRESSURE Pressure PWRDRVR Power RAT Flow SPGR Specific Gravity TMP Temperature TMP2 Alt Temperature VISCOS Viscosity VOL Gas or Solid Volume VOLUME Gas or Solid Volume WIDTH Equipment Width WTH Equipment Width Developing and Using a Unit Cost Library (UCL) The instructions below use as an example a library of asbestos abatement (ASBABT) costs and man-hours. This example has been selected because environmental remediation data is difficult to model, since costs and man-hours tend to vary greatly based on site conditions and project types. Items of a unique and/or variable nature are ideal for storing in a UCL. The instructions take this example through the following stages: 1 creating a unit cost library 2 adding items to the library 3 adding a library item to a project as a component 4 forming an assembly in the project out of multiple UCL items 7 Developing and Using Cost Libraries 483 Creating a Unit Cost Library To create a unit cost library: 1 With no project open, go to the Palette’s Libraries tab view. Expand Cost Libraries in the tree-structure, and then expand Unit Cost Library. The libraries are divided into Inch-Pound and Metric. 2 To create a library for use in projects with an Inch-Pound units of measure basis, as in the ASBABT example used in these instructions, right-click on Inch-Pound and click New on the pop-up menu. 3 In the New Unit Cost Library dialog box, type a file name (required) for the UCL and a brief description (optional). 4 Click OK to create the new UCL. 484 7 Developing and Using Cost Libraries An empty Library dialog box appears. You can now add items to the new UCL. Adding an Item to a UCL To add items to a UCL: 1 If you just added a library, the Library dialog box is displayed, and you can skip to Step 2. If not, follow these steps: A Go to the Palette’s Libraries tab view. B Expand Cost Libraries, Unit Cost Libraries, and either Inch-Pound or Metric. C Right-click on the library to which you want to add an item, and then click Modify on the pop-up menu. 2 Click Add on the Library dialog box. 3 Enter a Reference ID for the item in the Add Item dialog box. The one- to six-character alphanumeric Reference ID uniquely identifies the library item being added. The ID is used to sort and search for library items. The first character must be a letter. 7 Developing and Using Cost Libraries 485 4 Click OK. 5 In the Develop Unit Cost Library form, enter information for the new item. Note: Costs for the item will be allocated to the specified Code of Account (COA). See Icarus Reference Chapter 34 for COA definitions. Aspen Capital Cost Estimator uses the Material Cost Per Unit and Labor Cost Per Unit to cost the item in an estimate. If Labor Hours Per Unit is specified and Labor Cost Per Unit is left blank, Aspen Capital Cost Estimator will calculate the labor cost using the project wage rates at the time of the estimate. The Unit of Measure can be designated for “each” or by any appropriate unit (for example, “1000 SF”). Be sure to sufficiently describe the item so that you know what the unit costs include when the item is retrieved at some future date. The quantity is entered when the library item is retrieved into a project. The Date and Source are for your reference and are not transferred into an estimate. 6 When done entering specifications for the item, click OK. 486 7 Developing and Using Cost Libraries 7 To add a set of items as in the ASBABT example, repeat the process (Steps 2-4) to add the following items in addition to the one shown in the previous graphic. Code of Refere Item Accou nce No. Description nt Mat’l Cost Per Unit Labor Cost Unit of Per Measu Unit re Date of quotat ion AAB200 Polyethylene 800 Sheeting .021 .004 SF 04APR0 1 AAB201 Duct Tape (300’ roll) 800 3.50 ROLL 04APR0 1 AAB202 Adhesive Spray (60’ / can) 800 6.00 CAN 04APR0 1 AAB300 Decontamin ation Shower 800 300.00 2 EACH 04APR0 1 AAB301 Neg Air Pressure System 800 300.00 2 EACH 04APR0 1 AAB400 Lighting Fixture Removal 800 .01 EACH 04APR0 1 After the above are added, the Library dialog box will appear as shown below. 8 When done adding items to the UCL, click close on the Library dialog box. 7 Developing and Using Cost Libraries 487 Adding a UCL Item to a Project To add a single UCL item to a project: 1 Open the project to which you want to add the UCL item. To add an item from the ASBABT library developed as an example in the previous instructions, you can open either an existing or newly created US/I-P based project. 2 In Project Explorer (Project view), right-click on the area in which to add the UCL item, and then click Add Project Component on the pop-up menu. 3 On the Icarus Project Component Selection dialog box, specify a project component name for the item. 4 Select Unit Cost Library and click OK. 5 At the Select a Unit Cost Library File dialog box, select the UCL to which you added the item and click OK. 488 7 Developing and Using Cost Libraries 6 At the Select a Unit Cost Library Item dialog box, select the item you added and click OK. 7 On the Component Specifications form, click the Option drop-down button and select Unit Cost Items. Aspen Capital Cost Estimator retrieves the unit cost data you set up in Libraries. 7 Developing and Using Cost Libraries 489 8 You can now enter the quantity data and modify any of the retrieved data. 9 Click OK to save the specifications and close the form. Creating an Assembly of UCL Items This section shows how to add several items from the library to form an assembly. In the example, the items from the ASBABT library are added to form an Asbestos Abatement Area Preparation Assembly. To create an assembly of UCL items in a project: 1 In Project Explorer (Project view), right-click on the area in which to add the UCL item, and then click Add Project Component on the pop-up menu. 2 On the Icarus Project Component Selection dialog box, enter as the project component name a description of the assembly. 490 7 Developing and Using Cost Libraries 3 Click Unit cost library; then click OK. 4 On the Select a Unit Cost Library File dialog box, click the UCL containing the first item to add to the assembly; then click OK. 5 On the Select a Unit Cost Library Item dialog box, click the first item to add to the assembly; then click OK. 7 Developing and Using Cost Libraries 491 6 On the Component Specifications form, click the Options drop-down button; then click Unit Cost Items. 7 Click Add. 8 On the Select a Unit Cost Library File dialog box, click the UCL containing the next item to add to the assembly; then click OK. 9 On the Select a Unit Cost Library Item dialog box, click the next item to add to the assembly; then click OK. 492 7 Developing and Using Cost Libraries 10Repeat the process of adding items until the form contains columns for all the items in the assembly. 11After entering quantities for the items, click OK. The assembly is listed as one project component on the Project Explorer (Project view) and the List view. You can now run an evaluation on the item (see page 607 for instructions). An Item Report would summarize total costs and man-hours, as well as list each assembly item’s costs and man-hours. X 7 Developing and Using Cost Libraries X 493 Working with Cost Libraries Equipment model and unit cost libraries share the functions described in this section. Copying a Library Item When adding a library item similar to one that already exists, it is easier to copy the existing library item and modify the necessary specifications. To copy a library item: 1 Highlight a library item in the Library dialog box; then click Copy. 2 Enter a Reference ID for the new item. The one- to six-character alphanumeric Reference ID uniquely identifies the library item being added. The ID is used to sort and search for library items. The first character must be a letter. 3 Click OK. Aspen Capital Cost Estimator adds the new item with all the same data as the original — only the Reference ID has changed. Deleting a Library Item When a library item is no longer useful, it can be removed from the library file. To delete a library item: 1 Highlight a library item in the Library dialog box and click Delete. A dialog box appears to confirm the delete. 2 Click Yes to delete the selected library item. -orClick No to retain the library item in the library file. Escalating Library Costs Library items contain costs that change over time due to inflation. Escalating library costs bring the library costs up to date. 494 7 Developing and Using Cost Libraries To escalate library costs: 1 Click Escalate on the Library dialog box. The Escalate Costs dialog box appears. 2 Enter the escalation specifications. In this field type New Base Date The date of escalation or the date at which the prices are current. Material Escalation The amount by which to escalate material costs. Labor Escalation The amount by which to escalate labor costs. Because EMLs only include setting man-hours, not labor costs, this field appears only when escalating unit cost libraries. 3 Click OK to escalate all library items in the library file. Importing a Cost Library You can import UCL files, which have the extension “.LIB”, and EML files, which have the extension “.EML”, from elsewhere on your computer or network. To import a cost library: 1 In the Palette (Libraries view), right-click the appropriate Units of Measure basis (Inch-Pound or Metric). 7 Developing and Using Cost Libraries 495 2 Click Import. The Select a File for Import dialog box appears. 3 In the Select a File for Import dialog box, click the file; then click Open. The file is now included in the Palette, and its items can be added as Aspen Capital Cost Estimator project components. Duplicating a Cost Library To duplicate a cost library: 1 In the Palette (Libraries view), right-click the library you wish to duplicate; then click Duplicate on the pop-up menu. 496 7 Developing and Using Cost Libraries 2 Enter a file name and description (optional) for the new library. Aspen Capital Cost Estimator displays the Library dialog box for the new Library, which contains the same items as the original. You can add, modify, or delete the items without affecting the original. Deleting a Cost Library To delete a cost library: 1 In the Palette (Libraries view), right-click the library to be deleted. 2 On the menu that appears, click Delete. 7 Developing and Using Cost Libraries 497 498 7 Developing and Using Cost Libraries 8 Changing Plant Capacity and Location Note: In order to have access to the features covered in this chapter, you must be licensed to use Aspen Process Economic Analyzer. You must also select at startup to use Analyzer in the Aspen Capital Cost Estimator environment. Aspen Process Economic Analyzer lets you evaluate alternate plant capacities and locations. When you change plant capacity, Analyzer re-sizes each project component to a desired plant capacity. Unique expert system rules, based on engineering principles, provide the basis for revising the size of every project component in the process facility that is implicated in stream flows, as well as the size of other plant facility components in the plant layout, including process and utility components inside battery limits (ISBL) and outside battery limits (OSBL), associated installation bulks, piping, cable runs, buildings, structures, pipe racks, and site improvements. Changing Plant Capacity Changing the production capacity affects not only every stream flow, but the size, and in some cases, the number of project components. Aspen Process Economic Analyzer’s Analyzer Scaleup Module (ASM) automatically examines each element of a project, applies a set of scale-up rules unique to that element and recreates the entire plant description according to the new production capacity. ASM contains hundreds of rules for each of the hundreds of Aspen Icarus project components. Rules are based on 8 Changing Plant Capacity and Location 499 engineering principles for elements that are directly linked to production capacity. For other elements that are footprint oriented such as building and structures, rules based on heuristics are applied. When the scaled project is evaluated, design quantities that are developed for the newly sized components are designed to meet the needs of a project. Further, revisions to P&IDs and similar user adjustments contained in the baseline project are also treated in the same way. The idea is to design a scaled project as it is intended to be built. This methodology eliminates the need for applying a factor to the baseline plant cost to scale it up or down. Given a new capacity, ASM recreates the entire plant. The ASM process is automatic and rapid. ASM revises sizes of components to meet a revised capacity and the project evaluation engines do the difficult, time-consuming evaluation work. Users find ASM performs its re-sizing operation results to be similar to engineering design methods with the added benefit of much reduced time and resources. Further, equal confidence can be applied to evaluation results before and after using ASM as rules are discipline-based and the before and after evaluation processes are identical. To change plant capacity: 1 Open your baseline project and save it under a new scenario name that reflects the new capacity. This will ensure that your baseline project remains intact, separate and apart from your about-to-be scaled project. 2 On the Run menu, click Decision Analyzer or click the “A” button on the toolbar. 500 8 Changing Plant Capacity and Location The Decision Analyzer dialog box appears. 3 Select the Change Plant Capacity by (5-600%) check box. 4 Type the desired percentage adjustment or select it using the Up/Down arrow buttons. For example, if you need to revise the capacity by a value beyond 600% to 700%, scale your project twice. For this, the Evaluate Project check box should be cleared. Then you can split the desired 700% into two parts: first use 350%, and on completion, scale it again at 350%. 5 Click OK to initiate the Analyzer Scale-up Module. 6 Upon completion, save the scaled project. Analyzer Scale-Up Module (ASM) How ASM Works Scale-up of a project to a new production capacity is a two-step process. 8 Changing Plant Capacity and Location 501 1 The Aspen Scale-up Module is invoked. The ASM processor 1 analyzes each specification in your project 2 applies the appropriate scale-up rule 3 revises the specification to a new value 4 moves on to the next specification You can follow the progress of this phase by noting the item names in the display at the bottom of your screen. 2 The project is evaluated. This phase performs the designs, develops quantities, hours, costs, and so on, and prepares the basic set of reports for your project at the new capacity. On completion of this step, you can proceed to prepare special reports and perform other analyses on your newly scaled project. Save the project after the scale-up operation. Scale-Up Rule Set Analyzer contains rules for hundreds of components and cost elements that are based on (a) engineering design principles for scale-up of all process equipment, stream flows, etc and (b) heuristics for plant items that are based on footprint and plot plan. The current rule set in some instances modifies the number of items rather than change sizes, as in the simple example of trees along a fence line, where the number of trees would be revised rather than the size of each tree. In the current rule set, there is no automatic provision for increasing the number of project components. Limiting Conditions It is possible that on extreme capacity scale-ups, sizes of certain equipment or bulk items may surpass a system limiting value. In this case, an error condition would be issued. The user would then examine the scaled model for the particular item(s) and revise the size and number of out-of-range items accordingly, as an item in an error condition would be excluded from the estimate. Warning messages are generated after project scaling (via ASM) is performed notifying users if scaling rules could not be applied to certain equipment components due to min/max limits on equipment specs being reached. In the event scaled values fall outside either min. or max. equipment spec limits, the prescaled value is retained. Once an error condition is met, you 502 8 Changing Plant Capacity and Location have the option to either stop the scaling operation or continue. If stop is clicked then further operations based on your selection in the Decision Analyzer dialog (for example, evaluation) will not be run. These error messages are similar to scan errors dialog and will provide you with a listing of components in which the ASM rules cannot be applied (see example below). Scale-up Candidates ASM rules apply to the following types of project information:  Area specs: distances, dimensions, cost per unit weight  Project Component specs: specific rules based on item type and specification, typically size dimension, capacity, power and occasionally number of items     Note: Several sanitary process equipment items associated with batch food processing will not be scaled. Installation specs: quoted costs, hours and numeric specs for piping, duct, civil, steel, electrical, insulation, paint. Textbased sizes such as pipe schedule, wire size, and so on, are symbolic and are not scaled. Project Component Quoted Cost: While ASM has rules for quoted cost, the ASM rule may not be the best for your type of item. Here, it’s better to apply a % Adjustment to the system’s estimated cost in an amount that will bring the estimated cost up to your quoted value. Then, on scaling, the new reported cost will be calculated by applying your % Adjustment to the estimated cost. Based on the scaled sizes. Quoted hours: based on item type Quoted weight: based on item type 8 Changing Plant Capacity and Location 503  Stream flow rate: scaled to the new capacity Scale-Up for Configuration Analysis Often, sections of a proposed facility may be required to consist of parallel trains, joining up to meet downstream units. Situations such as these are best handled by creating models of these sections at a standard capacity and then scaling desired sections to say 50% capacity. You would then import the various sections into an overall model, with multiple trains being imported as many times as required. The resulting model would then be evaluated for capital investment and process economics. Analyzer Relocation Module (ARM) The Analyzer Relocation Module lets you evaluate the impact of worldwide location on capital cost and a variety of other econometrics. Specifically, you can “relocate” a project from one basis to any one of 89 worldwide locations. You can choose to retain the location of your engineering workforce or choose any one of 89 worldwide locations. When you need to evaluate a project that you might engineer and/or construct in a different city or country location, ARM will quickly and automatically revise your project parameters with those contained in its location knowledge base. The ARM knowledge base includes key location-dependent data and rules to properly convert your project from its starting basis to your selected location(s) using location dependent values for design parameters, engineering and construction work forces, cost of materials, and engineering, material and construction indirects. You can use ARM in combination with the Analyzer Scale-up Module (ASM) and Analyzer Economics Module (AEM) all in the same run or separately from the other modules. Relocation Terminology   504 Baseline project: initial case, before executing ARM. Relocated project: after ARM processing of the baseline project. 8 Changing Plant Capacity and Location     Relocation: a process of evaluating an initially formulated project (baseline project) to a new location (relocated project). Locations: a general location, characterized by a city and country name, which is used to represent a particular EPC function. The function may or may not be physically sited in that city. Engineering location: city and country name used to characterize the engineering workforce assigned to the project. Plant location: city and country name used to characterize the plant site. Workflow The figure below shows the general work process. ARM specs, contained in the ARM rule set are applied to the user’s model. A description of the elements in the table is provided in the section following the Workflow. 8 Changing Plant Capacity and Location 505 How the Analyzer Plant Relocation Module (ARM) Works Baseline Reports Relocation Reports For Base Engineering and Plant Location For New Engineering and Plant Location Analyzer Baseline Project Relocation Project Module Relocated Project ARM Specs Project Specs Construction Hours Construction Rates Material Quantities Engineering Hours Engineering Rates Construction Indirects Materials Indirects Engineering Indirects Construction Contingency Materials Contingency Engineering Contingency Construction Fee Construction Cost Engineering Cost Material Cost Project Contingency 506 8 Changing Plant Capacity and Location 1 Because ARM processing is automatic, it is wise to first save your base project under a new scenario name in advance of running ARM. Use a scenario name that refers to the planned new capacity. This will ensure that your baseline project remains intact for further evaluations. 2 On the Run menu, click Decision Analyzer or click the A button on the button bar: This will display the Decision Analyzer dialog box. Note: ARM shares space with ASM and AEM and Evaluate Project on the four-part Decision Analyzer dialog box. 3 Select the Change Plant Location to check box. 4 Select the Plant Location from its pull-down list. 5 Select the Engineering Location from its pull-down list. 6 Use the remaining check boxes to select options to Enable escalation for Aspen Capital Cost Estimator projects. Retain your defined construction start date and duration. If unchecked, a new date will be developed on relocation. 8 Changing Plant Capacity and Location 507 Note that the last line on the Decision Analyzer dialog box displays three pieces of information:  plant location  currency name  currency symbol, in parentheses This information is a reminder to users of the Analyzer Economics Module (AEM) who are interested in reporting costs in currency different from the plant location currency. For this, two entry slots are provided for an exchange rate and symbol. If AEM is not invoked, values so entered will not affect the reporting aspects of relocation aspects. In Figure 2, the user elected to run AEM. This would take place immediately after ARM completed the relocation process, described as follows. Example: The illustration below is for a plant to be engineered in Rotterdam and constructed in Singapore. The currency of the plant location is displayed in the last wire-frame. 508 8 Changing Plant Capacity and Location Relocating the Project 7 Once having completed the choices, click OK to run the project. If you choose CANCEL, all choices will be ignored and control will return to the explorer view. With your OK, Decision Analyzer’s relocation module automatically converts your base location project to the selected engineering and plant location. Your project then contains the results of the relocation, which you can review and modify. To do this: 1 Click the Project Basis view and click the desired basis category. 2 Open the associated form, review the data and modify the data, as you desire. 3 When you are satisfied with the results, save the project, ensuring that it is saved under a scenario name that describes the relocation and, most important, that your baseline project is not disturbed by the save. 4 Evaluate the project and review the results. 5 When you are satisfied, a final save will save the results. ARM Knowledge Base The ARM knowledge base consists of approximately ten thousand location-specific data values plus rules that govern the way the location data will be applied to your baseline project. The ARM knowledge base is derived from a variety of qualified sources including:  Aspen Richardson international construction data: raw data from this source (also used to prepare the Aspen Richardson International Cost Factor Manual) were analyzed and mapped into Icarus technology formats for use in ARM  Proprietary sources  Practicing professionals, EPC and owner customers and associates  Surveys  Technical publications that specialize in international construction costs  Government sources: seismic, climate data and other location data  Financial sources: exchange rates, etc. 8 Changing Plant Capacity and Location 509  Aspen Icarus models: to blend and fill in sparse data areas Five Bodies of Data The ARM knowledge base consists of five bodies of data:  Location specs  Project specs  Engineering specs  Construction specs  Material Cost specs Highlights of each component follow. Location Specs ARM is formulated for 89 locations in 33 currencies. Locations listed below include the four Icarus country base locations. The locations are similar to those in the Aspen Richardson International Cost Factor Manual list. Locations are organized and sorted by continental region, country and city. For Canadian and US locations, names include state, province or territory. Conventional short forms of country and city names are used for simplicity.  Regions - The number of locations for each region is listed in Table 1.  City Locations outside the US are listed in Table 2  US locations are listed in Table 3. TABLE 1. List of Locations in Each Region 510 Region Number of locations Africa 3 Asia 15 Australia 3 Canada 6 Central America 2 Europe 12 Middle East 6 South America 5 United States 37 All Locations 89 Non-US Locations 52 8 Changing Plant Capacity and Location TABLE 2. List of Non-US Locations Region City, Country Near Africa El Hassania, Morocco Casablanca Ibadan, Nigeria Johannesburg, South Africa Asia Beijing, China Guangzhou, China Shanghai, China Bhopal, India New Delhi Mumbai (Bombay), India Jakarta, Indonesia Kobe, Japan Tokyo, Japan Kuantan, Malaysia Kuala Lumpur Manila, Philippines Singapore, Singapore Seoul, South Korea Taipei, Taiwan Australia Samutprakam, Thailand Bangkok Binh Duong, Vietnam Hanoi Melbourne, Australia Perth, Australia Sydney, Australia Central America Guatemala City, Guatemala Mexico City, Mexico Canada Calgary, Canada Montreal, Canada Toronto, Canada Vancouver, Canada Windsor, Canada Winnipeg, Canada Europe Brussels, Belgium Paris, France Frankfurt, Germany Dublin, Ireland Milan, Italy Amsterdam, Netherlands Rotterdam, Netherlands Warsaw, Poland Moscow, Russia Barcelona, Spain London, United Kingdom Manchester, United Kingdom 8 Changing Plant Capacity and Location 511 Middle East Cairo, Egypt Kuwait City, Kuwait Dammam, Saudi Arabia Al Jubail Jeddah, Saudi Arabia Gebze, Turkey Istanbul Abu Dhabi, UAE South America Buenos Aires, Argentina Rio de Janeiro, Brazil Medellin, Colombia Lima, Peru Caracas, Venezuela 512 8 Changing Plant Capacity and Location TABLE 3. List of US City Locations Anchorage, AK Atlanta, GA Baltimore, MD Boston, MA Cape Girardeau, MO Cayey, PR Charlotte, NC Chicago, IL Cincinnati, OH Dallas, TX Denver, CO Fairbanks, AK Green Bay, WI Houston, TX Huntsville, AL Indianapolis, IN Kansas City, MO Knoxville, TN Las Vegas, NV Los Angeles, CA Louisville, KY New Orleans, LA New York, NY Newark, NJ Oakland, CA Philadelphia, PA Phoenix, AZ Portland, ME Portland, OR Sacramento, CA San Francisco, CA Seattle, WA Sherman, TX Spartanburg, SC St Louis, MO Syracuse, NY Wilkes-Barre, PA 8 Changing Plant Capacity and Location 513 Project Data The ARM knowledge base contains a comprehensive set of values for project level data. These should be considered as a starting point in the evaluation of a project. Concerned users should replace the ARM knowledge base values in their relocated project with more representative values obtained from company surveys of the intended site.  Currency: Exchange rate (FEX), as of the first day of the basis year, with exchange rate and currency units scaled to meet Icarus currency formats. Scaled currency units are provided at three levels: 3-character symbol, 8-character name and 24-character description. Values are listed in Table 4. Currency: 33 currencies are defined; some ARM locations share the same currency Exchange rate, for each location. The ARM knowledge base works with exchange rates relative to the currency of each of the four country bases (US, UK, JP, EU). The currency table contains the rates as of the listed date. Exchange rates are scaled in size to conform with Icarus exchange rate formats (0.01 to 99.9 in value) Scaled currency symbols, names and descriptions are defined to conform to Icarus format; these contain symbols such as K to represent thousands and M to represent millions of scaled currency units, as indicated in Table 4. TABLE 4. List of Currencies 514 Currency Symbol Exchange Rate, per USD (1 Jan 2010) Country Currency Description Currency Name Argentina Argentine Peso Peso-A P 3.8434 Australia Australian Dollar Dollar-A A$ 1.1144 Brazil Brazilian Real Real R 1.7578 Canada Canadian Dollar Dollar-C C$ 1.051 China Chinese Yuan Renminbi Renmimnbi R Colombia K Colombian Peso K Peso K-P 2.05533 Egypt Egyptian Pound Pound-E PDE 5.5581 European Union Euro Euro EUR 0.6961 Guatemala Guatemalan Quetzal Quetzal Q 8.4921 India Indian rupee Rupee R 46.899 Indonesia K Indonesian Rupiah K Rupiah K-R 9.42507 6.8291 8 Changing Plant Capacity and Location Japan K Japanese Yen K Yen K-Y 0.092586 Kuwait Kuwaiti Dinar Dinar DK 0.2871 Malaysia Malaysian Ringgit Ringgit R 3.4567 Mexico Mexican Peso Peso-MX P 13.0899 Morocco Moroccan Dirham Dirham-M D 8.1004 Nigeria K Nigerian Naira K Naira K-N 0.15154 Peru Peruvian Nuevo Sol Nuevo Sol NS 2.9128 Phillipines Phillipine Peso Peso-P P 46.766 Poland Polish Zloty Zloty Z 2.864 Russia Russian Rouble Rouble RBL 30.3477 Saudi Arabia Saudi Riyal Riyal R 3.7527 Singapore Singapore Dollar Dollar-S S$ 1.4036 South Africa South African Rand Rand ZAR 7.4034 South Korea K South-Korean Won K Won K-W 1.1773 Taiwan Taiwan Dollar Dollar-T T$ 32 Thailand Thai Baht Baht B 33.4768 Turkey Turkish New Lira New Lira NL 1.4991 United Arab Emirates Utd. Arab Emir. Dirham Dirham-U DK United Kingdom British Pound Pound-UK PDS 0.6202 United States US Dollar Dollar US USD 1 Venezuela K Venezuelan Bolivar K Bolivar K-B 2.1505 Vietnam K Vietnamese Dong K Dong K-D 18.6169 3.6731 Current European Union Locations:  Belgium  France  Germany  Ireland  Italy  Netherlands  Spain 8 Changing Plant Capacity and Location 515 Note: Certain combinations of location currencies and country base currencies may result in exchange rates that exceed the format bounds for exchange rate. In such cases, ARM will automatically scale the exchange rate ratio and revise the currency units, usually with a prefix of "K" to indicate thousands of the above-listed currency unit. Example: The exchange rate for Plant location: India, at 46.899 per USD and Country Base: Japan at 0.092586 is 495.74 R/K Yen, which is beyond the exchange rate bound: the resulting ratio will be scaled by 1000 to 0.496 KRupee/K Yen, and costs will be reported in KRupee (KR)  Equipment: design code (ASME, BS5500, DIN, JIS, or EN 13445 depending upon the plant location)  Civil and Steel: seismic acceleration, soil, footing depth, low/high ambient temperatures, wind velocity, hand excavation  Electrical: power supply frequency  Equipment Rental: a Construction Technology Level (CTL) parameter (L, M, and H) is assigned to each location. Locations assigned as H-level draw from the entire system slate of equipment rental items. S-level locations select from a smaller slate than M-level locations.  Use of gin poles vs. heavy cranes: each location is assigned a value for the heavy lift option Engineering Work Force The ARM knowledge base contains a comprehensive set of engineering workforce values, which should be considered as a starting point in the evaluation of a project. Concerned users should replace the ARM knowledge base values in their relocated project with more representative values obtained from company surveys of the intended site. The following are provided by ARM for each engineering work force location:  516 Hourly rates for each of 77 disciplines in the engineering workforce slate. Hourly rates are provided in the currency of the engineering location. During the processing of a project, these rates are converted, for consistent cost reporting, to the currency of the plant location using the exchange rate ratio: 8 Changing Plant Capacity and Location Discipline Rate in Plant Location Currency = Discipline Rate in the Engineering Location Currency x Plant Location Exchange Rate / Engineering Location Exchange Rate  Engineering workforce productivity – one value is provided for each engineering location, relative to the engineering productivity at the country base location  Engineering Indirect Costs – values are provided for each location for each of the eight phases of engineering: Expense rates Payroll burdens Office indirects The eight phases of engineering are: o Basic Engineering o Detail Engineering o Procurement o Engineering Management o Home Office Construction Services o Field Office Supervision o Construction Management o Start-up, Commissioning  Engineering confidence level, associated with the sources of the ARM knowledge base data, used to compute a value of engineering contingency. Engineering contingency is computed as the root-mean square value of the user engineering contingency and engineering confidence level. For example, if the user contingency before relocation UC =18% and the ARM location confidence value LC = 10%, then the computed contingency after relocation is =  (UC2 + LC2) =  (182+102 ) = 20.6% Construction The ARM knowledge base contains a comprehensive set of construction workforce values, which should be considered as a starting point in the evaluation of a project. Concerned users should replace the ARM knowledge base values in their relocated project with more representative values obtained from company surveys of the intended site. The following are provided by ARM for each construction work force location: 8 Changing Plant Capacity and Location 517        Field Craft rates – hourly rates (“nearly all-in”) for each of 28 field crafts in the construction work force slate and a foreman differential for each location. By “nearly all-in”, we mean that each craft rate is a unique composite of the following rate contributions: o Craft Worker Base Hourly Wage Rate o Health, Welfare, Pension o Fringe Benefits o Hourly Indirect Rate for:  Temporary Construction  Consumables and Small Tools  FICA Unemployment Workers Compensation Insurance  Multi-level construction Craft rates in the ARM knowledge base do not include indirect construction costs for the following categories as these would be determined during project evaluation: o Construction Equipment Rental, including Fuel, Oil, Lubrication, Maintenance (FOLM) o Field Supervision o Contractor Home Office Costs Construction workforce productivity – one value is provided for each plant location, relative to the construction productivity at the country base location Field indirect costs, including construction equipment rental (see Project Data, below), field supervision, home office costs Work week: hours, number of shifts, overtime Construction equipment rental: slate of items (see Project Data, below) Extent of hand excavation vs. machine excavation Construction confidence level, associated with the sources of the ARM knowledge base data, used to compute a value of construction contingency. Contingency is computed as the root-mean square value of the user construction contingency and construction confidence level. For example, if the user contingency before relocation UC =18% and the ARM location confidence value LC = 10%, then the computed contingency after relocation is: =  (UC2 + LC2) =  (182+102 ) 518 = 20.6% 8 Changing Plant Capacity and Location Material Costs  Location Indexing The ARM knowledge base contains a set of location indexes which will adjust country base material costs to the plant location. Two sets are provided. The first deals with equipment costs. The second applies to bulk materials. Use of the supplied location indexes should be considered as a starting point in the evaluation of a project. Concerned users should replace the ARM knowledge base values in their relocated project with more representative values obtained from company surveys of the intended site.   The location indexes make use of Aspen Richardson values for the average split of local vs. imported materials. Costs of local and imported materials are figured by applying location values for freight, taxes, VAT, and other expenses. Location indexes are stored for each of the four country bases and are used to characterize material costs by account code (100 to 299 for equipment, 300 to 999 for bulk materials.) Unit cost of rebar, ready-mix concrete, in the currency of the plant location Material cost confidence level, associated with the sources of the ARM knowledge base data, used to compute a value of material cost contingency. Contingency is computed as the root-mean square value of the user material contingency and material cost confidence level. For example, if the user contingency before relocation UC =18% and the ARM location confidence value LC = 10%, then the computed contingency after relocation is: =  (UC2 + LC2) =  (182+102 ) 8 Changing Plant Capacity and Location = 20.6% 519 520 8 Changing Plant Capacity and Location 9 Aspen Utility Modules Introduction Important: In Aspen Capital Cost Estimator, only the AUM_Air Utility Module is available. However, if you load Aspen Process Evaluator (Aspen Process Economic Analyzer) when you load Aspen Capital Cost Estimator, the AUM_CW Cooling Water Utility Module is also available. Both Utility Modules are available in Aspen Process Economic Analyzer. For convenience, the documentation for both is presented in this chapter. 9 Aspen Utility Modules 521 Analyzer Utility Modules (AUM) – Design and Scope Generators for Utility Systems One of the difficulties with process economic analyses, both capital cost and payback determination, is the lack of scope definition for non-process or outside boundary limit (OSBL) portions of the project. With AUM modules creating utility systems in harmony with the process sections of a project, more accurate, realistic and confident business assessments can be made for cost and economics. Each AUM module works in the same way. It extracts information on the specific utility needs of each project component and area in your project. You can then interactively revise default values for design preferences and configuration, evaluate messages, review reports of design results. On completion, a press of a Load button will automatically transfer to your project, a list of selected, sized, designed project components assembled within a unique date- and time-stamped utility area. Should a prior utility area of the same type be present in your project, you can chose to delete the old one and replace it with new scope. All of this takes place in times measured in minutes rather than traditional days and weeks. Of course, evaluation time depends on the size of the project. For front end engineering design work, AUM modules can be revisited in each cycle of scope change to ensure the project needs are properly satisfied by each utility system. A Control Panel, a task bar button and numerous hypertext links provide for easy navigation and rapid access to a status report, specs for preferences and configurations, reports, an a guide. Messages are provided to assure data integrity; an error condition will disallow loading of results into your project. AUM_CW: Cooling Water Utility Selection, Sizing, and Design Module The cooling water utility module requires Aspen Process Economic Analyzer or Aspen Process Economic Analyzer plus Aspen Capital Cost Estimator to identify cooling water resource streams and their flow conditions. Up to four cooling water systems can be configured for a project, each with its own set of 522 9 Aspen Utility Modules sized components: cooling towers, circulation pumps, chemical injection pumps, supply and return distribution piping, valves, and fittings. You can interactively define design conditions such as ambient air temperatures, size limits to distribution piping, equipment types, and assign individual areas to each cooling water system. Redundancy capabilities include stand-alone pumps, two 50% capacity pumps, stand-by spares. Distribution piping includes expansion loops for long runs and circuits include main lines, branch lines, area headers, and risers and laterals for 3D-type areas. Each line type has its own “iso” for valve and fitting type. Line sizes and pump heads are pressure drop based. AUM_Air: Instrument and Plant Air Utility Selection, Sizing, and Design Module The air utility module can be accessed by either Aspen Process Economic Analyzer or Aspen Capital Cost Estimator. AUM_ Air gathers air requirements from your project in two ways:  Instrument air: From a count of air operated control valves and controllers and instrument air flow required for each based on control valve size  Plant air: From an air usage model based on a common air tool usage set, with area utility stations derived from area size and equipment count within an area Up to four air plant units (APU) can be configured for a project, each with its own set of sized components:  air intake filters/screens  ductwork  compressors  interstage coolers  air receivers  pre-filters  air dryers  after-filters  piping distribution network You can interactively define design premises such as ambient air conditions, equipment types, equipment redundancy, etc. and assign individual areas to be served by each air plant unit. Redundancy capabilities include stand-alone compressors, start- 9 Aspen Utility Modules 523 up compressors, receivers, dryers. Redundancy choices include one at 100% capacity, two at 50% capacity, stand-by spares. Distribution piping includes two sets, each sized for the required flow of instrument air and plant air. Piping isos for line segments include expansion loops for long runs, valves and fittings, Line segments are defined for main feeders, main manifolds, main lines branch lines, area feeders, area headers and for 3D–type areas, risers and laterals. Each line type has its own “iso” for valve and fitting type. Line sizes are pressure drop based. Analyzer Utility Module (AUM) Cooling Water (AUM_Water) Introduction to Analyzer Utility Module (AUM) Cooling Water Cooling Water Selection, Sizing, Design Model This section is divided into four parts: 1 Overview  Analyzer Utility Module (AUM)  Cooling Water Design Model o Value in Time and Effort o The Key Steps 2 Working with the Cooling Water Model  Preparation Workflow  The Workflow Cycle  Accessing The Cooling Water Model o Interactive Session Workflow – the Design Phase o Overview o Details of the Work Process o The Initial Design  Interactive Session Workflow – The Design Phase o Overview o Details of the Work Process o The Initial Design 3 Working with the Cooling Water Model Worksheets 524 9 Aspen Utility Modules    Introduction o Worksheets o Button actions Cooling Water Design Model Worksheets Worksheet Details o Status Worksheet o Preferences Worksheet  How to Revise Default Values  Design Preference Categories o Circuits Worksheet  Initial Configuration  Step 1: Assignment of Areas to Circuits  How Area Assignments are Used for Circuit Design  Step 2: Assignment of Spacing Between Areas  Status messages and Values Used for Circuit Design 4 Basis for the Cooling Water Design Model o General Flow sheet for cooling water service o Cooling Water Model Circuitry o Cooling water distribution network o Naming conventions  Project cooling water area  Areas Requiring Cooling Water  Plant bulk pipe item descriptions  Distribution Piping Line types o Sequencing of Areas on the Main Line o Cooling Water ”Footprint Model” o Pipe, Valves and Fittings Count o Line Sizing and Pressure Drop Calculations  Projects with a prior cooling water utility model area  Cooling towers- terminology and the defining stream temperatures 9 Aspen Utility Modules 525 1. Overview Analyzer Utility Module (AUM) Water One of the difficulties with economic analysis, both capital cost and payback determination, is the lack of scope definition for non-process utility or outside boundary limit portions of the project. The Analyzer Utility Module, AUM, was created as the “home” for a series of automated utility design models to address this difficulty. The Cooling Water Selection, Design and Sizing Model is the first utility design model in AUM and its functionality and method of use is described in detail in this chapter. Cooling Water Design Model The Cooling Water Design Model is an automated, interactive and rapid design module that is contained in Aspen Decision Analyzer and works with stream-based projects. The cooling water model identifies heat exchanger equipment or any other type of project component that requires cooling water by its connection to a cooling water utility resource stream. To access the Cooling Water Design Model: 1 Starting with an open project that contains utility streams as part of its definition, click Run, then click Utility Model. Or, simply click the U button to access utility models. 2 Click Cooling Water. At this point built-in design and processing procedures do all the hard work under your control and guidance and a few minutes later, your project will be augmented with a new cooling water utility area that contains designed cooling water circuitry and associated project components. You can use the model results using its set of adjustable design parameters or revise any and default values within prescribed limits to suit your needs. In the discussions to follow, the term early design metrics is used to indicate values prepared by the cooling water model during an interactive design session. These are presented for guidance in advance of final design values that would be prepared on completing a project evaluation run. Note: Worksheet names are shown in italic bold face to distinguish the names from text. 526 9 Aspen Utility Modules Value in Time and Effort The cooling water design model does all the hard work – design, selection, reporting, loading the design results – in minutes rather than traditional hours and days. It is a powerful resource in the development of a typical Front End Engineering Design:  Early process technology evaluation stage - focus is on Inside Battery Limits (ISBL) components  With the process technology selected and additional scope, total project costs are sought. Outside Battery Limits (OSBL) components are required, particularly cooling water utility service. The cooling water design model  Automatically selects, designs, and adds sized utility system components to the project scope definition  Can be revisited in each cycle of scope change. The Key Steps On initiating the cooling water model, the model automatically analyzes your project for cooling water requirements and automatically generates selected, sized and designed cooling water utility service project components – all based on initial default design preferences and circuitry. Two interactive workbooks Preferences and Circuitry enable you to revise default values for the design and selection basis. Studying design alternatives starts with either a click of an option box or a data entry. Being interactive, the cooling water model enables you to cycle from design basis to early design results in a matter of mouse clicks. Each new specification results in a new design and a report of key decision metrics. The list of sized project components is retained until you choose to load the results into your project. Messages and metrics reports are provided extensively to guide you quickly and knowingly through a study of design alternatives. When you have settled on a design you can load the results into your project. The loading operation begins with a click of a Load button and processing is automatic. After a minute or so, the loading process will be complete and the Project Basis view will be displayed on your screen. Scope items added to your project include a uniquely named cooling water area followed by a list of cooling water utility project components: cooling towers, circulation pumps, chemical injection pumps, working and stand- 9 Aspen Utility Modules 527 by spares, and distribution piping, valves and fittings. Each component is selected, designed and sized in harmony with your design basis and the needs of heat exchange equipment in your various project areas. 2. Working with the Cooling Water Model Preparation Workflow The Cooling Water Design model requires a stream-based project built in either Aspen Process Economic Analyzer or Aspen Decision Analyzer, with components that require cooling water connected to one or more cooling water utility resources. The flow rates, water temperatures, duties and components provide the basis for the design requirements. The cooling water model will first diagnose the project’s requirements and initiate a design. The user can then revise the design basis and review early design metrics for a variety of design scenarios, settle on a design basis and load the design results into the project. The Workflow Cycle Figure 2.1 illustrates the cooling water design cycle: from project to design model and back to the project with added new scope. Two buttons control the process:  U to select the cooling water model  Load to load designed results Using these two actions, you can participate interactively in the design process, making design selections, reviewing early metrics, revising selections, and clearing any error messages. 528 9 Aspen Utility Modules Figure 2.1. The Workflow Cycle, extracted from the Welcome worksheet To initiate a cooling water design model session, three steps are required 1 Save the project under a new scenario name. 2 Evaluate the project 3 Run the Cooling water utility model Each of these steps is detailed and illustrated in the following sections. Accessing the Cooling Water Utility Model 1 SAVE AS: Since AUM-Cooling Water processing is automatic, it is wise to first save your base project under a new name. This will ensure that your base project remains intact for further evaluations. 9 Aspen Utility Modules 529 2 Evaluate the project: Click Run |Decision Analyzer as in Figure 2.2a or click the A button as in Figure 2.2b. This will provide the Decision Analyzer dialog box, Figure 2.2c. Check Evaluate Project and provide a file name. Figure 2.2a. To evaluate from Run: Figure 2.2b. To evaluate using the A-button. Figure 2.2c. Choose Evaluate Project. The reason for this step is to ensure that the project scope and cooling water requirements developed during evaluation are current and up to date. It will also eliminate an error message (Figure 2.2d) that would be displayed when accessing the cooling water model no evaluation data were available. 530 9 Aspen Utility Modules . Figure 2.2d. Error message if the project was not evaluated 3 Select the Cooling Water Model: To do this, click Run | Utility Model (Figure 2,2a) or press the “U” button on the button bar (Figure 2.3a): Figure 2.3a. To obtain utility models using the U-button. This will bring up the Utility Model dialog box, Figure 2.3b. A blank value under Status indicates the project does not contain a prior cooling water model area. If a project contained a prior area, the Status field would indicate Loaded. Figure 2.3b. Utility model selection 3b Select Cooling Water: Click OK. This will either initiate an interactive Cooling Water Design session in MS Excel and display a Load option or display a project-not-evaluated error message (see Step 2 above). Interactive Session Workflow – the Design Phase Overview When the cooling water model is invoked, it: 9 Aspen Utility Modules 531 (a) analyzes for project cooling water requirements (b) works from Preferences (user-modifiable, default set of design parameter values) (c) prepares an initial design. Results of the initial design and any subsequent interactive scenario are presented in a Capture worksheet. If the design meets with the user’s approval, a user click of the parked Load button will load the design results into the project, at which time the project can be re-evaluated. The Preferences and Circuits worksheets allow the user to modify the default design basis. Each spec change will result in a new design. Hyperlinks provide rapid access from one sheet to another and sections in a sheet. The Control Center toolbar button opens the Control Center worksheet, which has hyperlinks to other sheets and their major categories. Worksheet tabs are color coded to match hyperlinks at the top of each worksheet. The following sections provide a detailed description of the work process as well as detailed descriptions of each worksheet, category and item. Details of the Work Process With the click of the OK button in step 3b above, three actions will occur 1 The model first identifies if a prior cooling water model area is present in the project. If present, the user can choose to Delete the prior area and continue with the model or return to the project. If Delete is chosen, the utility model will proceed with the design and delay deletion until it is time to load the new results. 2 If no prior cooling water utility area is detected, the Welcome screen is displayed and remains present during a time when: a Project requirements are automatically passed to the model b The model prepares an initial design c A Load | Cancel | Minimize option is provided (Figure 2.4). To continue, click the minimize button at the top. This will park the button box for access during the design 532 9 Aspen Utility Modules phase. Cancel will end the cooling water model session and return normal project functions with no change to the project. Figure 2.4. Load-Cancel-Minimize button boxes  a Control Center button bar (figure 2.5) is provided to access the Control Center worksheet from any worksheet  Seven worksheets are presented in a MS Excel framework: o Welcome o Control Center o Status o Preferences o Capture o Guide 3 The model then displays the Control Center worksheet, which links to all other worksheets and provides an indication of success (green signal) or failure (red signal) to create an initial design based on default design parameters. The Initial Design On initiation, the cooling water model will report the Status of the design on the Control Center (see Figure 2.5) worksheet under Status Report, and if any, will identify clashes on the Status worksheet and further, on the Preferences and Circuits worksheet. A Status Report message: “Successful. A Load can proceed” indicates all is well between project requirements, design parameters and design methodology. At this point, it is wise to review early design metrics by accessing the Captured Results worksheet (see Figure 2.6). The user can return to Preferences and Circuits to study design alternatives. If captured results are acceptable, a click of the parked Load button will (1) carry the design results into the project, (2) close the worksheets and (3) return to the project for evaluation of the augmented project. 9 Aspen Utility Modules 533 Should the design basis produce a clash with project requirements, error messages and flags will be displayed in a top-down succession of worksheets. The first indication is given under Status Report on the Control Center Worksheet. The Status worksheet is the central reporting agency, where checks are made and links are provided to source locations in the Preferences and Circuits input worksheets. Figure 2.5. Illustration of the Control Center Worksheet, with display of Control Center toolbar and Load button 534 9 Aspen Utility Modules Figure 2.6. A section of a Results Capture sheet showing values in the project units of measure set. 3. Working with the Cooling Water Model Worksheets Introduction Worksheets: Seven worksheets are provided, of which Preferences and Circuits are for user input, to revise the design basis:  Welcome: greetings, workflow graphic  ControlCenter: navigation  Status: message center  Preferences: design selections  Circuits: circuit definition  Capture: early design metrics  Guide: help Button Actions: The Control Center toolbar is always available during a model session. A click will open the Control Center worksheet and a hyperlink click will direct you to a chosen 9 Aspen Utility Modules 535 worksheet. When the Control Center toolbar is parked together with the Excel Web toolbar you can quickly search forward and backward. You can step from one sheet to another, revise the design basis, review status and results, decide on an alternate design basis, make revisions, review the results and when ready, click the Load button (see Load-Cancel-Minimize) to inject the results in the project. Or, you can refuse the design using Cancel. Clicking Load conveys the design results to the project, the cooling water design model’s Excel sheets and return to normal Analyzer functions. Cancel bypasses the cooling water model and returns to Analyzer. Cooling Water Design Model Worksheets The SPECS cooling Model workbook consists of  Two design basis sheets – this is where you input your selections o Preferences: process and mechanical design specs:  Red error flags and messages are displayed for out of range or missing data values  Uses click boxes for either/or choices, “B” and “R” switches to select base (default) or revised value and user value to replace the base value o Circuits: assignment of areas to a circuit, spacing of areas in a circuit along the main line:  Assignment uses 1, 2, 3, 4 to assign an area to a circuit  Spacing uses the “B” and “R” switch method and user spacing to replace the base footprint model value  Status sheet – all messages are summarized here for your review and repair o Key status message is highlighted in color (green: Loading can be performed, red: Errors must be cleared) o Summarizes other messages, links directly to input locations for revision  Capture Results: displays early design metrics for decision making, provides the basis for alternative choices of preferences or circuitry. By “early design metrics” is H H 536 9 Aspen Utility Modules     meant values in advance of those created during project evaluation Guide: provides instructions, describes data entry, color coding Control Center: hypertext links interconnect all sheets and main categories for rapid navigation All sheets: are conveniently color coded, with red flags appearing on error condition. All error conditions must be cleared before results can be loaded Welcome sheet: Welcome, displayed during the initiation process, contains a workflow graphic On completion of an error-free interactive session, pressing the LOAD button will automatically load and inject the results into the project. The project will then contain new scope additions: (1) a uniquely named, time-stamped cooling water area will be used to contain (2) a selected, designed list of cooling water utility project components. Each item so added by the model may be opened, reviewed, revised in the same way as any other project component. Worksheet Details Status Worksheet The Status sheet reports messages and has hypertext links to source locations in the event of a reported error. Major report categories are:  Overall status  Existing cooling water area is in the project  Cooling circuit components – wet bulb temperature, minimum approach temperature, lowest desired cooling water temperature  Cooling water resources: naming, excluded streams and reasons, net number  Project components: total, number served by cooling water  Project areas: total number, those served by cooling water  Cooling water loads: total flow rate, total heat duty, excess capacity, total flow rate at excess capacity  Layout distances: number of parameters out of range  Pumps specs out of range  Piping specs out of range 9 Aspen Utility Modules 537   Circuit assignments out of range Spacing assignments out of range Figure 3.1 illustrates an extract of a Status sheet Figure 3.1 Extract, sample of a Status Sheet Preferences Worksheet Units of measure used in the Preferences worksheet correspond to those defined in the project. Error messages are displayed alongside each entry; errors are flagged in red. This sheet uses click boxes and data entry fields for specifying design preferences. Each preference is provided with a explanatory text, limit values, user entry field and a default value which is used in the initial design and any subsequent design should the user not provide an over-ride selection or value. How to Revise Default Values This worksheet uses two methods, check boxes and data entries controlled by switch boxes to revise the supplied set of default (base) design parameters. Throughout data entry discussions, the term used for a model-supplied set of data is referred to as default values. For a particular parameter, the model-supplied value is termed a base value, symbolized by the letter B. A value supplied by the user is termed a revised value and is symbolized by the letter R. A mouse click will switch between using a base value and a revised value. 538 9 Aspen Utility Modules See Figure 2.2c (page 530) for information on how to use a check box:  A default value is provided to the left of the check box  A check box title signifies the alternative to the default value  The resulting choice is displayed to the right  A status message is displayed that provides additional information X X Figure 3.2 Extract, sample of a Preferences sheet showing click box method of selection Design Preference Categories:  Cooling Tower (values in this section affect the circuitry, sizing of cooling towers and flow-related equipment such as circulation pumps and distribution piping) o Design Capacity, excess capacity o Design Temperature: Summer wet bulb temperature (see Cooling Tower discussion of wet bulb temperature, approach gradient, range) o Messages relating to cooling water resource requirements vs. design preferences o Number of Cooling Towers o Multiple Cooling Towers: choose either one tower for all circuits or one for each circuit o Working “Twin”: choose a single tower at 100% capacity or two “(twins), each at 50% capacity H 9 Aspen Utility Modules H 539   540 Layout (these are dimension limit checks that are applied to entries on the Circuits worksheet o Distance  From tower to first branch to an area  Minimum value to first branch to an area (often defined by fire regulations)  From a branch to an area header  Maximum spacing between areas (a limit check)  Status messages related to distance Pumps o Area Pressure Drop: pressure drop for equipment requiring cooling water, applies to all areas o Working Pumps  Limiting value for number of working pumps in a circuit  Pump type: horizontal (CENTRIF or API 610 model types) or vertical (TURBINE model type, at low speed only)  Pump speed: low or high RPM  Stand-by pumps if four or less pumps in a circuit: yes or no  Stand-by pumps if more than four pumps in a circuit: yes or no  Electrical power to pumps based on voltage choice: LV (low-voltage), MV (mid-voltage), HV (high-voltage). Limiting values of power per pump motor are displayed based on project specifications. A voltage choice defines the maximum power to a motor driver and hence, the number of pumps in a circuit. Recall that each change to a specification results in a completely new design; a voltage selection results in a design value for the number of pumps and can produce an error condition and message if the number of pumps exceeds the limiting value for number of pumps in a circuit.  Design messages for pumps and piping for each of four possible circuits 9 Aspen Utility Modules  Piping: Limiting values for line size, by line type, where line sizes are in the units of measure of the project, either “IN DIAM” or “MM DIAM”  Suction line size for circulation pumps (a flow rate per pump suction line based on selected line size is provided for information purposes)  Main line segment line size  Branch line size  Area header line size  Risers line size (for 3D area types)  Laterals line size (for 3D area types) Circuits Worksheet Units of measure used in the Circuits worksheet correspond to those defined in the project This worksheet is designed to handle up to one hundred cooling water areas. Areas are listed vertically. The worksheet is divided into five major categories in columns of data: 1 Initial Configuration See Figure 3.3 for the initial configuration Figure 3.3 Extract from Circuits sheet – Initial Configuration (left), Step 1 (right) The following (see Figure 3.3, left side) are reported for each area being served by a recognized cooling water utility resource stream: 9 Aspen Utility Modules 541  Initial Sort Sequence: sequenced by area, from the area with highest cooling water requirements to the area with the lowest  Area Name: user-assigned name, carried into the cooling water design model from project area specs  Area Type: user-assigned area type, carried into the cooling water design model from project area specs  Area CW Rate: area cooling water (CW) flow rate, the sum of all recognized cooling water flow rates for equipment in an area as adjusted by the Excess Capacity value in the Preferences worksheet  Initial Circuit Number: always 1 as all areas are initially assigned to a single circuit  Initial Circuit ID: always “A” 2 Step 1 – Assignment of Areas to Circuits (User entry one of two) Please refer to Figure 3.3 (right side):  Enter a Circuit Number 1, 2, 3, or 4: user value is required; if only one area requires cooling water, enter 1. If two areas, use 1 for both or assign 1 to one area and 2 to the other. The design model will sequence the areas. In an error condition, an error message and a red flag will be displayed. Error conditions must be resolved to obtain loadable design results.  System-Assigned Circuit Id: The model will assign a letter ID (A, B, C, D) to each area based on circuit assignments and total circuit flow rate. If the project contains four or more areas, then it is possible to assign areas to circuit numbers 1 to 4. The model will collect all the area flow rates in each circuit and sequence the circuits from greatest flow to least in the sequence A, B, C, D. The “A” circuit will have a larger total flow rate than circuit “B”, “B” will be greater than circuit “C” and “D” will have the least flow rate. Similarly, for three areas in a project, valid circuit numbers range from 1 to 3 and circuit IDs assign to these circuits, based on total flows will be sequenced and labeled A, B and C. A one-area project will be assigned a circuit ID of “A.”  Status o Status of all entries: summarizes number or errors to be resolved; if none, “OK” is displayed 542 9 Aspen Utility Modules o Status for individual entries: message is issued for invalid circuit numbers and field is flagged in red 3 How Area Assignments are Used for Circuit Design Please refer to Figure 3.4 Figure 3.4 Extract of Circuits sheet – defining area spacing using the B/R switch Each line item in this section represents an area and its properties. Areas are sorted and sequenced in descending total circuit flow rate and then by area flow rate. Circuits are labeled A, B, C, D with circuit A being the one with the highest flow rate; B is next etc. An area that was tagged as circuit 2 in step 1 may be in a circuit with the lowest flow and would be organized accordingly and given a Circuit ID letter depending on the other circuit flows. This section displays the properties and attributes of each area in the sequenced list. Values displayed for information purposes are:  New Sort Sequence: displays values vertically in the sequence 1, 2, 3, etc  Initial Sort Sequence: displays the initial sort sequence number for the area  ID of Area In Report Group (ArRg): the ArRg ID for the area  Area name: user-assigned project area description  Area CW Rate: displays the cooling water rate, as adjusted by the Preferences value for excess capacity  Area Heat Duty: heat duty requirements for all equipment within the area identified as requiring a valid cooling water resource H H H H H 9 Aspen Utility Modules H 543    User circuit number: value entered in Step 1, for reference purposes Circuit ID: letter A, B, C, D assigned by the cooling water model based on sequencing circuit flow rates Position Of Area In Circuit: Only one area can be first in line in a circuit. “First” if the area has the highest flow rate of all areas in the circuit, otherwise no a blank display. The area with a “First” position will take on a default distance from the cooling tower as defined by the Preferences value for that distance. H H 4 Step 2: Assignment of Spacing Between areas Each line item in this section corresponds to item 4 above. A line item represents an area and its properties, with areas being sorted and sequenced in descending circuit and area flow rate. This section enables the user to revise base values for the spacing of areas along the main line. It uses the “Switch” method to revise a base value as described in the section on Preferences.  Base Value for Spacing Along Circuit Main Line: This is the run length of the main segment between the prior and current area as developed by the footprint model.  Enter Switch: B for Base, R to revise. Choose a blank entry or enter either a B (or b) to indicate use of the base value. Use R (or r) to indicate use of a revised value o Switch value is blank: design will use the base value o Switch value is B or b: design will use the base value o Switch value is R or r: indicates a forthcoming user value will revise the default spacing value. The design will use the revised value if the user value is within range of prescribed limits.  Enter Revised Spacing Along The Circuit Main Line: This value will replace the base value if it meets range limit conditions set forth in the Preferences worksheet. By spacing is meant the distance between successive areas. As the line items in this section represent areas that are sorted and sequenced, the spacing for a particular line item is the spacing between the start of the prior area and the start of the current area. This spacing is a measure of the area’s main line segment. See the section on the Cooling Water Footprint Model. Piping runs lengths are H H 544 H H 9 Aspen Utility Modules typically longer than spacing as they include pipe to configure fittings, expansion loops, etc. Enter a value. The resulting action depends on the corresponding switch value o Switch value is blank, B or b: user value is ignored, base value will be used o Switch value is R or r: user value is tested against range limits and design criteria. If error free, the user value will be displayed as the Applied Value. Error conditions will display instructional status messages, red flag, and prevent completion of a valid design 5. Status messages and values used for design o Flag: A red flag is displayed to indicate a line item error condition o Status: B (Base) uses base value, R (Revise) uses revised value or status message (displays limiting values, error messages) o Value used for spacing along circuit main line: The value used in the design 4. Basis for the Cooling Water Design Model This section describes the basis of the cooling water design model. It is presented with numerous graphics to enable a clear understanding of the work being performed by the model when it is analyzing and designing cooling water project components that are in harmony with your design preferences and the needs of components requiring cooling water. General Flow Sheet for Cooling Water Service Figure 4.1 is a schematic diagram of a typical cooling water circuit. In this figure, circulation pumps draw cooled cooling water, the cooling water supply stream, from the supply basin at the bottom of a cooling tower and distribute it through piping to heat exchanger located in one or more project areas. Cooling water return streams are combined and sent to a cooling tower where it is cooled, principally by evaporative cooling. Motor driven fans mounted on the tower draw (induced draft) or force (forced draft) ambient air into the cooling tower where it 9 Aspen Utility Modules 545 contacts the downward flow of cooling water. The cooled cooling water drops down from the tower into a supply basin, awaiting withdrawal by the circulation pumps. Water is added to make up for losses through evaporation, airborn drift and for blow-down. Water drawn from the system to prevent the build-up of contaminants is termed “blow-down.” See below for more on cooling towers, terminology and defining stream temperatures H H Cooling water in such a circuit tends to accumulates algae, corrosion contaminants and particles that slough off the distribution system. Water treatment chemicals are added to alleviate these conditions, with the degree of such treatment depending on the water supply source and environmental conditions. Five types of treatment chemicals are typically used in small quantities to control the water quality. The cooling water model provides each cooling tower with a diaphragm type of pump and a stand-by for each of the treatment chemicals. The model uses the following labels to identify the types:  Sulfuric acid (pH control)  Sodium hypochlorite (pH control)  Biocide (algae growth control)  Corrosion inhibitor  Dispersant (suspended particles control) Figure 4.1 Illustration: Cooling Water Flow Diagram 546 9 Aspen Utility Modules Cooling Water Model Circuitry The cooling water model is designed to support up to four independent cooling water circuits. Each circuit can have its own cooling tower or all circuits can be defined to share a cooling tower. A circuit consists of pumps and distribution piping to and from project areas. It is the P&ID specs that define the component’s hook-up piping to the cooling water model’s circuitry. Summarizing, the cooling water model develops piping runs to a project area and distributes cooling water to components in the area via an area header or risers and laterals in the case of 3D area types. Each circuit is provided with a supply and return distribution network; what is supplied must be returned: one supply line implies one return line. Figure 4.2 is a schematic diagram showing several areas that have equipment requiring cooling water and one that does not. The cooling water model will not serve an area that does not have cooling water requirements. If such an area is to be included, then it is recommended that one or more exchangers connected with cooling water utility streams be introduced in that area. The cooling water model allows for a one cooling tower (or two 50% towers) to serve all circuits or individual cooling tower (or two 50% towers) for each circuit. Clearly, if only one area requires cooling water, only one circuit can be defined, up to two circuits for two areas, up to three circuits for three areas and a maximum of four circuits for four or more areas requiring cooling water. 9 Aspen Utility Modules 547 Figure 4.2 Single, Independent Cooling Water Circuit Figure 4.3, case (a) is a diagram showing a single treed circuit. Figure 4.4, case (b), illustrates multiple treed circuits. The difference between the two cases is (a) one cooling tower for each circuit or (b) one for all circuits. Case (a) would apply to projects with a single area or for multiple circuits, with each circuit being served by its own cooling tower. 548 9 Aspen Utility Modules Figure 4.3 (case a). Illustration of one cooling tower used to serve a set of areas in a single circuit. The model will permit up to four single circuits, each having its own cooling tower and circulation pumps. Figure 4.4 (case b). Illustration of one cooling tower used to serve multiple circuits. For this case, the model will provide one cooling tower for all circuits and a set of circulation pumps for each circuit. 9 Aspen Utility Modules 549 Cooling Water Distribution Network This      section describes the methodology used in circuit design Naming conventions Sequencing of areas on the main line Cooling water footprint model Pipe, valves and fittings count Line sizing and pressure drop calculations Naming Conventions Project Cooling Water Utility Area: The cooling water design model will create a cooling water model utility area to contain project components for each circuit. On loading, the area will be named with a date and time stamp to ensure it is unique and can be detected and properly deleted when a new design is to take its place. The naming convention is: “AUMCoolWater ddmmmyy_tttt”, where  dd is the day number of the session month (1, 2, 3, ….., 31)  mmm is a three character representation of the session month (jan, feb, mar, apr, may, jun, jul, aug, sep, oct, nov, dec)  yy is the last two digits of the session year (05 for 2005, etc)  tttt is the decimal fraction of the session day Utility project components are time-stamped in a similar manner. As only four digits are used (tttt), it is possible that a load action might span two tttt times (one ten-thousandth of a day, duration of 8.64 seconds) with no significant resulting consequence. Once a cooling water utility area is loaded in the project, the user may access any item in the usual way, by using the Project View, clicking on any component and viewing the design parameters in the forms view. Any and all data in the cooling water utility area may be modified as required. Areas Requiring Cooling Water: Each area that requires cooling water is identified by a unique ArRg number that is made up of system–assigned numeric values for Area ID and Report Group. An ArRg value of 201 indicates Area ID = 2 in Report Group 1. The user-assigned area description, which may not be unique in 550 9 Aspen Utility Modules a given project, is printed in reports along with its unique ArRg value. Plant Bulk Pipe Item Descriptions: The naming convention above is combined with the Area Code and is time stamped when loaded into the project. For example, “MainSeg, ArRg 201_T7883” is the item description for main line supply and return line segment that serves area 2 in report group 1, time stamped T7883. Distribution Piping Line Types: The distribution network in this cooling water model consists of the following named types of lines:  Main line segment: a portion piping along the main line o “MS” o “MainSeg” o “MainChk” for a main segment that contains a check valve  Branch segment: a short run of pipe, from the main line to a specific project area o “B” o “Branch” o “BrChk” for a branch that contains a check valve  Area header: a line of pipe, valves and fittings that distributes cooling water along the long dimension of the base of a project area o “AH” o “Area Header” o “ArHdrChk” for an area header that contains a check valve  Risers – vertical runs of pipe to bring cooling water to each level in a 3d structure o “R” o “Risers” o “RiseChk” for a riser that contains a check valve  Laterals – horizontal runs of pipe that distribute cooling water to each floor in a 3D structure o “L” o “Laterals” o “LatChk” for a lateral that contains a check valve 9 Aspen Utility Modules 551  Vents and drains – high-point vents, low-point drains on supply and return lines, short runs of small bore pipe o “VD” o “VentDrain” Lines with check valves are of minimal length to satisfy the plant bulk PIPE mode and are separate line items as only one check valve is assigned to a supply-return line pair. Figures 4.5 and 4.6 illustrate these line types for 2D (PAD, GRADE) and 3D area types (OPEN, EXOPEN, FLOOR, MODULE) Figure 4.5 Schematic of cooling water piping for a 2D area type (PAD, GRADE) 552 9 Aspen Utility Modules Figure 4.6 Schematic of cooling water piping for a 3D area type (OPEN, EXOPEN, FLOOR, MODULE) Sequencing of Areas on the Main Line Upon identifying which areas that require cooling water and their assigned circuit, the cooling water model arranges the areas in decreasing cooling water usage. The largest consuming area is placed at the front of the line and the smallest consumer is placed at the end. In this way, min line segments will be larger in diameter at the front of the line and decrease as each consumer reduces the total flow rate to the next area. Figure 4.7 illustrates various line types and sequenced areas. 9 Aspen Utility Modules 553 Figure 4.7 Schematic of Line Types Serving Areas Requiring Cooling Water Cooling Water “Footprint Model” Upon identifying an area as one that requires cooling water, the footprint model develops an area footprint by using (a) the total number of components in an area, (b) the area type (2D or 3D), (c) the number of level and (d) a packing density (number of components in a bay) and (e) area aspect ratio, length:width, of 1.5:1.0. The result of the footprint model is a set of dimensions for each area requiring cooling water. These dimensions are used to develop a default value of the spacing between the start of one area along the main line and the next area. The default spacing distances are reported in the Step 2 of the CIRCUITS worksheet and can be over-ridden by the user. Pipe, Valves and Fittings Count Each line type is provided with a piping iso model that consists of set of pipe, valves and fittings. Pipe and fitting diameter is determined by volumetric flow rate and limiting line velocity (suction lines being different from distribution lines). Line length is determined by (a) minimum length of pipe required to each type of fitting and (b) the long area dimension, which is 554 9 Aspen Utility Modules developed from a cooling-water “footprint model” for each project area and area type. Fittings are assigned to each line type from a list that includes elbows (EL), tees (TE), reducers (RE), flanges (FL), blind flanges (BL), gate valves (GA), check valves (CH). H H Each line type is based on five configuration components. The total line length is determined by as the sum of the linear run distance plus pipe lengths of pipe to satisfy the make-up of the configuration components. The make-up of each configuration component is based on line type and consists of quantities of the following:  “Main run” component: pipe, of length determined by (a) the footprint model, or (b) user preference value  “Fixed” component: FL, GA, CH fittings, pipe length based on diameter of run  “Head” component: EL, FL fittings, pipe length based on diameter of run, to provide directional change  “Branch point” component: TE, RE, FL, BL fittings, for connection to next line type  “Vent and drain station” component: TE, FL GA fittings, pipe; frequency of placement is based on linear run distance  “Expansion loop” component: EL fittings, pipe length based on diameter of run, frequency of placement is based on linear run distance Expansion loops and vent and drain stations are placed along the run based on line length The configuration of each line type serving each area is defined as a project component located in the cooling water area created by the cooling water model. Once loaded in the project, any line configuration can be reviewed and modified in the usual manner by opening that project component in its form. Line Sizing and Pressure Drop Calculations The Cooling Water Model has a Preferences worksheet where, in the Piping section, limiting sizes of each line type are defined. Once areas are assigned to a circuit, the flows through the circuit are known. Areas are ordered in sequence according to their flow requirements, with the largest consumer at the head of the line. The computations are interactive and a new design will be computed unnoticed each time a design value is revised. It is 9 Aspen Utility Modules 555 wise to check early design results that are displayed in the Capture worksheet when revising design specifications. Line size and pressure drop computations take place in this general manner:  Starting point is limiting velocity, as defined in the Icarus Reference Guide  Flow rate combined with limiting velocity results in required flow area  Maximum line size determines number of parallel lines  Built-in iso for each line type defines valve and fitting count  Line length is derived from spacing between areas from circuitry input, minimum spacing between areas and minimum lengths from line  Total run length is a combination of line length and number of parallel runs  Pipe friction is based on Fanning type equation  Line-size based fitting resistances are used to determine fitting friction losses  A single average value for the pressure drop across cooling water usage components in any area is defined in the Preference worksheet  Pressure at junctions, where flows meet, is common to junction streams  Overall circuit pressure drop comes from a stepwise calculation across all junctions  An addition head loss due to cooling tower elevation completes the pressure drop determination It is possible that the limiting line size for branch and area headers may be too small for some circuits with large flows. This would result in a cluster of two or more parallel lines. To alleviate this condition, consider increasing the limiting line size. Projects with a Prior Cooling Water Utility Model Area The cooling water model will allow a single cooling water utility area of its making in a project. If a project contains a prior area, the model will detect its presence and defer action until the user decides to load a new cooling water model design. Choosing to load will delete the prior area and the new one will be loaded. Is 556 9 Aspen Utility Modules the choice is not to load, the model worksheets are closed with a return to the normal view. Cooling Towers: Terminology and the Defining Stream Temperatures Figure overview_4.8 shows a cooling tower with air and cooling water streams and their temperatures. Terms used in the cooling tower industry, illustrated in Figure 4.8, are:  Cooling tower: a device used to cool water by the countercurrent action of ambient air against a downward flowing stream of water to be cooled. The cooling process involves the cooling of entering water by evaporative cooling of water and sensible heat to a much lesser degree  Cooling water supply stream: cooling water supplied to heat exchangers for purpose of cooling process streams  Cooling water return stream: cooling water streams leaving heat exchangers, combined for return to a cooling tower  Range: cooling water return temperature, Tr – cooling water supply temperature, Ts, directly related to the heat duty  Approach Gradient: the difference between the wet bulb air temperature and cooling water leaving the cooling tower. Theoretically, the cooling water temperature can not drop below the air wet bulb temperature. For a given cooling water flow rate, as the approach gradient decreases, the cost of a cooling tower will increase. 9 Aspen Utility Modules 557 Notes to Analyzer Utility Model (AUM) Users: Cooling Water utility resources that must accounted in the Analyzer Utility Model (AUM) should be named either: Cooling Water or "Cooling Water xx" where: xx can be two digits ranging from 01 to 99, for example, Cooling Water 01 User created utility resources that do not adhere to this format (for example, CW, Sea Water, Cooling Water o3) will not be identified as cooling water streams and will be excluded from AUM's cooling water analysis. Cooling water streams that are not associated with any equipment, will be assigned to the Area with the maximum cooling water flow rate. For areas assigned to two or more circuits, the collected unassigned cooling water flow rate will be assigned to the first area in the circuit handling the largest circuit flow rate. Cooling water can either be bought or be made. If it is to be made, the dew point of ambient air added to the lower model limit for the approach gradient will determine the lowest possible deliverable temperature. To ensure that your specified cooling water utility resource streams can be made, please review the limits for the two cooling water models:  CTWCOOLING  CTWPACKAGED AUM_Air Utility Design and Scope Generator for Instrument and Plant Air Overview The Air Utility Module automatically and interactively: 558 9 Aspen Utility Modules    selects, designs, and sizes air plant project components that conform to your: o Project scope design basis o Interactive entries for air utility design and configuration preferences Augments the scope of your project with a list of designed air utility project components in a unique air utility area on the click of the Load button Interactive session enables a review of results prior to LOAD creates o Status messages, suggestions to alleviate design clashes o Interactive report of equipment and distribution piping design results With the Air Utility Module, you can review, revise, add other project components and/or Run the augmented project to obtain a new project evaluation. The Air utility model can be  applied to projects that have been created using o Aspen Aspen Process Economic Analyzer, Aspen Decision Analyzer o Aspen Capital Cost Estimator  within Aspen Aspen Process Economic Analyzer or Aspen Capital Cost Estimator Project areas and their project components   Aspen Process Economic Analyzer/Analyzer projects: o Each group of project components is contained in a unique “Report Group” o A report group is a project area Aspen Capital Cost Estimator projects: You can create o A project area o A report group to coordinate a group of project areas o The AUM Air utility module works with each project area and its air requirements Benefits:  You get early design metrics for decision making 9 Aspen Utility Modules 559      Decide what’s best, then trigger the LOAD operation With LOAD, a new Air utility area will be inserted into your project with its designed list of air system project components Before LOAD, air system project components are interactively o Selected based on your selection preferences o Designed in accordance with your project basis and air design preferences o Sized o Reported In a small fraction of the time and effort it takes to do this work in the traditional manner Change the project scope? Re-run the utility module! How AUM_Air Works General AUM_Air Workflow 1 Press U button to initiate. 2 Select Air Utility. AUM_Air opens in MS Excel 3 Move the supplied Control Center toolbar to the top and click it. 4 Check Status. 5 Review the Guide, page 568. 6 Select and enter Preferences. X 560 X 9 Aspen Utility Modules 7 Check messages, review results in Report. 8 Revise Configuration parts 1 and 2. 9 Check messages, review results in Report. 10Click the Load button to close AUM_Air and load the design results into your project. 11Review Area and components. 12Run the project, review results. Using AUM_Air Accessing AUM_Air To access AUM_Air: 1 Starting with an open project that has been evaluated, click Run, then click Utility Model. Or, click the U button to access utility models. The Utility Model dialog box appears: 2 Click Air – Instrument, Plant. 3 Click OK. Three actions now occur 1 The model first identifies if a prior Air – Instrument, Plant model area is present in the project. If present, you can choose to Delete the prior area and continue with the model or return to the project. If you click Delete, the utility model will proceed with the design and delay deletion until it is time to load the new results. 9 Aspen Utility Modules 561 2 If no prior Air – Instrument, Plant utility area is detected, the Welcome screen is displayed and remains present during a time when: a Project requirements are automatically passed to the model b The model prepares an initial design c The model then displays the Control Center worksheet, which links to all other worksheets and provides an indication of success (green signal) or failure (red signal) to create an initial design based on default design parameters. 3 A Load | Cancel | Minimize dialog box is provided. 4 To continue, click the minimize button at the top. This parks the button box for access during the design phase. Cancel ends the Air – Instrument, Plant model session and returns normal project functions with no change to the project. 562 9 Aspen Utility Modules Note: A Control Center button bar is provided to access the Control Center worksheet from any worksheet. Nine worksheets are presented in a MS Excel framework:  Welcome  Control Center  Guide  Status  Preferences  Config 1  Config 2  EquipStats  PipeStats The Initial Design On initiation, the Air – Instrument, Plant model reports the status of the design on the Control Center worksheet under Status, and if there are any, identifies clashes on the Status worksheet and, further, on the Preferences worksheet. A Status Report message: Successful. A Load can proceed indicates all is well between project requirements, design parameters, and design methodology. At this point, it is wise to review early design metrics by accessing the EquipStats and PipeStats worksheets. If captured results are acceptable, a click of the parked Load button:  carries the design results into the project  closes the worksheets  returns to the project for evaluation of the augmented project Should the design basis produce a clash with project requirements, error messages and flags are displayed in a topdown succession of worksheets. The first indication is given under Status Report on the Control Center worksheet. The Status worksheet is the central reporting agency, where checks are made and links are provided to source locations in the EquipStats and PipeStats worksheets. 9 Aspen Utility Modules 563 To load the Air – Instrument, Plant data into your Icarus project: When you are satisfied with the model and the Status worksheet shows that there are no errors, you can load the Air – Instrument, Plant model into the project. 1 Click the Maximize button on the parked Load | Cancel | Minimize dialog box. 2 Click Load. The Aspen Icarus Loader appears, showing the progress of loading the XML data into Icarus. 564 9 Aspen Utility Modules When the Air – Instrument, Plant data has been loaded into Aspen Icarus, the following confirmation message appears: 3 Click OK. The Air – Instrument, Plant data is now included in your project. Modifying Air – Instrument, Plant Data When you have loaded Air – Instrument, Plant data in your project, you modify that data using the AUM_Air module. To Modify Air – Instrument, Plant Data: 1 On the main menu, click Run, then click Utility Model. Or, click the U button to access utility models. The Utility Model dialog box appears. Note that the Status column says Loaded. 2 Click Air – Instrument, Plant. 3 Click OK. The following warning message appears: 9 Aspen Utility Modules 565 Note: Clicking Yes does not actually delete the Air – Instrument, Plant data in your project. You can click Yes, modify the Air – Instrument, Plant data, then choose not to replace the previous Air – Instrument, Plant data with the modified data by clicking Cancel on the Load | Cancel | Minimize dialog box. 4 Click Yes. 5 Modify the data to your satisfaction. If you want to replace the loaded data with your modified data, follow the steps below. 1 Click the Maximize button on the parked Load | Cancel | Minimize dialog box. 2 Click Load. The Aspen Icarus Loader appears, showing the progress of loading the XML data into Icarus. 566 9 Aspen Utility Modules When the Air – Instrument, Plant data has been loaded into Aspen Icarus, the following confirmation message appears: 3 Click OK. The Air – Instrument, Plant data is now included in your project. If you want to keep loaded Air – Instrument, Plant data and not replace it with your modified data, follow the steps below. 1 Click the Maximize button on the parked Load | Cancel | Minimize dialog box. 2 Click Cancel. The following warning message appears: 3 Click Yes to cancel the loading process. Your original loaded Air – Instrument, Plant data is retained. 9 Aspen Utility Modules 567 Guide for the Air Utility Model (AUM) SPECS Organization Chart About this SPECS Book 568 9 Aspen Utility Modules 9 Aspen Utility Modules 569 About an Air Plant Unit About Distribution Piping for an APU Methods In the conceptual design phase, lacking a plot plan, this method is used to develop air distribution piping.  Some runs may be long, some short.  Components in the augmented project scope definition may be modified, deleted, new ones added. The following is a brief description of the methods used.  Areas assigned to an APU are collected in the sequence of the project and are assembled in a column-row array  Array dimensions are determined from area dimensions  Row and column dimensions are figured from total area, number of areas and an initial aspect ratio of 3:2 Air Distribution  Piping is developed for Instrument Air as well as Plant Air.  Piping for each service is developed in the same way, except for volumetric flow and line size Distribution Piping  The APU feeds air to the array through a Main Feeder (MF)  The Main Feeder length is defined in Preferences 570 9 Aspen Utility Modules        Two Main Manifolds (MM) are used on extra-wide arrays, els one or none for an array one column wide Each MM feeds a Main Line (ML) Main lines feed Branch Lines (BR) A tee of the Branch line supplies air to an Area Feeder (AF) Area Feeders connect to Area Headers (AH) Area headers, for 2-D area types such as Grade, Pad, etc supply air to the I-P transducers, control valves o P&ID information from the original project provide the requirements for I-P and control valve components o Utility station requirements are developed for each area based on anticipated air tool usage and area size  A plant air connection is made off the Area Header Plant for each utility station Area headers, for 3-D area types such as open steel structures, etc supply air to Risers, then Laterals which then connect to I-P transducers and control valves. o Utility station requirements are developed for each 3-D type area based on anticipated air tool usage and area size Schematic The following schematic was prepared to illustrate a large project of 78 areas: 9 Aspen Utility Modules 571 Configuration of Air Utility Project Components      Project Components An Air Plant Unit - APU Schematic of an APU Multiple APUs Compressor Redundancy Project Components The Instrument and Plant Air Utility Model creates a set of project components in accordance with the needs of your:  Project Scope definition  Design and selection preferences for Instrument and Plant Air 572 9 Aspen Utility Modules Typical components         Air Compressors Interstage and After-coolers Air Filters Air Receivers Air Dryers Air distribution piping (instrument, plant air) Utility Stations (air, water, steam, condensate drain services) Associated installation bulks would be developed during project run Components are contained in a uniquely defined Area   Area Title contains a unique time and date to differentiate one run from another Area can be modified or deleted in the usual way using Aspen Capital Cost Estimator, Aspen Aspen Process Economic Analyzer/Analyzer An “Air Plant Unit” - APU        Air intake screens Air intake ductwork Air compressors o One main compressor at 100% capacity or two at 50% capacity each o Optional standby spare compressor o Optional start-up compressor Interstage and after-stage coolers o Optional TEMA water cooled or fin-fan air cooled exchangers Air receivers o Optional individual receivers for instrument and plant air or combined receiver o Optional main receiver or two at 50% capacity each o Optional stand-by receiver Air filters – pre-filter and post-filter, one or more of each Air dryers - dual tower type (one working, one regenerating) 9 Aspen Utility Modules 573   o One main at 100% capacity or two at 50% capacity each o Optional standby spare air dryer o Optional dryer for Plant Air Utility piping for turbine steam/condensate, cooling water/return Distribution piping o Instrument and plant air o Utility stations o Cooling water, steam/condensate headers o Interconnects between two or more air plant units Schematic of an Air Plant Unit 574 9 Aspen Utility Modules General Layout Multiple Air Plant Units for Multiple Areas One or up to four Air Plant Units to serve area air requirements. Two distribution networks for each APU:  instrument air  plant air 9 Aspen Utility Modules 575 Compressor Redundancy: Multiple, Standby, Start-up Design Considerations     Units of Measure Designed Components Volumetric Air Flow Rate Equipment Selection and Design o Compressor Model Selection o Interstage and After Coolers; choice of  Air Coolers (for rack mounting)  Shell & Tube Heat Exchangers o Air Receivers o Air Filters o Air Dryers Units of Measure Values are reported in the Unit of Measure set of the user’s project, in the:  Utility Module interactive worksheets and reports 576 9 Aspen Utility Modules  Augmented user’s project file Air Utility Area   Designated as AUM_Air_ddmmyy_tttt (date and time stamped) Contains Air Utility system project components Air Utility Project Components Each item is selected and sized:  Area headers for cooling water/return, steam/condensate, instrument and plant air  Air intake screens  Air intake ductwork  Compressors  Interstage coolers  Utility piping for turbine steam/condensate, cooling water/return  Plant and Instrument Air Receivers  Air Pre-filters, After-filters  Air Dryers  Distribution Pipe, Valves, Fittings o Distribution circuits: up to four circuits (one to four air plant units) o Distribution piping, for 2D, 3D area types o Utility stations (total number of stations) 9 Aspen Utility Modules 577 Instrument Air (IA) Requirements: Air Flow Rate Plant Air (PA) Requirements: Air Flow Rate 578 9 Aspen Utility Modules Compressor Model Selection Method Sizes compressor based on      Total project air flow Number of desired air plant units Project areas assigned to each air plant unit Air plant unit redundancy (working spares, stand-by spares) Specs for start-up compressor Model type is based on compressor air flow rate    Low flow rates – reciprocating High flow rates – centrifugal Flow rates less than model minimum -reciprocating Reciprocating Compressor for Low Capacity Range 9 Aspen Utility Modules 579 Gasoline Motor-Driven Reciprocating Compressor for Low Capacity Range, Stand-by Spare Centrifugal Compressor for High Capacity Range 580 9 Aspen Utility Modules Inter- and After-compression stage Coolers Air Filters 9 Aspen Utility Modules 581 Air Receivers Air Dryers Interactive Specs     582 Design Basis o Equipment Redundancy o Equipment Configurations o Selection Specs o Design Preferences o Air Distribution Areas and Air Plant Units Layout Air Distribution Configuration 9 Aspen Utility Modules o Assignment of APUs to Areas User Preferences    User enters specs interactively in MS Excel SPECS workbook Preferences worksheet– design and equipment configuration basis o Organized by category o Color coded o Either/or selections are provided with a base (default) value o Numeric selections are provided with a base (default) value o Help messages assist selections o Error messages are issued for out-of-limit or design clash conditions CONFIG worksheets: basis for distribution air piping to areas o Part 1: Assignment of plant air to areas devoid of equipment o Part 2: Assignment of an APU to an area Equipment Redundancy     Main item at 100% capacity Main item split into two, each at 50% capacity Stand-by spare o Optional o Same size as main item or main item at 50% capacity o Power option for stand-by compressors  Electric motor drive  Large compressors: steam turbine drive  Small compressors: gasoline engine drive Start-up compressors only o Optional o Size based on user % of total capacity of main item 9 Aspen Utility Modules 583 Equipment Configurations Equipment configuration choices: Combined air train Individual Instrument air train Wet or dry plant air train Basis for Design: Preferences - 1 With the exception of item 1 (Conversion of “Quoted cost” items ….) where no default value is provided, every other user preference is supplied with a default value and minimum and maximum limit values where appropriate. Item 1 requires user entry for an exchange rate which is used in an air utility internal cost model to evaluate costs of air intake screen/filters. 1 Conversion of "Quoted cost" items to Project Currency Units (PCU) o Exchange rate, Project Currency Units per USD: Note: This entry is required. 2 Ambient Air Conditions (one set for all APUs) 584 9 Aspen Utility Modules o Dry bulb temperature o Wet bulb temperature o Atmospheric pressure 3 Air Requirements - Capacity for Instrument and Plant air (one set for all APUs) o Excess capacity, %  Instrument air  Plant air o Air system leakage, % o Install utility stations? o Number of utility stations, % adjustment 4 Air intake screens/filters (uses an AUM_Air cost model) o Air to media ratio o Adjustments to model estimate  Cost  Hour to install  Weight 5 Compressors (one set of specs for all APUs) Main compressor: o Main compressor  One at 100% capacity or two each at 50% capacity  Limiting flow rate for a single main compressor, % of model maximum flow o Stand-by spare compressor  Install?  Driver type (electrical or other: turbine, gas motor) o Start-up compressor  Install?  Minimum flow rate to qualify for installation  Running time o Interstage Coolers  Type:  Water cooled (small: Pre-engineered type or large: TEMA BEU)  Air cooled (AIR COOLER)  Cooling water inlet and rise temperature 9 Aspen Utility Modules 585  Air temperature rise for fin-fan air coolers Notes: If low capacity type is selected, may generate multiple low capacity compressors High capacity compressors may require project mid- and/or high voltage power distribution levels. o Utility services for compressors  Steam lines: run distance from boiler house to turbines  Cooling water lines: run distance from cooling water plant 6 Air Receivers o Common or separate receivers for instrument air and plant air? o One main receiver at 100% capacity or two, each at 50% capacity o Install a stand-by spare? o Horizontal or vertical vessels? o Maximum diameter o Maximum tangent-to-tangent length o Instrument air supply time during emergency shutdown o Plant air supply time during emergency shut-down 7 Air Dryers (Dual Bed–one working, one regenerating) o Common air dryer for instrument and plant air? o Is plant air to be dried? o One main dryer at 100% capacity or two, each at 50% capacity o Air purge rate 8 Air Filters o Instrument air  Number of pre-filters  Number of post-filters o Plant air  Number of pre-filters  Number of post-filters 9 Distribution piping o Minimum line size for air piping 586 9 Aspen Utility Modules o Distance from APU to process area o Typical tie-in run length from one APU to another Configuration Layout Method and Distribution Basis for Air Utility Model Piping o Layout and primary distribution piping is based on the specs for all areas assigned to an APU o Area feeder and header, risers, laterals are based on area specs Area layout in lieu of a project plot plan o Project areas are arranged in project sequence o Each area is given an ID code based on its report group and area number  Example:  Report group 2 “Solvent Recovery”  Area 4 description: “Distillation”  Is given an ID code of 100 x 2 + 4 = 204  ID code 204 is characterized by its report group name and area description o Areas are placed in a rectangular array according to the total number of areas with an initial aspect ratio of 2:3 (fewer columns than rows) o Column-row arrangement is modified to obtain a row-column balance o A branch line is run across each row with area feeder take-offs to each area in a row o Area headers (and risers and laterals for 3D area types) connect to individual project components in that area o Branches are fed using a Main Line o Main Lines are fed by Main Manifolds for wide arrays o Main Manifolds are fed by a Main Feeder from the Air Plant Unit 9 Aspen Utility Modules 587 APU Configuration: o Choose default (one APU for all) or assign each Report Group to one of four APUs Example layout – group of areas served by APU “A” Circuit Preferences: Configuration of APUs     588 Worksheet provides a list of Project Areas and air consumption Configuration in two parts: o Part 1: enables areas with no Instrument air requirements to be provided with plant air, else no air is provided o Part 2: enables each area to be assigned to an APU Initial configuration: all areas are assigned to APU “A” o Design results are presented for the initial configuration Revised configuration: use of up to four (4) APUs o Design results are presented for the revised configuration 9 Aspen Utility Modules Sample Layouts: One APU Sample Layouts: Multiple APUs Design Methods   Sizing Distribution Piping Schematic of Distribution Piping 9 Aspen Utility Modules 589 Basis for Sizing Air Distribution Piping   Configuration (IA = instrument air; PA = plant air) o Assignment of an APU to Project Areas o Initial configuration: all are areas assigned to one APU o APU Air flow for IA and PA is determined from sum of area usage requirements Sizing o Air Module uses a built-in layout model to estimate air distribution piping line lengths o Each line type is assigned an “Iso” with valve and fitting counts, expansion loops for long runs o Areas provides air flow requirements for each line o Lines are sized based on air consumption and a pressure drop of 1 PSI per 100 ft [22.6 KPAG/100 M] or less with a minimum line size as defined in Preferences o Design pressure: 150 psig [1350 KPAG] Air Distribution Piping to Project Areas 590 9 Aspen Utility Modules Distribution for a 3D-Type Area Sample AUM_Air Worksheets Displayed below are sample AUM_Air worksheets. Note the following details about AUM_air and these sample worksheets:  sheets are non-functional  all worksheets visible to the user have the version number printed at the bottom of the sheet  the project illustrated is Aspen Process Economic Analyzer ETOH Sample Project  except for currency and exchange rate, sheets are in the user's units of measure defined in the user's project specs o currency is referred to as PCU - project currency unit o you must enter an exchange rate when opening a project for the first time. The exchange rate value will be "remembered" on opening the project thereafter o ControlCenter, Status and Preferences sheet will always show an error because you must enter an exchange rate for the currency of the project (hyperlinks lead the you from ControlCenter to Status to Preferences to the item to be revised) o on entering a proper value, the error message is not displayed 9 Aspen Utility Modules 591 List of AUM_Air Worksheets          Welcome ControlCenter Guide Status Preferences Config_1 Config_2 EquipStats PipeStats Welcome Worksheet 592 9 Aspen Utility Modules Control Center Worksheet Guide Worksheet 9 Aspen Utility Modules 593 594 9 Aspen Utility Modules 9 Aspen Utility Modules 595 596 9 Aspen Utility Modules 9 Aspen Utility Modules 597 Status Worksheet 598 9 Aspen Utility Modules 9 Aspen Utility Modules 599 Preferences Worksheet 600 9 Aspen Utility Modules 9 Aspen Utility Modules 601 Configuration Part 1: Assignment of Plant Air to Areas Not Requiring Instrument Air Configuration Part 2: Assignment of Areas to an APU 602 9 Aspen Utility Modules Note: For clarity in this documentation, the following screen shot is shown below the one above it. On the actual Config 2 Worksheet, they are side by side. Report – Equipment Component Stats 9 Aspen Utility Modules 603 604 9 Aspen Utility Modules Report – Pipe Stats 9 Aspen Utility Modules 605 606 9 Aspen Utility Modules 10 Evaluating the Project Running a Project Evaluation After all the process simulator data has been properly mapped and defined, you are ready to run a project evaluation. The project evaluation produces capital costs reports that can then be viewed in Aspen Icarus Reporter and Icarus Editor. If any of the components are modified, the evaluation process must be re-run. To run a project evaluation: 1 Click on the toolbar. – or – On the Run menu, click Evaluate Project. 2 The dialog box shows the default Capital Costs report file name, Cap_Rep.ccp. This is the report reviewed in Icarus Editor. If you want to give this file a different name, type the file name in the Report File field. 3 Click OK. 10 Evaluating the Project 607 If you are using the default Preferences, Aspen Capital Cost Estimator scans the project specifications for errors and/or inconsistencies and any found are listed in the Scan Messages window. Note: You can select in Preferences to skip the scan for errors (see page 58). X X There are four types of messages: Scan Message Description/Importance Level INFOrmational For your information WARNing Design can be produced, but you are alerted to problems ERROR A design or cost cannot be produced for an item FATAL Rare instance for extreme problems You have the option to continue or stop the evaluation process (except in the case of FATAL errors, which stop the evaluation process). You should carefully review these and fix any problems before proceeding. When the project evaluation is done, Aspen Capital Cost Estimator lists all errors found in the capital cost evaluation for your reference. 608 10 Evaluating the Project If you are using the default preferences, Aspen Capital Cost Estimator automatically displays reports in Icarus Editor when the evaluation is complete. Note: You can select in Preferences not to have Icarus Editor automatically appear after the evaluation (see page 58). X X Reviewing Results in Icarus Editor Icarus Editor is a fully OLE-compliant, Multiple Document Interface (MDI) text editor program. Accessing If you are using the default preferences, Aspen Capital Cost Estimator automatically displays evaluation reports in Icarus Editor immediately after you run a project evaluation. If you have selected not to automatically display results, you will need to complete the steps below to display evaluation reports in Icarus Editor. Even if you are using the default preferences, you may want to use the following procedure if the project was evaluated previously and has not changed since. To display evaluation reports in Icarus Editor: 1 Click – or – on the toolbar. Click Capital Costs View on the View menu. The Select Report Type To View dialog box appears. 2 Select the Evaluation Reports check box; then click OK. 10 Evaluating the Project 609 Icarus Editor opens displaying the evaluation reports. The right-hand pane contains the reports. The left-hand pane contains a tree-structure Contents view that lets you jump to different sections. Note: Click on the toolbar to turn the Contents view on and off (or click Contents on the View menu). Printing a Single Section The Contents view also lets you print a single section, rather than the entire report. To print a single section: 1 Right-click a section. 2 Click Print Barcharts. Icarus Editor Toolbar Click this 610 to 10 Evaluating the Project New Open Save File Properties Print Print Preview Page Setup Cut Copy Paste Bold Italic Underline Select Font Find (CTRL+F) Preferences Toggle Contents Cascade Tile Horizontal Tile Vertical Help Contents open a new document in the Document View open an existing document save current document to disk view selected properties of current document print the current document print preview the current document specify how the current document will be printed cut selected text to windows clipboard copy selected text to windows clipboard paste contents of windows clipboard into insertion location bold selected text italicize selected text underline selected text specify font for selected text find any text string within the current document set and save your preferences turn OFF/ON the Contents View display multiple documents cascaded display multiple documents tiled horizontally display multiple documents tiled vertically display on-line help Report Sections Title Page The Title Page includes the following:  Estimate Base: financial quarter from which cost basis is derived and date of Icarus Evaluation Engine (IEE). 10 Evaluating the Project 611     IEE version number. Run Date: Date and time that project evaluation was run. Currency symbol used in the report. Telephone numbers to call for technical support. Aspen Capital Cost EstimatorVersion: 12.1 Estimate Base: 1st Quarter 2002 (IEE: 31.0) May 25, 2002 Run Date: 26JUN02-16:57:49 Aspen Capital Cost Estimatoris a Product of: *********** Aspen Technology/Icarus Office * ******* Throughout this report * 600 Jefferson Plaza 5th Floor * * Rockville, MD 20852-1150 *** the Symbol "USD" represents U.S. DOLLARS * * *************** U.S.A. Telephone: 301-795-6800 Fax: 301-795-6801 In the United Kingdom: Ltd. In Japan: AspenTech Limited AspenTech Japan Co., Birkdale House, The Links Birchwood Atlas Building 5 Ichibancho Warrington WA3 7RB United Kingdom Chiyoda-Ku, Tokyo 102 Japan Telephone: +44-192-584-4400 3262-1710 5425 612 Fax: +44-192-584-4444 Telephone: +81-3Fax: +81-3-3264- 10 Evaluating the Project Web: http://www.aspentech.com Support: sup support@aspentech.com port@aspentech.com Contract Structure The Contract Structure section provides names of contractors and reporting arrangement. Contents The Table of Contents lists section names and the page number n on which each starts. The number of sections may vary depending on the number of report groups. If the project contains only one, then there will be only a single summary. If more than one, there will be a separate summary for each, plus a summary forr the total project. Project Summary The Project Summary provides an overview of project costs. Project Data Sheet The Project Data Sheet lists items with se separate parate columns showing user--entered entered values and system default values. 10 Evaluating the Project 613 Project Schedule Total Manpower Schedule The Total Manpower Schedule shows construction manpower loading based on the CPM Constr Construction Schedule. 614 10 Evaluating the Project Ways to influence this schedule include:  Adjusting productivities, shifts per day, length of the workweek using the General Rates specifications form and the Craft Rates specifications form. These forms are accessed in Project Basis view under Project Basis\Basis Basis for Capital Costs\Construction Construction Workforce.  Indexing man man-hours hours either at the Project level (Project Basis\Basis Basis for Capital Costs Costs\Indexing) Indexing) or at the Area level. The number of MEN PER DAY for each vertical bar is generated by summing ng the labor assigned to all the work items that fall within the period represented by that bar in the barchart. Cashflow Summary The Cash Flow Summary shows total capital cost spent. 10 Evaluating the Project 615 This barchart schedul schedule assumes that the DESIGN ENG’G AND PROCUREMENT monies are already spent at the start of construction the curve is not truly tied to the CPM schedule. During construction, capital is then spent for material, direct field labor, equipment rental and subco subcontract ntract work, Home and Field Office, Start-up, and so on on,, as the cost is incurred. By the end of construction, the TOTAL,AMOUNT given in the Project Summary is indicated here. Operating costs, such as start start-up up utilities, raw materials, initial catalyst charges, ges, and so on, are not included. Project Schedule Data Sheet The Project Schedule Data Sheet lists the fabrication and ship times for equipment items b by y class and provides barcharts of the following: 616 10 Evaluating the Project    General Schedule Schedule:: Balanced display of Basic and Detail Engineering, Procurement and Construction (EPC). Engineering Schedule Schedule: Details for Basic and Detail Engineering and Procu Procurement; rement; summary for Construction. Construction Schedule Schedule: Details for Construction- others summarized.  Contracts Schedule: Schedule for contractor(s). When a single contractor is performing all work, this schedule shows no new information. Contract Summary The Contract Summary breaks costs down by contractor. 10 Evaluating the Project 617 Summaries By Report Group Summaries By Report Group provides the direct material and labor costs and manhours by report group for all areas reporting to that group. Area Lists of Equipment and Bulk Material For each Area, the Equipment and Bulk Material List is divided into three sections. First there is the Component List, followed by the Area Bulk Report, and finally the Area Data Sheet. Following the last Area of each Report Group, there are two more reports the Report Group Summary and the Report Group Equipment Summary. Appendix A- Detailed Bulk Material and Field Manpower Listing Appendix A lists the design and cost details for every component, whether system-generated or user-added. The results are reported in the sequence that the items appear in the Area tree diagram. Appendix B- Bulk Material and Field Manpower Summary- by Report Group Appendix B consists of one summary of the material and manpower man-hours and cost for all direct costs in the project. There is one report per Report Group; if there is only one Report Group, then this report is eliminated. It is replaced by the project bill of material (see Appendix C description below). 618 10 Evaluating the Project Appendix C –Bulk Material and Field Manpower Summary - Total Project Appendix C is a project bill of material (BOM) providing a material and manpower summary for each plant bulk category. Due to the fact that the numbers are large, this is the best source of material costs and man-hours for calibration. Appendix D – Direct Material and Manpower Summary by Major Account - Total Project Appendix D is a project bill of material (BOM) providing direct material and manpower summary by major account for the total project. Appendix E – Units of Measure Data Sheet Appendix E lists the Icarus default units of measure as well as any user modifications. Reviewing Results in Aspen Icarus Reporter Accessing Aspen Icarus Reporter To access Aspen Icarus Reporter: 1 Click on the toolbar. – or – Click Capital Costs View on the View menu. The Select Report Type To View dialog box appears. 2 Keep Interactive Reports selected; then click OK. 10 Evaluating the Project 619 Reporter imports and loads the reports from Aspen Capital Cost Estimator. After the reports are loaded, the Aspen Icarus Reporter window appears. 620 10 Evaluating the Project Reporter allows you to select and run multiple Standard reports or Excel reports or Update On Demand reports. These selections can be remembered by clicking the Remember Selections button shown in the figure below. These selections are retained and shown the next time the Reporter application is run. In V7.3, reporter remembers these selections product as well as project wise. In V7.2 and prior versions the selections are cleared once the reports are displayed. In V7.3 these selections are retained until you choose to do otherwise. 10 Evaluating the Project 621 Remembering selections product wise In V7.2 and prior versions, reporter does not remember these selections product wise separately and only remembers the last selections made among all the three Economic Evaluation Products (Aspen Capital Cost Estimator, Aspen In-Plant Cost Estimator and Aspen Economic Analyzer). In V7.3, this limitation has been removed and reporter can remember the selections for all the three types of products separately. When a reporter application is run on a newly created project, last remembered selections (if any) for that product type are 622 10 Evaluating the Project shown by default. Similarly, for an existing unsaved project last remembered selections (if any) for that product type are shown by default. Remembering selections project wise In V7.3, you can save selections product wise as well. These selections remembered by clicking Remember Selections can be saved permanently with the project by selecting the File | Save menu item or clicking the Save Project toolbar button on the main Economic Evaluation frame window. When the reporter is invoked on such a saved project, it retains the selections saved with the project. Note: Clicking Remember Selections saves or updates the selections for the current report mode (Standard Reports or Excel Reports or Update On Demand) only. If you want to save or update the selections for other type of reports then you need to select that report type and then click Remember Selections after selecting the reports. Clear these selections before adding or removing any new custom reports. Aspen Icarus Reporter Menu Bar File Menu Click this to Import Data Import project reports. See page 649 for instructions. Run Report Run selected report. See pages 625 (Standard reports), 641 (Excel reports), and 636 (HTML reports) for instructions. X X X X X X X X Open Workbook Open the last Excel workbook created. See page 645 for instructions. Create User Database Export SQL database. See page 650 for instructions. Exit Close Aspen Icarus Reporter. 10 Evaluating the Project X X X X 623 Trend Menu Click this to Add Trend Data to Database Add the trend data from the project reports currently loaded in Aspen Icarus Reporter to the trending database. See page 646 for instructions. Create New Trend in Excel Export trending database to Excel. See page 647 for instructions. View Existing Trend Data Open the trending data workbook in Excel. See “Data Trending,” pages 645 through 649, for instructions. Clear All Saved Trends Clear the trending database. See page 645 for instructions. X X X X X X X X X X Which Report Mode? Four report modes are available:  Standard reports  HTML reports  Management reports  Excel reports  Update on Demand All but Management reports present Capital Costs and Design and Basis reports. Management reports contain snapshots of project data frequently requested by project management. Standard, HTML, and Excel reports do not just present the same data in different applications. Because of the differing capabilities of the applications, data is presented differently in each. The choice of mode may depend upon what you wish to do with the data at a particular time. Standard Reports With Standard reports selected in the Report Mode section, the Reports section displays a tree-structure grouping of standard reports. 624 10 Evaluating the Project Report Descriptions Open the necessary category and sub-category folders and click on a report to display a brief description of that report in the Description section. Note: See page 624 for descriptions of all Standard reports. X X Opening a Report Not all of the reports contain each of the features described in this user’s guide. For example, the Contents view only appears on reports with multiple sections. In order to see all the features described, select the Contractor – COA Summary report located in the following folder: Capital Cost Reports\Direct Costs\COA Summaries To open the selected report:  Do one of the following  Click the Run Report button. 10 Evaluating the Project 625 -or On the File menu, click Run Report. -or Double-click on the report. The report window appears. Navigating If there are multiple sections, a tree-structure Contents view appears on the left side of the window, allowing you to jump to a section simply by clicking the section in the Contents. The arrow buttons on the toolbar allow you to page through the report: Next Page Previous Page Last Page First Page Since the last page of a report usually contains the totals, clicking the Last Page button is a convenient way to access them. 626 10 Evaluating the Project Magnification To change the magnification level:  Click in the Magnification box; then click the desired level from the menu. You can also click directly in the Magnification box (without clicking ) and then zoom in and out using the up and down arrow keys on your keyboard. When viewing the report at large magnification, you may wish to hide the Contents view by clicking the Toggle Group Tree button . This makes more room for the report. Segregating a Cost Section If the cursor changes into a magnifying glass icon when placed over a cost section’s title or totals, you can double-click to open a separate tab window containing only that cost section. For example, under Civil in the Contractor – COA Summaries report, the cursor changes into a magnifying glass when placed over the Concrete cost section’s title or totals. 10 Evaluating the Project 627 Double-clicking on this cost section’s titles or totals opens a separate tab window. Note: Here, the Concrete cost section is displayed in a separate tab window, where it can be viewed and printed apart from the rest of the report. Searching To search the report: 628 10 Evaluating the Project 1 Click on the toolbar. 2 Enter the text string for which you want to search and click Find Next. The next instance of the text string is framed in red. Printing To print the report: 1 Click on the toolbar. 2 The Print dialog box appears. 3 Make any desired changes to the default settings and click OK. 10 Evaluating the Project 629 List of Standard Reports 630 10 Evaluating the Project 10 Evaluating the Project 631 632 10 Evaluating the Project 10 Evaluating the Project 633 634 10 Evaluating the Project HTML Reports With HTML reports selected in the Report Mode section, the Reports section displays a tree-structure grouping of HTML reports. Report Descriptions Open the necessary category and sub-category folders and click on a report to display a brief description of that report in the Description section. 10 Evaluating the Project 635 Opening an HTML Report To open the selected report: 1 Do one of the following:  Click the Run Report button. -or On the File menu, click Run Report. -or Double-click on the report. A status window tells you when the export is complete and asks if you would like to view the report now. 2 Click Yes. Your browser displays the report. Note: Generating the report as .htm file allows the report to be sent in an e-mail. 636 10 Evaluating the Project Management Reports When Management Reports is selected as the Report Mode, the Reports section displays a tree-structure grouping of Management reports. These reports are intended to serve as snapshots of the project scenario. Opening a Management Report To open a Management report:  Select the report and do one of the following:  Click the Run Report button. -or On the File menu, click Run Report. -or Double-click on the report. The Management Reports Viewer displays the report. Pictured below is the Detailed Weight Information report, one of the Piping reports in the Discipline folder. Other reports, like the Equipment Cost (Total Cost) report shown below, show simply a bottom-line total. 10 Evaluating the Project 637 Exporting Management Reports to Excel You can export Management reports to Excel. This is particularly useful for when you want to be able to e-mail the report. To export a Management report to Excel: 1 Click Export to Excel on the Viewer’s File menu. 2 Reporter searches for the last Excel workbook to which you exported a report.  If no existing workbook is found, Reporter asks you to specify a worksheet name (see step 3) and creates a workbook – either DefaultWB.xls in the Reporter output folder (if this is your first export to Excel since last re-booting) or a workbook with the file and path name of the last workbook to which you exported since starting your computer.  If an existing workbook is found, the Export to Excel Workbook dialog box appears, asking if you want to overwrite the existing workbook, append the report to the existing workbook, or create a new workbook. 638 Click To do this Overwrite existing workbook Reset the existing workbook with the selected report as the only worksheet; any previously created worksheets will be cleared. Append to existing workbook Add the report as another worksheet in the existing workbook; previously created worksheets will be retained. Create new workbook Specify a new workbook in which the selected report will appear as a worksheet. 10 Evaluating the Project Clicking Create new workbook expands the dialog box to let you select a folder and enter a file name. Note: Do not enter a file extension or period when entering a new workbook name. 3 Make your selection and click OK. 4 Enter a name for the worksheet. 5 Click OK. The Export Status dialog box informs you when the export is done and asks if you would like to open the workbook now. 10 Evaluating the Project 639 4 Click Yes to open the workbook. Excel displays the report. Excel Reports When you select Excel reports as the Report Mode, the Reports section displays a tree-structure grouping of Excel reports. Report Descriptions You can have Aspen Icarus Reporter display a description of the selected Excel report. To display a brief description of a report: 1 Open the necessary category and sub-category folders. 640 10 Evaluating the Project 2 Click a report to display a brief description of that report in the Description section. Opening an Excel Report To open a report: 1 Mark the checkbox next to the desired report. You can mark multiple report checkboxes to open multiple reports. Marking a folder’s checkbox will open all of the reports in the folder. 2 Click the Run Report button or click Run Report on the File menu. Reporter searches for the last Excel workbook to which you exported a report. 10 Evaluating the Project 641  If no existing workbook is found and this is your first export to Excel during this session, Reporter creates DefaultWB.xls in the Reporter output folder: ...Economic Evaluation V7.3\ic_cache\Reporter\Output  If no existing workbook is found, but you have exported from Reporter to Excel since you last started you computer (to a file that’s since been moved or deleted), Reporter creates a workbook with the file and path name of the last workbook to which you exported.  If an existing workbook is found, the Export to Excel Workbook dialog box appears, asking if you want to overwrite the existing workbook, append the report to the existing DefaultWB.xls workbook, or create a new workbook. Click to do this Overwrite existing workbook Reset the existing workbook with the selected report as the only worksheet; any previously created worksheets will be cleared. Append to existing workbook Add the report as another worksheet in the existing workbook; previously created worksheets will be retained. Create new workbook Specify a new workbook in which the selected report will appear as a worksheet. Clicking Create new workbook expands the dialog box to let you enter a workbook path and name. 642 10 Evaluating the Project Note: Do not enter a file extension or period when entering a new workbook name. 3 After you make your selection, click OK. Excel opens a workbook displaying the report. 10 Evaluating the Project 643 Note: Exporting the report to an .xls file allows it to be sent in an e-mail AutoFilter Several of the larger Excel reports generated by Aspen Capital Cost Estimator take advantage of the AutoFilter feature in Excel. In order to view a report that includes AutoFilter, open the following report: Capital Cost Reports\Direct Costs\Item Summaries\Combined When AutoFilter is available, clicking next to a column displays a list of all entries made in the column. Selecting an entry displays only rows that contain that entry in the column. For example, clicking 105 – Misc. Item Allowance in the COA Description column of the Item Summary Combined report would display only accounts with Code of Account (COA) 105.  Clicking Top Ten displays only items that contain one of the top ten most frequent entries.  Selecting Blanks (from the bottom of the list) displays only rows that contain a blank cell in the column, while clicking NonBlanks displays only rows that contain a value in the column. 644 10 Evaluating the Project Opening Workbook without Running a Report To view the last workbook created without running a new report, click Open Workbook on the File menu. Update on Demand Reports The Update on Demand option is intended for data modification, for example:  deleting line items  modifying line items  calculating intermediate results The Update on Demand option is available only if stored table and stored queries entries exist. In the Stored Reports table, specify: Set type = UoD. Click the Update on Demand option to run any query in the Stored Queries table. Your query is run only when a user specifies it with the Update on Command option. Data Trending Data Trending facilitates comparison of scenarios by allowing you to review capital cost summaries of different scenarios in a single Excel workbook. If, for example, you created three different scenarios for a project, you could use the Data Trending feature to display the direct costs of each on one spreadsheet, with a separate row for each scenario. Clearing Trending Database Since you only wish to compare certain scenarios, the first step is usually to clear the database used to populate the Excel trending workbook. To clear the trending database: 1 On the Trend menu, click Clear All Saved Trends. 10 Evaluating the Project 645 A confirmation dialog box appears. 2 Click Yes to confirm clearing of the data. The Trending Data Update dialog box tells when this is done. 3 Click OK. Adding Trend Data to Database The next step is to add trend data to the database. To add the current project reports’ trend data to the database: 1 On the Trend menu, click Add Trend Data to Database. The Trending Data Update dialog box tells you when Reporter has finished adding the trend data. 646 10 Evaluating the Project 2 Click OK. You will need to add the trend data from the project reports of the other scenarios you are comparing. For each of the other scenarios, open the reports in Reporter and complete the Adding Trend Data to Database instructions above. Using Reporter’s import function, you can open the other scenarios’ reports in Reporter without opening the scenarios in Aspen Capital Cost Estimator. See page 649 for instructions. X X Creating a New Trend in Excel After you have added the trend data from the Capital Cost reports of the scenarios you are comparing, you are ready to create a new trend in Excel. To create a new trend in Excel: 1 On the Trend menu, click Create New Trend in Excel. The Export to Excel Trending Workbook dialog box gives you the choice of either appending the trend data to the existing file or creating a new file. 2 Make you selection and click OK. The Export Trend Data into Excel dialog box appears. By default, all six capital cost categories are marked. 10 Evaluating the Project 647 3 Clear any categories you wish to exclude from the workbook and click OK. The Export Status window tells you when the export is complete and asks if you would like to open the trending workbook now. 4 Click Yes. Excel displays the trending workbook containing a spreadsheet for each of the capital cost categories. Each set of trend data entered into the trending database is displayed on a separate row. (The workbooks for any categories excluded at the Export Trend Data into Excel dialog box are blank). 648 10 Evaluating the Project After having created the trending workbook, you can access it from Reporter by clicking View Existing Trend Data on the View menu. Importing Data into Aspen Icarus Reporter When you have a project scenario open in Aspen Capital Cost Estimator and select Capital Costs (Interactive) from Aspen Capital Cost Estimator, Reporter automatically imports that project scenario’s Capital Cost reports as it opens. However, once you’re at the Aspen Icarus Reporter window, you can import a project scenario’s Capital Cost reports without having the project scenario open in Aspen Capital Cost Estimator. To import a Capital Cost report: 1 Click Import Data from the File menu. 10 Evaluating the Project 649 The Import Selection dialog box appears. 2 Use the browse tree to locate the project scenario folder, which should be at: ...Data\Archives_Aspen Capital Cost Estimator\[Project]\[Project Scenario] After clicking the project scenario folder, PROJID should appear in the File set to import section. 3 Select PROJID and click Import. Reporter imports the data. When complete, the selected scenario’s reports can be run from Reporter. Creating a User Database You can export the Icarus SQL Database, listing the Relation attributes used by the Icarus Evaluation Engine (IEE), to a Microsoft Access Database (.mdb) file. Note: Icarus Reference, Chapter 35, “Database Relations”, defines the Icarus Database Relations and the different attributes under each. 650 10 Evaluating the Project To create a user database: 1 On the File menu, click Create User Database. Reporter searches for the last .mdb file it created. If the file is not found or if this is your first database creation, the Create User Database dialog box appears with only one Export Option: Create New Workbook. The lower part of the dialog box provides fields for selecting a path and filename. However, if the last created file is found, the Export Options also include Overwrite Existing Workbook. This option is marked by default, so the lower part of the dialog box is not visible until you mark the Create New Workbook checkbox. 2 Select a folder, enter a database name, and then click OK. Reporter creates the .mdb file. To review and work with the database:  Start Microsoft Access and open the .mdb file. 10 Evaluating the Project 651 Splitting Very Large CCP Reports Because very large Capital Cost Project (CCP) Reports (greater than 100mb) can cause problems, Aspen Capital Cost Estimator splits CCP Reports greater than 100 MB by section and content. The entire data file still loads initially, but navigating through the results will be done via section selected You select the section you want to view in left side content pane (for example, Design Data Sheets). Only results for the selected section appear (which helps improve speed of the application). Notes:  You cannot move/print above or below that section in the main window.  Searching capabilities only apply to section selected. Projects with CCP Reports less than the 100 MB are not split. You can specify the split file size when using the splitting workflow. To specify the Split File Size: 1 On the Report Editor menu bar, click Options | Preferences. 2 On the Preferences dialog box, click the Document tab. 652 10 Evaluating the Project The document tab appears. 3 On the document tab, in the Documents group, specify the Split File Size. Reviewing Investment Analysis Note: Investment Analysis is only included in Aspen Capital Cost Estimator if you are licensed to use Icarus Process Evaluator (Aspen Process Economic Analyzer) or Analyzer and you select at startup to use one of them in the Aspen Capital Cost Estimator environment. If you are using the default Preferences, Aspen Capital Cost Estimator automatically displays the four Investment Analysis spreadsheets in the Main Window after you run a project evaluation. You can set Preferences so that Aspen Capital Cost Estimator does not automatically display the spreadsheets, in which case you would have to select to view them as described below. Viewing Investment Analysis To view the Investment Analysis: 1 Do one of the following:  Click 10 Evaluating the Project on the toolbar. 653 –o –  Click Investment Analysis View on the View menu. 2 Use the tabs at the bottom of the window to move among the four spreadsheets. Equipment Summary The Equipment Summary (EQUIP.ICS) contains a list of project components used in the analysis. For each component, the summary contains the following information: 654 Area Name The name of the operational unit area. Component Name The name of the project component. Component Type The type symbol for the component. Total Direct Cost The total direct material and labor costs associated with the project component (including installation bulks), in the project currency. 10 Evaluating the Project Project Summary Project Summary (PROJSUM.ICS) contains a project summary for the capital costs (equipment plus bulks) and schedule. This worksheet also includes operating unit costs (labor wage rates and utility unit costs), utility flow/use rates (steam/water flow rates, and so on) and operating and maintenance costs. Project Summary Input Data The following information on the Project Summary spreadsheet is user-entered, except where noted: Project Information Project Name Aspen Capital Cost Estimator project name Project Description Brief description of Aspen Capital Cost Estimator project, from Project Properties Analysis Date and Time The date and time this analysis was performed Simulator Type The name of the process simulator from which process data was imported Simulator Version The version of the process simulator Simulator Report File The name of the process simulator report file Simulator Report Date Date and time of the process simulator report file Economic Analysis Type The name of the Icarus system used for the evaluation Aspen Capital Cost Estimator Version Version number for Aspen Capital Cost Estimator system 10 Evaluating the Project 655 Project Directory Directory path for the current Aspen Capital Cost Estimator project Scenario Name Name of the current scenario (if applicable) Scenario Description Description of the current scenario, from Project Title in General Project Data Capital Cost Evaluation Basis Date Date of capital costs/schedule analysis Country Country basis for the capital costs/schedule analysis Units of Measure Units of Measure for analysis Currency (Cost) Symbol System currency symbol which depends on the selected country basis Currency Conversion Rate Conversion factor between user-selected currency to the currency used by the system internally for the selected Country basis. For example, if the US country basis is selected, the internal system currency is US Dollars. Therefore, all numbers will be reported in US Dollars. However, if a currency conversion rate of 1.5 is specified, all internal values will be multiplied by 1.5 and then reported System Cost Base Date The capital costs basis date of the system. The Adjusted Total Project Cost represents the calculated capital cost of the project (calculated at this base date) escalated to the Start Date of Engineering. Project Type Project type identified in the standard basis specs Design code Selected design code for equipment Prepared By Identifier for the preparer of the process evaluator Plant Location Location of the plant Time Difference Between System Cost Base Date and Start Date for Engineering Number of days between the date of the system’s Cost Base data (for example, first quarter, 2000) and the project’s start date for basic engineering. User Currency Name User assigned name for the currency User Currency Description User assigned description of the currency User Currency Symbol User assigned symbol of the currency. This is the symbol used for reporting the cost results in the reports. Descriptions for the following parameters are provided in more detail under Investment Parameter specifications (page 214). X X Time Period 656 10 Evaluating the Project Period Description Duration of time Operating Hours per Period Number of hours in specified period Number of Weeks per Period Number of weeks in specified period Number of Periods for Analysis Set to 20 periods for investment analysis Schedule Start Date for Engineering The beginning date for EPC (engineering, procurement, and construction) Duration of EPC Phase The calculated EPC duration in weeks Length of Start-up Period Number of weeks scheduled for start-up beyond the end of the EPC phase Duration of Construction Phase The calculated construction duration in weeks Completion Date for Construction The calendar date for the end of EPC Capital Costs Parameter Working Capital Percentage Percentage of total capital expense per period required to operate the facility until the revenue from product sales is sufficient to cover costs. Operating Costs Parameters Operating Supplies Indicates the lump-sum cost of operating supplies. Laboratory Charges Indicates the lump-sum cost of laboratory charges. User Entered Operating Charges (as percentage) Indicates the user-entered value for total operating charges. Operating Charges (Percent of Operating Labor Costs) Includes operating supplies and laboratory charges. If the user enters a lump-sum value for either “Operating Supplies” or “Laboratory Charges”, the addition of the two values will override the “User Entered Operating Charges” Plant Overhead (Percent of Operating Labor and Maintenance Costs) Consists of charges during production for services, facilities, payroll overhead, and so on G and A Expenses (Percent of Subtotal Operating Costs) General and administrative costs incurred during production such as administrative salaries/ expenses, R&D, product distribution and sales costs. General Investment Parameters 10 Evaluating the Project 657 Tax Rate The percent per period of earnings that must be paid to the government. Desired Rate of Return Indicates the desired (that is, user- entered) return rate, in percent per period, for the investment. Economic Life of Project Indicates the length of time in terms of periods over which capital costs will be depreciated. Salvage Value (Fraction of Initial Capital Cost) The expected value of an asset at the end of its usable life for the company. The difference between an asset’s cost and its salvage value is the amount to be depreciated over the asset’s usable life. Depreciation Method There are four depreciation methods allowed in Aspen Capital Cost Estimator: Straight Line, Sum of the Digits, Double Declining (Balance), Accelerated Cost Recovery System (ACRS). See “Investment Parameters” in Chapter 3 for a detailed definition of each depreciation method. Escalation Project Capital Escalation Rate at which project capital expenses may increase expressed in percent per period. If the addition of Engineer-Procure-Construct (EPC) period and start-up period is greater than one whole period, Project Capital Escalation is used to escalate the capital expenses for periods beyond the first period. Products Escalation Rate at which the sales revenue from products of the facility are to be escalated (increased) in terms of percent per period. Raw Material Escalation Rate at which the raw material costs of the facility are to be escalated (increased) in terms of percent per period. Operating and Maintenance Labor Rate at which the operating and maintenance costs of the facility are to be escalated (increased) in terms of Escalation percent per period. The operating labor costs include operators per shift and supervisory costs. Utilities Escalation User-entered percentages reflecting the anticipated utility price increase each period. Project Summary Output Data The following OUTPUT data is generated by Aspen Capital Cost Estimator : Project Results Summary Total Project 658 The total capital cost investment needed for 10 Evaluating the Project Capital Cost the project. If the calculated EPC period is more than a year, the capital costs expenditure will be spread out over the length of the EPC period. Total Raw Materials Cost The total raw material cost of the facility ex pressed in terms of cost per period. Total Products Sales The total product sales of the facility expressed in terms of cost per period. Total Operating and Maintenance Labor Cost The operating labor (including operators/shift and supervisors/shift) and maintenance labor costs in terms of cost per period. The maintenance cost includes maintenance labor and supplies. Total Utilities Cost The total utilities usage cost expressed in cost per period. Total Operating Cost The total of raw material, utility, operating labor, maintenance, operating charges, plant overhead and G and A expenses. Operating Labor Cost Includes operators per shift and supervisors per shift costs. Maintenance Cost Maintenance cost of the equipment including labor and materials. Operating Charges Includes operating supplies and laboratory charges. Plant Overhead Consists of charges during production for services, facilities, payroll overhead, and so on Subtotal Operating Cost Subtotal cost of raw materials, operating labor, utilities, maintenance, operating charges, and plant overhead. G and A Cost General and administrative costs incurred during production. This is calculated as a percentage of the Subtotal Operating Costs. The costs listed under Project Results Summary are broken down into individual elements under Project Capital Summary: Project Capital Summary Purchased Equipment The total material cost of process equipment and quoted equipment cost items. Material cost is accounted for in the codes of account 100 299. Equipment Setting The total construction labor cost for setting equipment in place. Piping Civil Steel Instrumentation Electrical Insulation 10 Evaluating the Project The cost reported for each of these items indicates the total material and construction labor cost calculated for the category. The above cost items may have originated from two sources: Installation Bulks (please refer to Icarus Reference). 659 Paint User: The user can add project components that create cost items in these categories. The project components may be in the following categories: Plant bulks, Site development and Buildings. Other This item is the total of the following costs: design, engineering, and procurement costs; material charges (freight and taxes); and construction field indirect costs (fringe benefits, burdens, consumables/small tools, insurance, equipment rental, field services, field office construction supervision, and plant start-up). Subcontracts The total cost of subcontracted work. This cost item is normally zero in Aspen Capital Cost Estimator. G and A Overheads General and administrative costs associated with engineering, materials, and construction work. Contract Fee The total cost of contract fees for engineering, material, construction, any subcontracted work. Escalation The total capital costs escalation amount. This cost item is normally zero in Aspen Capital Cost Estimator. Contingencies The additional costs required to bring this project to completion. In Aspen Capital Cost Estimator, this cost item is automatically calculated based on the project type and process complexity. Total Project Cost The total project capital cost of the plant calculated by the Icarus Capital Costs Engine as of the “System Cost Base Date”. Adjusted Total Capital Cost Indicates the Total Project Cost (described above) adjusted to the Start of Basic Engineering. The Total Project Cost is escalated (using the Project Capital Escalation Parameter) from the system Cost Base date to the start date of basic engineering. Raw Material Costs and Product Sales 660 Raw Materials Cost per Hour Total raw material usage cost per hour specified in the Raw Material Specifications file. Total Raw Materials Cost Total cost of raw materials per period. This number is generated by multiplying Raw Products Sales per Hour Total produced product sales expressed in cost per hour. Total Products Sales Total product sales per period. This number is generated by multiplying Products Sales per Hour by Operating Hours per Period. 10 Evaluating the Project Main Product Name The main product of the plant is considered to be the product which produces the largest sales figure per period. This field contains the description of the main product (assigned by the user). Main Product Rate The production rate of the main product. Main Product Unit Cost The unit cost rate of the main product. Main Product The production basis (or unit of measure) of Production Basis the main product (LB, GALLONS, and so on). Main Product Rate per Period The production rate of the main product per period . Main Product Sales The total sales figure of the main product per period. By-product Sales The total sales figure per period of the byproducts (that is,, products other than the main product of the plant). Operating Labor and Maintenance Costs Operating Labor Operators per Shift The number of operators per shift per hour necessary to operate the plant. Unit Cost The wage rate for each operator expressed in cost per operator per shift. Total Operating Labor Cost Total operating labor cost obtained by multiplying number of operators per shift by the unit cost and by Operating Hours per Period. Maintenance Cost/8000 Hours The cost of maintaining the facility equipment for 8000 hours of operation of the facility. Total Maintenance Cost The total maintenance cost of the facility per period. Supervision Supervisors per Shift The number of supervisors per shift per hour necessary to oversee personnel who operate the facility. Unit Cost The wage rate for each supervisor expressed in cost per supervisors per shift. Total Supervision Cost Total supervising labor cost obtained by multiplying number of supervisors per shift by the unit cost and by Operating Hours per Period. 10 Evaluating the Project 661 Utilities Costs The utility cost breakdown is given below for electricity, potable water, fuel and instrument air as well as user defined process utilities such as steam. The description of each utility includes: Rate The rate of use of the utility in terms of amount per hour. Unit Cost The unit cost of the utility in cost per amount. Total Cost The total cost of the utility in cost per period. Cashflow Cashflow (CASHFLOW.ICS) calculates the Net Present Value (NPV), Internal Rate of Return (IRR), Profitability Index (PI), payback period, and so on The spreadsheet displays the cashflow information shown by period. The beginning part of the spreadsheet contains data/results carried over from the Project Summary (PROJSUM.ICS) spreadsheet. Item 662 Description TW Number of Weeks per Period T Number of Periods for Analysis 10 Evaluating the Project DTEPC DT Duration of EPC Phase Duration of EPC Phase and Startup WORKP Working Capital Percentage OPCHG Operating Charges PLANTOVH Plant Overhead CAPT Total Project Cost RAWT Total Raw Material Cost PRODT Total Product Sales OPMT Total Operating Labor and Maintenance Cost UTILT Total Utilities Cost ROR Desired Rate of Return/Interest Rate AF ROR Annuity Factor TAXR IF Tax Rate ROR Interest Factor ECONLIFE Economic Life of Project SALVAL Salvage Value (Percent of Initial Capital Cost) DEPMETH Depreciation Method DEPMETHN Depreciation Method Id ESCAP Project Capital Escalation ESPROD Products Escalation ESRAW Raw Material Escalation ESLAB Operating and Maintenance Labor Escalation ESUT Utilities Escalation START Start Period for Plant Startup PODE Desired Payout Period (excluding EPC and Startup Phases). Reserved for future use. POD Desired Payout Period: Reserved for future use. DESRET Desired Return on Project for Sales Forecasting: Reserved for future use. END End Period for Economic Life of Project. GA G and A Expenses. DTEP 10 Evaluating the Project Duration of EP Phase before Start of Construction. 663 OP Total Operating Labor Cost. MT Total Maintenance Cost. Sales A number will appear in this category only after the time allotted for all prior phases (engineering, procurement, construction and startup phases) has expired. SP (Products Sales) The total products sales value per period calculated in PROJSUM.ICS. SPF Reserved for future use. (Forecasted Sales Annuity Factor) SF Reserved for future use. (Forecasted Sales) S (Total Sales) 664 Indicates the amount received per period from sold products. This number is either SP or SF. 10 Evaluating the Project Expenses Includes both capital and operating expenditures per period listed below. CAP (Capital Costs) Indicates, by period, total funds spent prior to startup. Unescalated Cumulative Capital Cost: Indicates the total capital costs spent through the current period. This is based on the Total Project Capital Cost in PROJSUM.ICS. Capital Cost: Indicates, by period, the amount of initial, non-variable costs associated with the project. This number is based on the Total Project Capital Cost found in PROJSUM.ICS. Cumulative Capital Cost: Indicates capital expenditures through period n. For example, the number in period 4 represents the total capital expenditures beginning in period 1 and ending in period 4. Working: Indicates the amount required to operate the facility before the revenue from product sales is sufficient to cover costs. Working Capital is a lump-sum amount which takes effect during the start-up period. It is escalated at rate equal to the Project Capital Escalation rate. OP Indicates, by period, the total (Operatingexpenditure on the following items Costs) necessary to keep the facility operating: Raw Materials, Operating Labor Cost, Maintenance Cost, Utilities, Operating Charges, Plant Overhead, Subtotal Operating Costs, and G and A Costs. This number is the Total Operating Cost imported from PROJSUM.ICS and entered in this field after capital expenditures cease. 10 Evaluating the Project 665 666 10 Evaluating the Project (R)Revenue Indicates, by period, the amount of money available after capital and operating expenses have been paid. This number is obtained by subtracting Capital Costs and Operating Costs from Sales. DEP Indicates the amount by which the value of the capital cost decreases each period. The Total Project Capital Cost is depreciated, via the chosen depreciation method, over the useful Economic Life of the facility. The Straight Line Method assumes that the item will depreciate by a constant amount over its Economic life. When the Sum of the Years Method is used, the depreciation expense decreases during each year of the project’s useful life. When the Double Declining Balance Method is used, the project is depreciated in geometric increments. The Accelerated Cost Recovery System assumes that the project begins operating in the second half of the first year, rather than in the beginning of the first year. E Indicates the funds available after all expenses have been paid. This number is obtained by subtracting the Depreciation and the Interest Expenses from the Revenue. TAX Indicates amount owed to the government. This number is obtained by multiplying the tax rate by Earnings Before Taxes. NE Indicates the funds available after taxes have been paid. This number is obtained by subtracting the Taxes from the Earnings Before Taxes. TED Indicates total cash available from project. This number is computed by adding the Depreciation Expense to the Net Earnings. Since the depreciation expense is a non-cash expense (no cash actually leaves the facility in order to pay the depreciation expense) adding the depreciation to the net earnings gives the total cash flow obtained from the project. Inclusion of the Depreciation Expenses reduces the amount of taxable income. TEX Specifies the total expenses of the project including capital, operating, and any interest expense. FVI Sums the Sales received through period n and indicates what the Sales would be if they had been received in the current period. For example, the value in period 4 is what the sales in periods 1-4 would have been if all of these funds had been received in period 4. 10 Evaluating the Project 667 PVI Indicates the current worth of all the cash received through period n. For example, the number in period 4 represents the value that the sales generated in periods 1 through 4 would be if those sales were received in the first period. This number is obtained by summing all of sales from prior time periods adding this amount to sales in the current time period. Using the specified interest rate, this total is then discounted back to the first time period. PVOS If the user enters a number for PODE, this number indicates the current worth of all of the cash paid through period n. PVOP Indicates the current worth of all of the cash paid through period n. For example, the number in period 4 represents the value that the expenses paid in periods 1 through 4 would be if those expenses were paid in the first period. This number is obtained by summing all of the outflows (Capital Costs, Operating Costs, Interest Expense) from prior time periods and adding this amount to the outflows in the current period. Using the specified interest rate, this total is then discounted back to the first time period . PVO Represents PVOS or PVOP depending on whether or not you entered a desired payout period. If you entered a desired payout period, the basis for the cash outflow calculation is the Forecasted Sales. Otherwise, the basis is Product Sales. PV Indicates the present worth of the Total Earnings received in the current period. For example, the number in period 4 represents the value that the Total Earnings generated in period 4 discounted back to the first time period. Final results are shown below: NPV Indicates the current worth of all the Net Earnings received through period n. For example, the number in period 4 represents the value that the Net Earnings generated in periods 1 through 4 if those earnings were received in the first period. This number is obtained by summing all of the Net Earnings from prior time periods and adding this amount to the Net Earnings in the current time period. Using the specified interest rate, this total is then discounted back to the first time period. The sign of this value determines the analysis result. If, in a certain period, the sign of the net present value is negative, then the proposed 668 10 Evaluating the Project investment appears not to be profitable, thus far. For example, if the sign of the net preset value is negative in period 3, then the project does not appear to be profitable during periods 1, 2, and 3. However, if the sign is positive, then the project appears to be profitable, from period 3 onward. If the net present value equals zero, then the project does not incur any losses or gains (breakeven point). IRR Is the rate at which the present value of all cash flows is zero. It is also known as the Discounted Cash-Flow Rate of Return. This value is calculated at the “End Period for Economic Life of Project” (that is,, “Economic Life of Project” and considering the length of EPC and Startup Period). At the “End Period for Economic Life of Project”, it is assumed the salvage value of the plant and the working capital are recouped. IRR is the after-tax interest rate at which the organization can borrow funds and break even at the end of the project life. MIRR Indicates the profitability of the project. The internal rate of return is the interest rate which equates the present value of a project’s expected cash inflows to the present value of the project’s expected costs (or outflows). The internal rate of return for each period is calculated by dividing the Present Value of Cumulative Inflows by the Present Value of Cumulative Outflows and raising this to a power and multiplied by 100. Two criteria are critical in evaluating the internal rate of return. First, if the sign of the rate of return is negative, the project appears not to be profitable. If the sign is positive, then the project appears to be profitable. If the rate of return equals zero then the project incurs no losses or gains (break-even point). In addition, if the rate of return is greater than the rate which could be obtained from other opportunities (that is,, investing in a bank), then the project probably should be undertaken. NRR Indicates the profitability of the project. The net rate of return for each period is calculated by dividing the Net Present Value by the Present Value of Cumulative Outflows and then multiplying the result by 100. PO Represents the expected number of years required to recover the original investment in the project. This row will indicate the length of time that the facility needs to operate in order to recover the initial capital investment (total capital cost plus working capital). If a number is entered for the Desired Payout Period, the spreadsheet will determine the amount of Sales necessary to meet this desired payout. 10 Evaluating the Project 669 ARR Measures a project’s contribution to the firm’s net income. This number is the ratio of the project’s Average Annual Expected Net Income to its Average Investment. For example, the Average Annual Expected Net Income for the fourth period is determined by summing net earnings from periods 1 through 4 and divided by 4. The Average Investment is determined by finding the Salvage Value, and adding this number to the Total Project Cost and dividing this total by 2. If the accounting rate of return is greater than one, then this is an indication that the project might be a profitable undertaking. If the sign is negative, then the project does not appear to be profitable. If this number equals zero then the project incurs no losses or gains (breakeven point). PI The profitability index shows the relative profitability of any project; it shows the present value of the benefits relative to the present value of the costs. For each period, this number is computed by dividing the Present Value of the Cumulative Cash Inflows by the Present Value of the Cumulative Cash Outflows. If the profitability index is greater than one, then the project appears to be profitable. If this index is less than one, then the project appears not to be profitable. If this number equals zero then the project incurs no losses or gains (break-even point). Analysis Analysis results are shown by period. “( - )” indicates the project in the current period appears unprofitable, while “0” indicates break-even status. Depreciation Calculations This section presents details on the calculation of depreciation. Executive Summary Executive Summary (EXECSUM.ICS) contains a project summary intended to be reviewed by executives and other business decision makers. 670 10 Evaluating the Project It contains the following information: PROJECT NAME Aspen Capital Cost Estimator project name CAPACITY Capacity of plant for major product PLANT LOCATION Location of plant BRIEF DESCRIPTION Brief description of project, from Project Properties SCHEDULE Start Date for Engineering The beginning date for EPC (engineering, procurement, and construction) Duration of EPC Phase The calculated EPC duration in weeks Completion Date for Construction The calendar date for the end of EPC Length of Start-up Period Number of weeks scheduled for start-up beyond the end of the EPC phase 10 Evaluating the Project 671 INVESTMENT Currency Conversion Conversion factor between userselected currency to the currency used by the system internally for the selected Country basis. For example, if the US country basis is selected, the internal system currency is US Dollars. Therefore, all numbers will be reported in US Dollars. However, if a currency conversion rate of 1.5 is specified, all internal values will be multiplied by 1.5 and then reported Total Project Capital The total capital cost investment needed for the project. If the calculated EPC period is more than a year, the capital costs expenditure will be spread out over the length of the EPC period Total The total of raw material, utility, Operating Cost operating labor, maintenance, operating charges, plant overhead and G and A expenses Total Raw Materials Cost The total raw material cost of the facility expressed in terms of cost per year Total Utilities Cost The total utilities usage cost expressed in terms of cost per year Total Product Sales The total product sales of the facility expressed in terms of cost per year Desired Rate of Return Desired rate of return expressed in terms of percent per year. PROJECT INFORMATION 672 10 Evaluating the Project Simulator Type The name of the process simulator from which process data was imported Version The version of the process simulator Report File The file name of the process simulator report file Report Date Date and time of the process simulator report file Economic Analysis Type The name of the Icarus system used for the evaluation Version Version number of the Icarus system. System Cost Base Date The capital costs basis date of the system. The Adjusted Total Project Cost represents the calculated capital cost of the project (calculated at this base date) escalated to the Start Date of Engineering. Project Directory Directory path for the current Aspen Capital Cost Estimator project Analysis Date Date investment analysis was run. Country basis Country basis for the capital costs/schedule analysis Project Type Project type identified in General Specs Design code Selected design code for equipment Prepared By Identifier for the preparer of the process evaluator 10 Evaluating the Project 673 Using the Reporting Assistant The Reporting Assistant feature lets you create your own customized report spreadsheets, combining information from all other Icarus generated spreadsheets. To develop a customized spreadsheet file and template: 1 On the Tools menu, click Options and then Reporting Assistant. The Reporting Assistant Options dialog box appears. 2 On the Report File tab view, click New. 3 In the Save As dialog box, type a name for the report file that will contain your customized spreadsheet. For example, type “Custom” as shown below. 674 10 Evaluating the Project 3 Click Save. 4 Switch to the Report Templates tab view. 5 In the Template Files section, click New. 6 In the Save As dialog box, type a name for the template file (for example, “summary”) and click Save. 10 Evaluating the Project 675 Note: This example creates a reporting template for future use called Summary.tra. 7 In the Template Entries section, click New Entry. In the Column Label field, enter a label (for example, “Project Name”) for the first column on your custom report spreadsheet. The Display Column box should automatically display “1”. 8 The Entry Definition section defines the data to be entered in the above column. Select a file name in the Source box, then enter the column and row of the source data. For example, in the figure below, the contents of Column C, Row 8 of Project.ics has been specified to appear in the customized report spreadsheet’s Project Name column. 676 10 Evaluating the Project 9 Follow the same procedure (steps 7 - 8) to add more entries. You can use a variety of sources. For example, adding the following entries will result in a report template that uses all three of the previously discussed .ics files as sources. Column Label Display Column Source Source Column Source Row Project Name 1 projsum.ics C 8 Start Date for Engineering 2 projsum.ics C 61 Tax Rate 3 projsum.ics C 112 Purchased Equipment Cost 4 projsum.ics C 172 Total Project Cost 5 cashflow.ics C 14 Total Maintenance Cost 6 cashflow.ics C 40 Completion Date for Construction 7 execsum.ics B 17 10When all the template entries are added, return to the Report File tab view. To the right of the Template File field, click Browse. 11Select the newly created template file (for example, Summary.tra) and click Open. 12Click OK to exit the Reporting Assistant Options dialog box. Generating the Custom Report To generate a report developed in Reporting Assistant: 1 Run a project evaluation. 2 On the Run menu, click Add Entry for Reporting Assistant. Aspen Capital Cost Estimator generates the report based upon the template created in the Reporting Assistant. The data that was entered under List of Entries on the Reporting Assistant Options dialog box appears as columns in the spreadsheet. 10 Evaluating the Project 677 Every time Add Entry for Reporting Assistant is selected, the latest data is entered on the bottom row of the report. This way, you can compare results. Item Evaluation Aspen Capital Cost Estimator lets you run an evaluation on a single component and view an Item Report. The type of Item Report displayed can be selected in Preferences (see page 59). X X To run an item evaluation and display the Item Report: 1 Right-click on the component in either Project Explorer or the List view, and then click Evaluate Item on the pop-up menu. Aspen Capital Cost Estimator runs the item evaluation. 2 Right-click on the component and click Item Report on the pop-up menu. You can also click the Evaluate button on the Component Specifications form to run the item evaluation and display the Item Report. Aspen Capital Cost Estimator displays the Item Report in the Main Window. 678 10 Evaluating the Project Note: If the evaluation has already been run, you only have to select Item Report. You can include multiple components in the Item Report: on the List view (area level), select the desired components, right-click on one of the components, and click Item Report on the pop-up window. The resulting Item Report lists individually the summary data (cost or sizing) for each selected component. Automatic Item Evaluation You can have Aspen Capital Cost Estimator automatically run an item evaluation whenever you click OK or Apply on a Component Specifications form. To turn automatic item evaluation on and off: 1 On the Tools menu, point to Options. 2 On the Options sub-menu, a check appears next to Automatic Item Evaluation when the feature is turned on. Clicking Automatic Item Evaluation turns the feature on and off. 10 Evaluating the Project 679 680 10 Evaluating the Project Sample Item Report The following Item Report is for a floating head shell and tube heat exchanger with “Example” as its item description 10 Evaluating the Project 681 Sample Item Report (continued) 682 10 Evaluating the Project 11 Introducing IPS ICARUS Project Scheduler (IPS) is the intelligent scheduling interface between Aspen Capital Cost Estimatorand Primavera Enterprise Project Manager (P3E). IPS creates complete P3E project networks, including all of the activities, resources, and durations that represent the engineering and construction work contained in your Aspen Capital Cost Estimatorproject estimate. IPS provides three types of networks, AREA, ITEM and FULL. AREA - Summary activity for all similar components per area IPS will generate a concise, easy-to-manipulate, summary bar chart schedule with a detailed overview of the engineering, procurement and a summary overview of construction phases of the project. ITEM - One summary activity per major code of accounts (COA) for each component IPS will generate a concise, easy-to-manipulate, summary bar chart schedule similar to AREA type except in the construction phase it will generate one summary activity per major COA for each component in an area. FULL - Detailed list of activities for each component IPS will generate a detailed overview of engineering, procurement, and detailed installation tasks in each bulk account (piping, steel, civil etc.) for each project component. Depending on your need, IPS can present you with a P3E project showing summary tasks to more detailed construction installation tasks. The network developed from IPS contains many chains of activities and adapts them dynamically to the scope of your Aspen Capital Cost Estimator project. Relationships are re-evaluated based on actual tasks to be performed as identified in the estimate. You can also make any 11 Introducing IPS 683 desired modifications to condense or delete activities, add or delete relationships to activities, and/or change durations for activities using options in the IPS Project Schedule Settings. IPS will jump-start your effort by providing your planning staff with the opportunity to benefit from engineering knowledge and project scope data previously validated by the Aspen Capital Cost Estimatorestimate. Additional benefits can be derived by configuring the estimators’ data to include the planner’s recommendations for duration adjustments, delivery times, and parallel work areas. 684 11 Introducing IPS 12 Getting Started With IPS Installing Icarus Project Scheduler (IPS) The Icarus Project Scheduler (IPS) product requires successful installation of a number of Primavera products in order to function. Although the Primavera documentation provides all the necessary information for installation, the information is distributed over various unrelated documents, and, often, not readily available. A brief summary is presented here to summarize the essential requirements for the Aspen IPS product to function. This is not intended to replace the Primavera documentation, and the sole purpose of providing this summary information is to provide Aspen Capital Cost Estimator/IPS users with a checklist of installation requirements. For further details, consult the appropriate Primavera documentation. Installation Steps and Sequence Primavera Project Management (P3E) stores scheduling data into the SQL Server/Oracle database (default database name is PMDB). A successful installation of P3E and Integration API would require the following steps in order: 1. Install database and load application data The latest version of Primavera Project Management (version 6.0 and above) software includes SQL Server Express 2005. This can be installed by running setup.exe in the SQLSERVER directory. It can also be installed by selecting Primavera-Standalone option when prompted during installation step (see step 2 below). Selecting this option also installs client applications, an empty database and sample data (optional). 12 Getting Started With IPS 685 If you already have the database server installed, you can use the P3E database wizard for creating a new database structure and loading the application data into the database. You can run the Database wizard to create a new database from a client computer that has the Microsoft SQL Server client or Oracle installed or Primavera Project Manager client application (version 4.0 and above), or you can run the wizard from the server itself. The Database wizard creates any necessary file structures and users for you. The project manager database (PMDB) stores the project manager data used by Primavera Enterprise. Installation of the database is required. This wizard can be run by executing dbsetup.bat file (located in the install\database directory) in Primavera Project Management Application Version 6.0 and above. Use ConfigAsst.exe (located in the install\database directory) to invoke the database wizard for version prior to Primavera Project Management Application Version 6. 686 12 Getting Started With IPS 2. Install the Primavera Project Manager Enterprise Client Application and configure database After installing the Primavera database in step 1, install the Primavera Project Manager Enterprise Client application, by running the Setup wizard. The application requires approximately 23 MB of disk space. Administrator rights are required to install the Primavera client application. Selecting the Custom option when prompted lets you install Project Management and Job service. On the Configure SQL Server Connection dialog box or the Configure Oracle Connection dialog box, enter the database connection settings. If you are configuring Microsoft SQL Server or SQL Server Express, type the database host name and database name. The database name was specified when the database was created; for example, PMDB. The host name is the name of the computer or IP address where Microsoft SQL Server is installed. If you are configuring Oracle, type the Oracle database name. 12 Getting Started With IPS 687 The screenshot below shows an example for configuring database connection for SQL Server. Where, Host Name: P3E\PRIMAVERA P3E: System name where SQL Server is running PRIMAVERA: SQL Server instance name. Database name: PMDB$PRIMAVERA PMDB: Name of the database created during step 1 on PRIMAVERA SQL Server. 3. Install the Primavera Job Service If the Primavera Job Service component is not installed in step 2, install it by running the setup wizard again. The Primavera Job Service lets you configure scheduling, summarizing, exporting, and applying actual operations to run in the background. The Primavera Job Service runs as a Windows NT/2000 service and can support an unlimited number of jobs, each with its own schedule of execution. Jobs are defined in Project Manager and stored in the enterprise’s project manager database. If you are working with more than one project manager database, you can run jobs for all of the databases from one Windows NT/2000 server. If you do not 688 12 Getting Started With IPS have a Windows NT or 2000 service, you will not have the project scheduled after loading from the IPS software. Then, you must manually use the Tools | Options | Preferences | Schedule menu in the Project Manager application. 4. Configure Primavera Project Management Application Have the Primavera administrator configure the licenses to allow access to both the Primavera Project manager and the integration API. The Primavera enterprise user licensing can be modified using the Admin | Users menu item in Primavera Project Management application. Corresponding licenses should also be available. Follow the steps below to configure Primavera Project Management to use Primavera Integration API: 1. Open and login to Primavera Project Management application. 2. Click the Admin | Users top level menu item 3. Select Integration API. 5. Know your SQL Server database port 12 Getting Started With IPS 689 The SQL Server database host port is required while configuring Primavera Integration API. To identify Database Host Port perform following steps 1. Open and login to Primavera Project Management application. 2. Click Help | About Primavera. 3. The System tab in the About Primavera dialog displays username, database name, SQL Server name, SQL Server Database Host Port. For example, 1153 is the Database Host port as shown below 6 Install the Java Runtime Environment or Java Development Kit A copy of JRE (Java Runtime Environment) is included in the install\database directory. JRE or JDK (Java Development Kit) can also be downloaded from the Sun Microsystems Web site. If you are using the Java SDK, ensure that it is installed before running the Integration API setup. It is essential that the JDK be installed in a directory that does not have spaces in its name. Presumably this limitation will be removed shortly. During installation of Java Integration API, a suitable Java Virtual Machine (JVM) needs to be specified by selecting its java.exe file from the java installation (bin) directory. 7 Install the Integration API 690 12 Getting Started With IPS Go to the root folder of the Integration API Installation CDROM; double click setup.exe. Specify the installation mode to be Local Mode, using it without the Java RMI. Specify the database type to be the same as what you installed earlier. Specify the database connection parameters. The first time you install the Integration API, choose Create a new configuration. This is necessary to support the addition of new configuration settings for the release. Use the database configuration wizard to configure the Integration API license. Where, Default User Name: pubuser Default Password: pubuser Database Name: Same as in step 2 above Database Host Address: Same as in step 2 above Database Host Address: From step 5 above. 8 Configure User, Password and API location in the Aspen Capital Cost Estimator/IPS Application. After successful installation of the P3E enterprise client and the Integration API, it is necessary to provide information regarding the P3E user name, password, and the location of installation of the Integration 12 Getting Started With IPS 691 API in the client machine (since IPS only supports local mode installation of the API). All three data may be added to the IPS through the use of Tools | Options | Preferences | Schedule menu, or changed inside a project by adding to the Primavera Project information tab in the Project basis tab of the IPS and Aspen Capital Cost Estimator products. 692 12 Getting Started With IPS System Requirements for the Integration API The Primavera Integration API has the following system requirements for local mode installation:    Java Runtime Environment JRE 1.4 or higher (developers will require Java SDK 1.4 or higher, which includes the JRE) You can download the JRE or Java SDK from the Sun Microsystems Web site. If you are using the Java SDK, ensure that it is installed before running the Integration API setup. Install it in a directory without blanks in the names. Operating Systems The Primavera Integration API is fully supported on Windows operating systems. Project Manager Database Primavera version 4.0 or higher, and a Project Manager database (Oracle, and SQL Server are supported) are required. Either a SQL Server or Oracle client must be installed on the machine or, alternately you can install the database from the server machine. Primavera Enterprise Client and Server Requirements   Supported Platforms for Primavera Enterprise Client Applications o Microsoft Windows 98 Second Edition o Microsoft Windows NT 4.0 (SP6a recommended) o Microsoft Windows 2000, (SP1, SP2) o Microsoft Windows XP o Microsoft Windows Vista, 7.0 (32-bit) Minimum Client Configurations For clients running Project Manager: o 128 MB of RAM, 256 MB free recommended o 40 MB of hard-disk space (per application) o Microsoft Internet Explorer 5.0.1 o Netscape Communicator 4.75 o TCP/IP network protocol 12 Getting Started With IPS 693 Starting Icarus Project Scheduler After completing the installation, you can start IPS. To start IPS: 1 Click the Windows Start button. 2 Point to Programs and then to AspenTech. 3 Point to Aspen Engineering Suite and then to Economic Evaluation V7.3. On the Economic Evaluation V7.3 menu, click Aspen Icarus Project Scheduler 2006.5. IPS starts. The Main Window, empty because no project is open, appears on the left. The Palette appears in the upper-right and the Properties Window appears in the lower-right. 694 12 Getting Started With IPS Note: You can change the position of the Main Window, Palette, and Properties Window, as explained under Customizing the Interface Arrangement on page 46. X X Starting a Project Scenario Note: Viewing the sample project scenario provided with IPS before creating a new one will allow you to familiarize yourself with IPS without having to fill out specifications. To open the sample project, follow the instructions under “Opening an Existing Project Scenario”. Creating a New Project Scenario To create a new project scenario: 1 On the File menu, click New. –or– Click 2 on the toolbar. Select a Aspen Capital Cost Estimator project as a basis for a new IPS project from the dialog box. 12 Getting Started With IPS 695 3 In order to schedule a project in IPS, it is necessary to have a developed and evaluated Aspen Capital Cost Estimator Project scenario available. If you do not have an Aspen Capital Cost Estimatorproject scenario available, use Aspen Capital Cost Estimatorto develop and evaluate a full project. (Without a pre-existing, evaluated Aspen Capital Cost Estimator project, it is not possible to schedule using IPS.) Select an existing Aspen Capital Cost Estimator project and scenario, and click OK, a Create New Project dialog box appears. Enter a new project name,long filenames are accepted, including spaces. However, punctuation marks, such as question marks (?), exclamation points (!), tildes (~), and asterisks (*), are not allowed. 4 Enter the Scenario Name. This is the name of the scenario within the project. As with the Project Name, long filenames are accepted, including spaces, while punctuation marks, such as question marks (?), 696 12 Getting Started With IPS exclamation points (!), tildes (~), and asterisks (*) are not allowed. If you do not enter a Scenario Name, IPS uses “BaseCase” as the default. 5 Click OK. The Project Properties dialog box appears. 6 Enter a Project Description. The description can be up to 500 characters in length and can be comprised of letters, numbers, and punctuation. You can enter or revise the description later on the Project Properties form accessed from the Project Basis view (). Opening an Existing Project Scenario To open an existing project scenario: 12 Getting Started With IPS 697 1 On the File menu, click Open. –or– Click on the toolbar. The Open Existing Project dialog box appears. 2 Click the project scenario you want to open; then click OK. Creating a Primavera Schedule For both IPS and Aspen Capital Cost Estimator/IPS, the primary step towards scheduling a project involves clicking the Run | Project Scheduler button as shown below. Upon completion of loading the Aspen scheduling engine results into the Primavera database, the P3E (or P3E/C for Construction) interface is launched automatically. You must enter the password as shown in the next figure. 698 12 Getting Started With IPS Upon entering the password, the primavera project manager screen “Select Project Portfolio” appears. Select the “Open Existing Project” button and choose the appropriate project from the P3E project list. (IPS creates P3E projects with titles specified in the Project Basis View using the IPS project schedule settings ->Schedule Appearance Adjustments -> Title form). This brings up the Project Manager “Home” screen where the user may select the activities button in the left hand pane to arrive at a schedule layout as shown in the subsequent page. 12 Getting Started With IPS 699 700 12 Getting Started With IPS 12 Getting Started With IPS 701 Navigating the Schedule in P3E It is possible to view the predecessors, successors, resources, and activity codes under the activity layout using the Show/Hide Bottom Layout icon on the P3E activity pane. A number of example layouts are provided in the AspenTech\ Economic Evaluation V7.3\Program\Schedule folder; these can be imported by pressing the Layout dropdown button in the activities screen. These layouts are named Aspen Icarus ---.plf. In a similar manner, a number of standard reports have been created and placed in the AspenTech\Economic Evaluation V7.3\Program\Reports directory. These reports (.ERP files) may be imported into P3E using the Tools | Reports | Reports menu function on the P3E activities screen. Once the P3E Reports screen appears, right click on the Report Name button to locate and import the desired report. These reports can be run using the P3E database. Developing Schedule Basis Libraries Development of the Icarus Project Scheduler settings input is not a trivial task. To facilitate reuse of prepared input models, you can use the library option. Outside a project, it is possible to create a “Project Scheduler” library. As shown below, use the Library tab to create different prepared input models. 702 12 Getting Started With IPS Selecting a Project Scheduler Library, brings up the IPS input tree structure, which can be edited with the input forms described earlier. Right-clicking on the Default file allows editing and/or duplication into user customized library files. Selecting a Schedule Basis inside a Project After an IPS basis is created, it can be used inside a project to load company specific data. Inside a project, right-clicking on the IPS project schedule settings brings up a list of IPS basis files that have been created. Selecting the appropriate basis file will lead to the reuse of previously generated IPS input data. Use of a standardized IPS basis, which can be company-specific, will lead to rapid schedule generation. 12 Getting Started With IPS 703 Understanding the Icarus Interface The Icarus interface lets you see multiple windows and documents. You can customize the interface arrangement. Refer to Getting Started in Aspen Capital Cost Estimator User Guide for details. 704 12 Getting Started With IPS 13 IPS Project Schedule Settings IPS Project Schedule Settings Note: IPS Project Schedule Settings are only included in Aspen Capital Cost Estimator if you are licensed to use Aspen Icarus Project Scheduler (IPS). You need to create a Aspen Capital Cost Estimator project with Project Execution Schedule Settings and Evaluate the project in Aspen Capital Cost Estimator before you can open the project in the IPS user interface. If you are licensed to use Aspen Icarus Project Scheduler (IPS) and selected to use IPS in the Aspen Capital Cost Estimator environment at startup or start the IPS product separately, the IPS Project Schedule Settings folder is included in the Project Explorer’s Basis view. The Project Schedule Settings discussed in this section lets you make adjustments to the Primavera Enterprise schedules produced by Aspen Capital Cost Estimator. 13 IPS Project Schedule Settings 705 Changes made to the IPS Project Schedule Settings will be reflected in the scheduling reports generated for display in Primavera. The following are descriptions of the settings. Schedule Appearance Adjustments Title To enter a project schedule title to replace the systemgenerated title: 1 Double-click Title (or Right-click and click Edit on the pop-up menu ). 2 Enter a title, up to 60 characters. 706 13 IPS Project Schedule Settings 3 Click Apply. Note: Regardless of the IPS Project/Scenario Name, any title entries made here will become, by default, the P3E project name. Description Modification - Engineering To modify an engineering activity description: 1 Double-click on Engineering (or Right-click and click Edit on the pop-up menu). If you have not previously entered a description modification, there should be one blank column (Item 1). If it has already been filled-in, click Add to add a new column in which to enter a modification. 2 Select an activity or group of activities for which the description modification is to be made. This is done by specifying all or part of the Activity Number. The parts of the Activity Number are broken up into the fields under ACTIVITY NUMBER. Activity Numbers are listed in Appendix A have 10 characters. If you want to modify a group of activities, you can enter “wildcard” asterisks in some fields. At least one of the fields (besides the two preset fields) must contain numbers. Note: See Appendix A for a list of Activity Numbers. 13 IPS Project Schedule Settings 707    Exception: where applicable, the seventh and ninth characters of the Activity Number indicate the process equipment class (01-26). Equipment classes are defined in Appendix C.   Preset engineering field 1 The first three characters of the Activity Number are fixed and the same for all activities. They are always “000”. Engineering phase The fourth character of the Activity Number indicates the major engineering phase: 0 – Basic engineering phase 1 – Detail engineering phase 2 – Procurement phase To select all phases, enter an asterisk (*). Engineering contractor number The fifth and sixth characters of the Activity Number indicate the engineering contract number. For fixed project-level activities, these characters will be “00”. The engineering contract number is determined based on your specifications for contractors under Basis for Capital Costs in the Project Basis (see ). It must be a number between 01 and 40. If all engineering contractor numbers are to be selected, enter two asterisks (**).  Account group number The seventh character of the Activity Number indicates the account group number. It is derived from the first character of the Code of Accounts. 0, 1, 2 – Equipment or general 3– Piping 4– Civil 5 – Steelwork 6 – Instrumentation 7 – Electrical 8 – Insulation 9– Painting If all account groups are to be selected for modification, enter one asterisk (*). Preset engineering field 2 The eighth character of the Activity Number is fixed and the same for all activities. It is always “0”. Sequence in account group number The ninth and tenth numbers provide sequential grouping within the major hierarchy of the first eight characters. If all numbers within a sequence group are to be selected, enter two asterisks (**). Note: where applicable, the seventh and ninth characters of the Activity Number indicate the process equipment class (0126). Equipment classes are defined in Appendix C. 708 13 IPS Project Schedule Settings 3 In the Description and tag mod. Option field, select whether to modify both the description and the tag (default), only the description, or only the tag. 4 If you are modifying the activity description, enter the new description in the Engg. activity description field (up to 32 characters). 5 If you are modifying the tag, enter the new tag in the Tag field (up to 12 characters). It will be used in place of the tag (if any) provided by the system. The tag may be used as a continuation of the description. 6 To modify another activity description, click Add. A new column will appear. Repeat the process for the other activity description. 7 Click Apply/Ok when done to commit the changes. Click Cancel to close the form without committing the changes. Description Modification – Construction To modify a construction activity description: 1 Double-click on Construction (or Right-click and click Edit on the pop-up menu). If you have not previously entered a description modification, there should be one blank item column (Item 1). If it has already been filled-in, click Add to add a new item column in which to enter a modification. 13 IPS Project Schedule Settings 709 2 Select an activity or group of activities for which the description modification is to be made. This is done by specifying all or part of the Activity Number. See page Appendix D for the Equipment Code definitions. The construction activities are listed in Appendix B, by the last three characters of the Activity Number. These last three characters form the account group number and account code. The Activity Number is broken up into the fields under ACTIVITY NUMBER. Construction Activity Numbers are listed in Appendix B have 12 characters. If you want to modify a group of activities, you can enter “wildcard” asterisks in some fields. However, at least one of the fields must contain numbers.  Area number The first and second characters of the Activity Number indicate the Area number, 01 through 90, or other project-level items, such as substations, control panel and power transmission lines, which always use 91. If activities from all Areas are to be selected, enter two asterisks (**).  Identification number The third through fifth characters contain the user-specified reference number from the specifications form for equipment items and plant bulks. For substations, the fourth and fifth characters contain the substation reference number (01-99) specified by the user or, if not specified, the System default reference number of 00. If all reference numbers are to be selected, enter three asterisks (***).  Equipment type The sixth and seventh characters contain the Equipment Code. See Appendix D for Equipment Code definitions. All other activities have a fixed identifier in positions six and seven of the activity number, as listed in Activity Numbering Conventions table in Appendix B. Enter two asterisks (**) if all Equipment Type numbers are to be selected.  Account group number The eighth character, the account group number, refers to the type of work performed in the activity. The account group number combined with the account code (in the field below), form the three-character code by which the construction and site development activities are listed in Appendix B. If all account group numbers are to be selected, enter an asterisk (*).  Account code Enter the ninth and tenth digits of the Activity Code for the activities to be selected for modification (that is,, excluding the first character, which is the Account Group number, above). If all Activity Codes are to be selected, enter two asterisks (**).  Contractor number The eleventh and twelth characters are the contractor numbers. If all contractors are to be selected, enter two asterisks (**). 3 In the Description and tag mod. Option field, select whether to modify both the description and the tag (default), only the description, or only the tag. 710 13 IPS Project Schedule Settings 4 If you are modifying the activity description, enter the new description in the Constr. activity description field (up to 32 characters). 5 If you are modifying the tag, enter the new tag in the Tag field (up to 12 characters). It will be used in place of the tag (if any) provided by the system. The tag may be used as a continuation of the description. 6 To modify another activity description, click Add. A new column will appear. Repeat the process for the other activity description. 7 Click Apply/Ok when done to commit the changes. Click Cancel to close the form without committing the changes. Schedule Adjustments by Duration The activity duration and construction crew size are interrelated, such that an adjustment to the duration will cause an inversely proportional adjustment to the activity crew size, and vice versa. You may specify either a duration adjustment, a maximum crew size, a minimum crew size, or all three. If a conflict occurs, the crew size adjustment will override the duration adjustment. If not adjusted, durations are calculated for each activity based on the type of activity and associated direct construction man-hours. Crew Size You can adjust the system activity durations by entering minimum/maximum crew sizes for various construction activities within each account group. To adjust crew size: 1 Double-click on Crew Size (or Right-click and click Edit on the pop-up menu). 13 IPS Project Schedule Settings 711 2 Specify minimum and maximum crew sizes for each construction crew type. 3 Click Apply/Ok when done to commit the changes. Click Cancel to close the form without committing the changes. Crafts The Craft Adjustments form lets you modify the system-defined crafts. The craft code and craft description may be completely replaced by a user-defined code and description. In addition, the maximum craft pool sizes may be modified as required. Modifying the craft pool sizes will affect the activity durations and the overall job durations. To adjust a craft: 1 Double-click on Crafts (or Right-click and click Edit on the pop-up menu). 2 Select the craft to be adjusted by entering the System craft code. See Icarus Reference, Chapter 30, for lists of craft codes by Country Base. 712 13 IPS Project Schedule Settings 3 Enter a numeric (01-99) User craft code to substitute for the preceding System craft code. Note: If you specify a craft code already in use (that is,, a system craft code or a previously added user craft code), Aspen Capital Cost Estimator will combine all pool sizes and resource requirements for the specified craft code and the existing code. 4 Enter a description for the craft in the User craft description field, up to 20 characters. 5 Enter the number of men in the user craft pool or enter an adjustment relative to the system craft pool size. The system craft pool size is calculated based on the system craft man-hours and schedule duration. 6 Enter a 4-character user craft symbol. If nothing is entered, the system craft symbol is used. 7 To enter another adjustment, click Add. This adds another column where you can repeat the process. 8 Click Apply/Ok when done to commit the changes. Click Cancel to close the form without committing the changes. Durations The engineering, construction, and procurement duration forms can be used to adjust durations by percentage. Engineering   Engineering Duration Adjustments You may enter a percentage adjustment to the durations calculated by the system for Basic Engineering, Detail Engineering, and/or Procurement. Client Review Period (Future Implementation) 13 IPS Project Schedule Settings 713 You can use the Basic engineering review period field to set the duration of Activity 0000003013, “CLIENT APPROVALESTIM&SCHED”. Since all Detail Engineering activities are preceded, directly or indirectly, by this activity, you may impose a delay of any duration on the continuation of engineering activity. This effectively breaks up the work flow to simulate, for example, budget approval delay. Construction You may enter a percentage adjustment to the durations calculated by the system for nine different construction activities. Any change in activity duration will cause a corresponding change in activity resource (crew). 714 13 IPS Project Schedule Settings Procurement For each equipment group, you may enter the number of weeks needed to fabricate and ship the equipment to the site after vendor data approval. If you make no adjustment, Aspen Capital Cost Estimator uses the following durations: Equipment Group Duration Vessels 24 weeks Towers 36 weeks Storage Tanks 32 weeks Pumps 22 weeks Compressors 50 weeks Turbines 50 weeks Heat Exchangers 32 weeks Boilers 55 weeks Furnaces 40 weeks Air Coolers 28 weeks Package Refrigeration 44 weeks Generators 26 weeks Air Dryers 24 weeks Conveyors 28 weeks Mills 45 weeks Fans 16 weeks Elevators 26 weeks Motors 16 weeks 13 IPS Project Schedule Settings 715 Dust Collectors 30 weeks Filters 16 weeks Centrifuges 40 weeks Mixers 16 weeks Cooling Towers 32 weeks Miscellaneous Equipment 26 weeks Package Items 36 weeks Packings and Linings 20 weeks Schedule Adjustments by Activity and Logic Logic Modification Aspen Capital Cost Estimator provides sequencing logic, varying with the activities present, for all engineering and construction activities, except the following:  Where logical relationships cannot be predicted for system-designed activities, such as project site development.  Where logical relationships cannot be predicted because the activity is user-specified.  Where a logical chain of activites has been substantially broken by deletion of activities. The Logic Modification forms provide the means to either add relationships between successor and predecessor activities not provided by the Aspen Capital Cost Estimator logic or to modify the Aspen Capital Cost Estimator logic by adding and deleting relationships. Separate forms are provided for engineering and construction sections of the network. When adding relationships, a particular relationship type may be specified. However, when deleting relationships, all relationships between the specified activities are deleted, regardless of relationship type. For engineering activities, only engineering predecessors are allowed. For construction activities, engineering and construction predecessors are allowed. 716 13 IPS Project Schedule Settings To add or delete an engineering relationship: 1 Double-click on Engineering (or right-click and click Edit on the pop-up menu) to display the Logic Modification form for engineering. 2 In the Add/delete logic option field, select + or – to indicate whether you are adding or deleting a relationship. 3 Select a successor activity, or group of activities, for which logic modifications are to be made. This is done by specifying all or part of the Activity Number. See Appendix A for a list of Activity Numbers. The parts of the Activity Number are broken up into the fields under SUCCESSOR ACTIVITY. Activity Numbers, which are listed in Appendix A, have 10 characters. If you want to modify a group of activities, you can enter “wildcard” asterisks in some fields. At least one of the fields (besides the two preset fields) must contain numbers.  Preset engineering field 1 The first three characters of the Activity Number are fixed and the same for all activities. They are always “000”.  Engineering phase The fourth character of the Activity Number indicates the major engineering phase: 0 – Basic engineering phase 13 IPS Project Schedule Settings 717 Exception: where applicable, the seventh and ninth characters of the Activity Number indicate the process equipment class (01-26). Equipment classes are defined in Appendix C. 4 5 1 – Detail engineering phase 2 – Procurement phase To select all phases, enter an asterisk (*). - Engineering contractor number The fifth and sixth characters of the Activity Number indicate the engineering contract number. For fixed project-level activities, these characters will be “00”. The engineering contract number is determined based on your specifications for contractors under Basis for Capital Costs in the Project Basis (refer to the Aspen Capital Cost Estimator User Guide for further information). It must be a number between 01 and 40. If all engineering contractor numbers are to be selected, enter two asterisks (**).  Account group number The seventh character of the Activity Number indicates the account group number. It is derived from the first character of the Code of Accounts. 0, 1, 2 – Equipment or general 3– Piping 4– Civil 5 – Steelwork 6 – Instrumentation 7 – Electrical 8 – Insulation 9– Painting If all account groups are to be selected for modification, enter one asterisk (*).  Preset engineering field 2 The eighth character of the Activity Number is fixed and the same for all activities. It is always “0”.  Sequence in account group number The ninth and tenth numbers provide sequential grouping within the major hierarchy of the first eight characters. If all numbers within a sequence group are to be selected, enter two asterisks (**). Note: where applicable, the seventh and ninth characters of the Activity Number indicate the process equipment class (01-26). Equipment classes are defined in Appendix C. Select an activity, or group of activities, to be added or deleted as predecessor(s) to the specified Successor. Use the fields under PREDESSOR – ENGG. ACTIVITY to select an activity the same way you selected a successor activity. In the Relationship type field, select the specific type of logical sequence to use when adding relationships: A – Finish-to-Start (default) 718 13 IPS Project Schedule Settings S – Start-to-Start F – Finish-to-Finish Finish-to-Start (A) and Start-to-Start (S) relationships use the Predecessor’s work week to calculate calendar lag between activities. Finish-to-Finish (F) relationships use the successor’s work week. The Relationship Type field is not used by the system when deleting relationships; all relationships between the specified activities will be deleted, regardless of relationship type. 6 7 8 Enter the Lag time, in whole working days, associated with the relationship type to be added. The default is 0 days. Click Apply. To add or delete another relationship, click Add and repeat the process. To add or delete a construction relationship: Note: Enter either an engineering or a construction predecessor, not both. 1 Right-click on Construction and click Edit on the pop-up menu. 13 IPS Project Schedule Settings 719 2 3 In the Add/delete logic option field, select + or – to indicate whether you are adding or deleting a relationship. Select a successor construction activity, or group of activities, for which logic modifications are to be made. This is done by specifying all or part of the Activity Number. The Activity Number is broken up into the fields under SUCCESSOR ACTIVITY. Construction Activity Numbers, which are listed in Appendix B, have 12 characters. If you want to modify a group of activities, you can enter “wildcard” asterisks in some fields. However, at least one of the fields must contain numbers.  Area number 720 13 IPS Project Schedule Settings See Appendix D for the Equipment Code definitions. The construction activities are listed in Appendix B by the last three characters of the Activity Number. These last three characters form the account group number and account code. 4 The first and second characters of the Activity Number indicate the Area number, 01 through 90, or other project-level items, such as substations, control panel and power transmission lines, which always use 91. If activities from all Areas are to be selected, enter two asterisks (**).  Identification number The third through fifth characters contain the user-specified reference number from the specifications form for equipment items and plant bulks. For substations, the fourth and fifth characters contain the substation reference number (01-99) specified by the user or, if not specified, the System default reference number of 00. If all reference numbers are to be selected, enter three asterisks (***).  Equipment type The sixth and seventh characters contain the Equipment Code. See Appendix D for Equipment Code definitions. All other activities have a fixed identifier in positions six and seven of the activity number, as listed in Activity Numbering Conventions table in Appendix B. Enter two asterisks (**) if all Equipment Type numbers are to be selected.  Account group number The eighth character, the account group number, refers to the type of work performed in the activity. The account group number combined with the account code (in the field below), form the three-character code by which the construction and site development activities are listed in Appendix B. If all account group numbers are to be selected, enter an asterisk (*).  Account code Enter the ninth and tenth characters of the Activity Code for the activities to be selected for modification (that is,, excluding the first character, which is the Account Group number, above). If all Activity Codes are to be selected, enter two asterisks (**).  Contractor number The eleventh and twelfth characters are the contractor numbers. If all contractors are to be selected, enter two asterisks (**). You can select either an engineering or a construction activity, or group of activities, to be added or deleted as predecessor(s) to the specified Successor. This is done by entering all or part of an engineering or construction Activity Number. To specify an engineering activity, enter all or part of an engineering Activity Number in the fields under PREDESSOR – ENGG. ACTIVITY. Engineering Activity Numbers, which are listed in Appendix A, have 10 characters. If you want to modify a group of activities, you can enter “wildcard” asterisks in some fields. At least one of the fields (besides the two preset fields) must contain numbers. 13 IPS Project Schedule Settings 721 See Appendixes A and B for lists of Engineering and Construction Activity Numbers. Exception: where applicable, the seventh and ninth characters of the Activity Number indicate the process equipment class (01-26). Equipment classes are defined in Appendix C.  Preset engineering field 1 The first three characters of the Activity Number are fixed and the same for all activities. They are always “000”.  Engineering phase The fourth character of the Activity Number indicates the major engineering phase: 0 – Basic engineering phase 1 – Detail engineering phase 2 – Procurement phase To select all phases, enter an asterisk (*).  Engineering contractor number The fifth and sixth characters of the Activity Number indicate the engineering contract number. For fixed project-level activities, these characters will be “00”. The engineering contract number is determined based on your specifications for contractors under Basis for Capital Costs in the Project Basis (see page 141). It must be a number between 01 and 40. If all engineering contractor numbers are to be selected, enter two asterisks (**).  Account group number The seventh character of the Activity Number indicates the account group number. It is derived from the first character of the Code of Accounts. 0, 1, 2 – Equipment or general 3– Piping 4– Civil 5 – Steelwork 6 – Instrumentation 7 – Electrical 8 – Insulation 9 – Painting If all account groups are to be selected for modification, enter one asterisk (*).  Preset engineering field 2 The eighth character of the Activity Number is fixed and the same for all activities. It is always “0”.  Sequence in account group number The ninth and tenth numbers provide sequential grouping within the major hierarchy of the first eight characters. If all numbers within a sequence group are to be selected, enter two asterisks (**). Note: where applicable, the seventh and ninth characters of the Activity Number indicate the process equipment class (01-26). Equipment classes are defined in Appendix C. To specify a construction predecessor activity or group of activities, enter all or part of a construction Activity Number it in the fields provided under 722 13 IPS Project Schedule Settings PREDECESSOR – CONSTR. ACTIVITY, the same way you specified a successor construction activity. 5 In the Relationship type field, select the specific type of logical sequence to use when adding relationships: A – Finish-to-Start (default) S – Start-to-Start F – Finish-to-Finish Finish-to-Start (A) and Start-to-Start (S) relationships use the Predecessor’s work week to calculate calendar lag between activities. Finish-to-Finish (F) relationships use the successor’s work week. The Relationship Type field is not used by the system when deleting relationships; all relationships between the specified activities will be deleted, regardless of relationship type. 6 7 8 Enter the Lag time, in whole working days, associated with the relationship type to be added. The default is 0 days. Click Apply. To add or delete another relationship, click Add and repeat the process. Activity Modification The Activity Modification forms for engineering and construction allow you to modify the coding of activities. Activities may be combined within a common activity number or deleted entirely. Activities can be combined by changing an activity number to another existing number. Specify all or part of an existing activity number, then all or part of the other activity number that will replace it. Icarus Project Scheduler (IPS) will sort the activities into numerical order, merging all identically numbered activities, including the craft resources. Activities can be deleted by selecting an activity and then entering asterisks instead of the number of a modified activity. To modify engineering activities: 1 Right-click on Engineering and click Edit on the pop-up menu. 13 IPS Project Schedule Settings 723 2 See Appendix A for a list of Engineering Activity Numbers. 724 Select a source activity. This is done by specifying all or part of the Engineering Activity Number. The parts of the Engineering Activity Number are broken up into the fields under SOURCE ACTIVITY. Engineering Activity Numbers, which are listed in Appendix A, have 10 characters. If you want to modify a group of activities, you can enter “wildcard” asterisks in some fields. At least one of the fields (besides the two preset fields) must contain numbers.  Preset engineering field 1 The first three characters of the Activity Number are fixed and the same for all activities. They are always “000”.  Engineering phase The fourth character of the Activity Number indicates the major engineering phase: 0 – Basic engineering phase 1 – Detail engineering phase 2 – Procurement phase To select all phases, enter an asterisk (*).  Engineering contractor number The fifth and sixth characters of the Activity Number indicate the engineering contract number. For fixed project-level activities, these characters will be “00”. The engineering contract number is determined based on your specifications for contractors under Basis 13 IPS Project Schedule Settings for Capital Costs in the Project Basis (see page 141). It must be a number between 01 and 40. If all engineering contractor numbers are to be selected, enter two asterisks (**).  Account group number Exception: where applicable, the seventh and ninth characters of the Activity Number indicate the process equipment class (01-26). Equipment classes are defined in Appendix C, page 779. The seventh character of the Activity Number indicates the account group number. It is derived from the first character of the Code of Accounts.   0, 1, 2 – Equipment or general 3 – Piping 4 – Civil 5 – Steelwork 6 – Instrumentation 7 – Electrical 8 – Insulation 9 – Painting If all account groups are to be selected for modification, enter one asterisk (*). Preset engineering field 2 The eighth character of the Activity Number is fixed and the same for all activities. It is always “0”. Sequence in account group number The ninth and tenth numbers provide sequential grouping within the major hierarchy of the first eight characters. If all numbers within a sequence group are to be selected, enter two asterisks (**). Note: where applicable, the seventh and ninth characters of the Activity Number indicate the process equipment class (01-26). Equipment classes are defined in Appendix C. 3 In the fields under MODIFIED ACTIVITY, specify the changes that are to be made to the source activity. 4 Click Apply. 5 To modify another activity, click Add and repeat the process. To modify construction activities: 1 Right-click on Construction and click Edit on the pop-up menu. 13 IPS Project Schedule Settings 725 2 Select a source activity. This is done by specifying all or part of the Construction Activity Number. The Construction Activity Number is broken up into the fields under ACTIVITY NUMBER. Construction Activity Numbers, which are listed in Appendix B, have 12 characters. If you want to modify a group of activities, you can enter “wildcard” asterisks in some fields. However, at least one of the fields must contain numbers.   726 Area number The first and second characters of the Activity Number indicate the Area number, 01 through 90, or other project-level items, such as substations, control panel and power transmission lines, which always use 91. If activities from all Areas are to be selected, enter two asterisks (**). Identification number The third through fifth characters contain the user-specified reference number from the specifications form for equipment items and plant bulks. For substations, the fourth and fifth characters contain the substation reference number (01-99) specified by the user or, if not specified, the System default reference number of 00. If all reference numbers are to be selected, enter three asterisks (***). 13 IPS Project Schedule Settings  Equipment type The sixth and seventh characters contain the Equipment Code. See Appendix D for Equipment Code definitions. All other activities have a fixed identifier in positions six and seven of the activity number, as listed in Activity Numbering Conventions table in Appendix B. Enter two asterisks (**) if all Equipment Type numbers are to be selected. See Appendix D for the Equipment Code definitions. The construction activities are listed in Appendix B by the last three characters of the Activity Number. These last three characters form the account group number and account code. 3 4 5  Account group number The eighth character, the account group number, refers to the type of work performed in the activity. The account group number combined with the account code (in the field below), form the three-character code by which the construction and site development activities are listed in Appendix B. If all account group numbers are to be selected, enter an asterisk (*).  Account code Enter the tenth and eleventh characters of the Activity Code for the activities to be selected for modification (that is,, excluding the first character, which is the Account Group number, above). If all Activity Codes are to be selected, enter two asterisks (**).  Contractor number The eleventh and twelfth characters are the contractor numbers. If all contractors are to be selected, enter two asterisks (**). In the fields under MODIFIED ACTIVITY, specify the changes that are to be made to the source activity. Click Apply. To modify another activity, click Add and repeat the process. Primavera Information To edit Primavera information: 1 Right-click on Project manager information in the Primavera information folder and click Edit on the pop-up menu. 13 IPS Project Schedule Settings 727 2 You can specify the following information:         3 728 User name Password Database name Name of Primavera database where Aspen IPS data will be loaded (for example,, pmdb). Remote or local host server Indicates mode of operation, remote server (RMT) or local machine (LCL). Enterprise project structure ID Project structure ID for Primavera Enterprise. If nothing is entered, the Aspen Capital Cost Estimator project name will be used. Enterprise project structure name Project structure name for Primavera Enterprise. If nothing is entered, the Aspen Capital Cost Estimator project name will be used. Enterprise project manager name Name of manager (OBS) responsible for Primavera Enterprise. If nothing is entered, the Aspen Capital Cost Estimator project name will be used. Enterprise project WBS name Work Breakdown structure name for Primavera Enterprise. If nothing is entered, the Aspen Capital Cost Estimator project name will be used. Click Apply to save changes. 13 IPS Project Schedule Settings IPS Appendix A: Engineering and Procurement Activity Numbers Numbering Convention Engineering and Procurement Activity Numbers include both fixed and variable numbers, as follows:  Fixed numbers – activities relating to the overall project.  Numbers that are repeated for each engineering contract, varying the digits that identify each contractor.  Numbers that vary for each class of equipment required within each area (see “Equipment Codes” on page 781). X X As illustrated by the table on the following page, the first three characters and the eighth character in the ten-character ID number are always “0” for all Engineering and Procurement activities. The rest of the characters – the fourth through seventh, the ninth, and the tenth – are used to indicated the engineering phase, area number, contract number, account number, equipment class, or simply sequential grouping, as described below:  The fourth character indicates the major engineering phase: 0 Basic Engineering 1 Detail Engineering 2 Procurement  The fifth and sixth characters indicate the engineering contract number. For fixed project-level activities, these IPS Appendix A: Engineering and Procurement Activity Numbers 729 characters will be “00” (unless contracts are used). The engineering contract number is determined by your specifications for contractors in the estimating system input and must be a number between 01 and 40.  The seventh character indicates the Code of Account series: 0, 1, 2 Either Equipment of General 3 Piping 4 Civil 5 Steelwork 6 Instrumentation 7 Electrical 8 Insulation 9 Paint  The ninth and tenth characters simply provide sequential grouping within the major hierarchy of the first eight characters. Note: There is one exception to the numbering conventions discussed here. Where applicable, the process equipment class is indicated by the seventh and ninth characters and can be a number from 01 to 26. See page 779 for Equipment Class definitions. X X Engineering and Procurement – Activity Numbering Conventions Category Range Basic Engineering: Fixed, project-level 000-0-CC-0-0-01 through 000-0-CC-7-0-09 Equipment, by contractor and class 000-0-CC-X-0-X1 through 000-0-CC-X-0-X9 Detail Engineering: Fixed, project-level 000-1-CC-0-0-11 through 000-0-CC-9-0-02 Variable, by contractor 000-1-CC-1-0-21 through 000-1-CC-7-0-97 Procurement: Variable, by contractor 000-2-CC-0-0-01 through 000-2-CC-9005 Equipment, by contract and class 000-2-CC-X-0-X1 through 000-2-CC-X-0-X5 CC = Contract Number (01-40) XX = Process Equipment Class (01-26); see page 779. X 730 X IPS Appendix A: Engineering and Procurement Activity Numbers List of Activity Numbers The Engineering and Procurement Activity Numbers are listed below, divided by Phase:  Basic Engineering: page 731  Detail Engineering: page 748  Procurement: page 759 X X X X Activity Number X X Definition Basic Engineering Preliminary 0000000001 0000000002 0000000003 0000000004 0000000005 0000000006 0000000007 0000000008 0000000009 AUTHORIZATION TO PROCEED START ENGINEERING STAFFING, MOBILIZATION REVIEW PREVIOUS JOB PROJECT STAFF CONFERENCE CUSTOMER COORDINATION MEETING ANALYZE OUTSTANDING CLIENT INPUT ONGOING CLIENT INPUT RECEIVE ALL CLIENT INPUT Basic Engineering – Project Level Materials, Vessels STDS 0000002071 0000002072 0000002073 0000002074 0000002075 PREP PRELIM MATERIALS OF CONST MATERIALS DEPARTMENT REVIEW PREP & ISSUE VESSEL STANDARDS CLIENT APPROVAL VESSEL STDS REVISE & REISSUE VESSEL STDS User-Specified Drawings – General 0000002080 0000002081 0000002082 0000002085 0000002086 0000002087 0000002090 0000002091 0000002092 0000002095 0000002096 0000002097 DRAFT & CHECK, APPROVAL, REVISE & IFC, DRAFT & CHECK, APPROVAL, REVISE & IFC, DRAFT & CHECK, APPROVAL, REVISE & IFC, DRAFT & CHECK, APPROVAL, REVISE & IFC, USER USER USER USER USER USER USER USER USER USER USER USER IPS Appendix A: Engineering and Procurement Activity Numbers DWG DWG DWG DWG DWG DWG DWG DWG DWG DWG DWG DWG (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) 731 Process Scope Estimating 0000003001 0000003002 0000003003 0000003004 0000003005 0000003006 0000003007 0000003008 0000003009 0000003010 0000003011 0000003012 0000003013 PREPARE PRELIM PROCESS SCOPE PROCESS SCOPE 50% COMPLETE ISSUE PROCESS SCOPE CLIENT APPROVAL PROCESS SCOPE UPDATE PROCESS SCOPE PREPARE BUDGET ESTIMATE CLIENT APPROVAL BUDGET ESTIMATE REVISE PROCESS SCOPE CLASS 2 ESTIMATE WORKSHEETS UPDATE CLASS 2 ESTIMATE COMPLETE 70% CLASS 2 ESTIMATE COMPLETE CLASS 2 ESTIMATE CLIENT APPROVAL - ESTIM & SCHED User-Specified Drawings – Piping 0000003080 0000003081 0000003082 0000003085 0000003086 0000003087 0000003090 0000003091 0000003092 0000003095 0000003096 0000003097 DRAFT & CHECK, APPROVAL, REVISE & IFC, DRAFT & CHECK, APPROVAL, REVISE & IFC, DRAFT & CHECK, APPROVAL, REVISE & IFC, DRAFT & CHECK, APPROVAL, REVISE & IFC, USER USER USER USER USER USER USER USER USER USER USER USER DWG DWG DWG DWG DWG DWG DWG DWG DWG DWG DWG DWG (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) Project Scope 0000004001 0000004002 PREP & ISSUE PRELIM SCOPE DOC PREP & REISSUE PROJECT SCOPE Fire Protection 0000004011 0000004012 0000004013 REVIEW FIRE PROTECTION REQMTS PREP & ISSUE FIRE PROTN SPECS CLIENT APPROVAL FIRE PROTECTION Soils 0000004021 732 SOILS ANALYSIS IPS Appendix A: Engineering and Procurement Activity Numbers 0000004022 PREP & ISSUE SOILS REPORT Environmental 0000004031 0000004032 PRELIM ENVIRONMENTAL INVESTIGTN ISSUE ENVIRONMENTAL DATA Structural 0000004041 0000004042 0000004043 0000004044 PREP & ISSUE STRUCTURAL SPECS CLIENT APPROVAL STRUCTURAL SPECS PRELIM FOUNDATION DESIGN CIVIL,ARCHITECTURAL & HVAC ESTIM Utilities 0000004051 0000004052 0000004053 0000004054 0000004055 0000004056 0000004057 0000004058 UTILITY DIAGRAM WORKSHEETS DRAFT & CHECK UTILITY FDS UPDATE & ISSUE UTILITY FDS CLIENT APPROVAL UTILITY FDS REVISE & REISSUE UTILITY FDS DRAFT & CHECK UTILITY P&IDS CLIENT APPROVAL UTILITY P&IDS UPDATE & ISSUE UTILITY P&IDS Electrical 0000004061 0000004062 0000004063 0000004064 0000004065 0000004066 0000004067 0000004068 0000004069 0000004070 0000004071 0000004072 0000004073 0000004075 PREP & ISSUE ELEC STANDARDS CLIENT APPROVAL ELEC STANDARDS PREP & ISSUE ONE-LINE DIAGRAM UPDATE ONE-LINE DIAGRAM PREPARE MAJOR ELEC EQPT REQNS APPROVE MAJOR ELEC EQPT REQNS MAJOR ELEC EQUIPMENT QUOTES TAB & SELECT ELEC EQPT VENDOR CLIENT APPROVE ELEC EQPT VENDOR PREPARE AREA CLASSIFCN PLAN DRAFT & CHECK CLASSIFCN PLAN CLIENT APPROVAL,CLASSIFCN PLAN REV & ISSUE CLASSIFICATION PLAN ELECTRICAL COST ESTIMATE User-specified Drawings – Civil/Building 0000004080 0000004081 0000004082 DRAFT & CHECK, USER DWG (XX) APPROVAL, USER DWG (XX) REVISE & IFC, USER DWG (XX) IPS Appendix A: Engineering and Procurement Activity Numbers 733 0000004085 0000004086 0000004087 0000004090 0000004091 0000004092 0000004095 0000004096 0000004097 DRAFT & CHECK, APPROVAL, REVISE & IFC, DRAFT & CHECK, APPROVAL, REVISE & IFC, DRAFT & CHECK, APPROVAL, REVISE & IFC, USER USER USER USER USER USER USER USER USER DWG DWG DWG DWG DWG DWG DWG DWG DWG (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) PFD’s 0000005001 0000005002 0000005003 0000005004 0000005005 0000005011 0000005012 0000005013 0000005014 ANALYZE PROCESS REQUIREMENTS HEAT & MATERIAL BALANCE PROCESS FLOWSHEETS DRAFT & CHECK PFDS UPDATE & ISSUE PFDS(1) CLIENT APPROVAL PFDS(1) REVISE & REISSUE PFDS(2) CLIENT APPROVAL PFDS(2) REVISE & REISSUE PFDS(3) Instrumentation 0000005021 0000005022 0000005023 0000005024 PREPARE INSTRUMENT STANDARDS CLIENT APPROVAL INSTRUMENT STDS REVISE & REISSUE INSTRUMENT PREPARE INSTRUMENT INDEX Piping 0000005031 0000005032 0000005033 0000005034 0000005035 0000005036 0000005037 0000005041 0000005042 0000005043 0000005044 0000005045 0000005046 0000005047 734 PRELIMINARY P&ID WORKSHEETS INTERNAL REVIEW P&IDS DRAFT & CHECK P&IDS UPDATE & ISSUE P&IDS(1) CLIENT APPROVAL P&IDS(1) REVISE & REISSUE P&IDS(2) PREPARE & ISSUE LINE LIST PREP & ISSUE PIPING STANDARDS CLIENT APPROVAL PIPING STDS REVISE & REISSUE PIPING STDS PIPING ARRANGEMENT STUDIES DRAFT INTERCONNG PIPING DWGS REV & ISSUE INTERCONNG PIPING PIPING MATERIAL TAKEOFF IPS Appendix A: Engineering and Procurement Activity Numbers Plot Plans 0000005051 0000005052 0000005053 0000005054 0000005055 0000005056 PREPARE SITE PLANNING MODEL GA, PLOT PLAN STUDIES DRAFT & CHECK GA, PLOT PLANS UPDATE & ISSUE GA, PLOT PLANS CLIENT APPROVAL GA, PLOT PLANS REVISE & REISSUE GA, PLOT PLANS User-Specified Drawings – Steelwork 0000005061 0000005062 0000005071 0000005072 0000005073 0000005080 0000005081 0000005082 0000005085 0000005086 0000005087 0000005090 0000005091 0000005092 0000005095 0000005096 0000005097 PRELIM SIZING MECHANICAL PREPARE ELECTRICAL LOAD LIST PREPARE & ISSUE MECH STANDARDS CLIENT APPROVAL MECH STANDARDS UPDATE & ISSUE MECH STANDARDS DRAFT & CHECK, USER DWG (XX) APPROVAL, USER DWG (XX) REVISE & IFC, USER DWG (XX) DRAFT & CHECK, USER DWG (XX) APPROVAL, USER DWG (XX) REVISE & IFC, USER DWG (XX) DRAFT & CHECK, USER DWG (XX) APPROVAL, USER DWG (XX) REVISE & IFC, USER DWG (XX) DRAFT & CHECK, USER DWG (XX) APPROVAL, USER DWG (XX) REVISE & IFC, USER DWG (XX) Process Studies 0000006001 PROCESS STUDIES Control System 0000006010 0000006011 0000006012 0000006013 0000006020 0000006021 0000006022 0000006030 0000006031 0000006032 PANEL/CONSOLE LAYOUT STUDY DRAFT & CHECK PANEL/CONSOLE DWGS APPROVE PANEL/CONSOLE DWGS REV & ISSUE PANEL/CONSOLE DWGS SCOPE SHARED DISPLAY SYSTEM IFQ DIGITAL CONTROL SYSTEM APPROVE DIG CONTROL SYSTEM PREPARE CONTROL PANEL SPECS IFQ CONTROL PANEL REQNS APPROVE CONTROL PANEL REQNS User-Specified Drawings – Instrumentation 0000006080 DRAFT & CHECK, USER DWG (XX) IPS Appendix A: Engineering and Procurement Activity Numbers 735 0000006081 0000006082 0000006085 0000006086 0000006087 0000006090 0000006091 0000006092 0000006095 0000006096 0000006097 APPROVAL, USER REVISE & IFC, DRAFT & CHECK, APPROVAL, REVISE & IFC, DRAFT & CHECK, APPROVAL, REVISE & IFC, DRAFT & CHECK, APPROVAL, REVISE & IFC, DWG (XX) USER DWG USER DWG USER DWG USER DWG USER DWG USER DWG USER DWG USER DWG USER DWG USER DWG (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) Misc, Documentation 0000007001 0000007002 0000007003 0000007004 0000007005 0000007006 0000007007 0000007008 0000007009 PREPARE PRELIM EQUIPMENT LIST SCHED & ESTIMATE PROCESS WORK PREPARE EARLY ENGINEERING CPM PREPARE EQUIPMENT STATUS LIST UPDATE & ISSUE EQUIPMENT LIST PREPARE & ISSUE BIDDERS LIST CLIENT APPROVE BIDDERS LIST REVISE & REISSUE BIDDERS LIST PREPARE & ISSUE PROJECT CPM User-Specified Drawings – Electrical 0000007080 0000007081 0000007082 0000007085 0000007086 0000007087 0000007090 0000007091 0000007092 0000007095 0000007096 0000007097 DRAFT & CHECK, APPROVAL, REVISE & IFC, DRAFT & CHECK, APPROVAL, REVISE & IFC, DRAFT & CHECK, APPROVAL, REVISE & IFC, DRAFT & CHECK, APPROVAL, REVISE & IFC, USER USER USER USER USER USER USER USER USER USER USER USER DWG DWG DWG DWG DWG DWG DWG DWG DWG DWG DWG DWG (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) Basic Engineering – Equipment, Variable by Class and Contractor Vessels 0000010011 736 PROCESS SPECS, 01 PRESS VESSELS- IPS Appendix A: Engineering and Procurement Activity Numbers 0000010012 0000010013 0000010014 0000010015 0000010016 0000010017 0000010018 0000010019 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 PRESS VESSELS- PROCESS SPECS, REV PROC SPECS, MECH DESIGN, PREPARE REQNS, OBTAIN QUOTES, SELECT VENDORS, APPROVE VENDOR, APPROVE REQNS, REISSUE REQNS, TOWERS-01 TOWERS-01 TOWERS-01 TOWERS-01 TOWERS-01 TOWERS-01 TOWERS-01 TOWERS-01 TOWERS-01 PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 STORAGE TANKS- PRESS VESSELSPRESS VESSELSPRESS VESSELSPRESS VESSELSPRESS VESSELSPRESS VESSELSPRESS VESSELS- Towers 0000010021 0000010022 0000010023 0000010024 0000010025 0000010026 0000010027 0000010028 0000010029 Storage Tanks 0000010031 0000010032 0000010033 0000010034 0000010035 0000010036 0000010037 0000010038 STORAGE TANKSSTORAGE TANKSSTORAGE TANKSSTORAGE TANKSSTORAGE TANKSSTORAGE TANKSSTORAGE TANKS- IPS Appendix A: Engineering and Procurement Activity Numbers 737 0000010039 REISSUE REQNS, 01 STORAGE TANKS- PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 PUMPS - PUMPS - PUMPS - PUMPS - PUMPS - PUMPS - PUMPS - PUMPS - PUMPS - PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 COMPRESSORS - COMPRESSORS - COMPRESSORS - COMPRESSORS - COMPRESSORS - COMPRESSORS - COMPRESSORS - COMPRESSORS - COMPRESSORS - Pumps 0000010041 0000010042 0000010043 0000010044 0000010045 0000010046 0000010047 0000010048 0000010049 Compressors 0000010051 0000010052 0000010053 0000010054 0000010055 0000010056 0000010057 0000010058 0000010059 738 IPS Appendix A: Engineering and Procurement Activity Numbers Turbines 0000010061 0000010062 0000010063 0000010064 0000010065 0000010066 0000010067 0000010068 0000010069 PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 TURBINES - TURBINES - TURBINES - TURBINES - TURBINES - TURBINES - TURBINES - TURBINES - TURBINES - EXCHANGERS - EXCHANGERS - EXCHANGERS - EXCHANGERS - EXCHANGERS - EXCHANGERS - EXCHANGERS - EXCHANGERS - EXCHANGERS - Heat Exchangers 0000010071 0000010072 0000010073 0000010074 0000010075 0000010076 0000010077 0000010078 0000010079 PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 Boilers 0000010081 0000010082 PROCESS SPECS, BOILERS 01 REV PROC SPECS, BOILERS 01 IPS Appendix A: Engineering and Procurement Activity Numbers - 739 0000010083 0000010084 0000010085 0000010086 0000010087 0000010088 0000010089 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 BOILERS - BOILERS - BOILERS - BOILERS - BOILERS - BOILERS - BOILERS - PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 FURNACES - FURNACES - FURNACES - FURNACES - FURNACES - FURNACES - FURNACES - FURNACES - FURNACES - PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, AIR COOLERS - AIR COOLERS - AIR COOLERS - AIR COOLERS - Furnaces 0000010091 0000010092 0000010093 0000010094 0000010095 0000010096 0000010097 0000010098 0000010099 Air Coolers 0000011001 0000011002 0000011003 0000011004 740 IPS Appendix A: Engineering and Procurement Activity Numbers 0000011005 0000011006 0000011007 0000011008 0000011009 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 AIR COOLERS - AIR COOLERS - AIR COOLERS - AIR COOLERS - AIR COOLERS - PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 PKG REFRIG - PKG REFRIG - PKG REFRIG - PKG REFRIG - PKG REFRIG - PKG REFRIG - PKG REFRIG - PKG REFRIG - PKG REFRIG - PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 GENERATORS - GENERATORS - GENERATORS - GENERATORS - GENERATORS - GENERATORS - Pkg Refrigeration 0000011011 0000011012 0000011013 0000011014 0000011015 0000011016 0000011017 0000011018 0000011019 Generators 0000011021 0000011022 0000011023 0000011024 0000011025 0000011026 IPS Appendix A: Engineering and Procurement Activity Numbers 741 0000011027 0000011028 0000011029 APPROVE VENDOR, GENERATORS 01 APPROVE REQNS, GENERATORS 01 REISSUE REQNS, GENERATORS 01 - PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 AIR DRYERS - AIR DRYERS - AIR DRYERS - AIR DRYERS - AIR DRYERS - AIR DRYERS - AIR DRYERS - AIR DRYERS - AIR DRYERS - PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, CONVEYORS - CONVEYORS - CONVEYORS - CONVEYORS - CONVEYORS - CONVEYORS - CONVEYORS - CONVEYORS - - Air Dryers 0000011031 0000011032 0000011033 0000011034 0000011035 0000011036 0000011037 0000011038 0000011039 Conveyors 0000011041 0000011042 0000011043 0000011044 0000011045 0000011046 0000011047 0000011048 742 IPS Appendix A: Engineering and Procurement Activity Numbers 0000011049 01 REISSUE REQNS, 01 CONVEYORS - PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 MILLS - MILLS - MILLS - MILLS - MILLS - MILLS - MILLS - MILLS - MILLS - PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 FANS - FANS - FANS - FANS - FANS - FANS - FANS - FANS - FANS - PROCESS SPECS, ELEVATORS - Mills 0000011051 0000011052 0000011053 0000011054 0000011055 0000011056 0000011057 0000011058 0000011059 Fans 0000011061 0000011062 0000011063 0000011064 0000011065 0000011066 0000011067 0000011068 0000011069 Elevators 0000011071 IPS Appendix A: Engineering and Procurement Activity Numbers 743 0000011072 0000011073 0000011074 0000011075 0000011076 0000011077 0000011078 0000011079 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 ELEVATORS - ELEVATORS - ELEVATORS - ELEVATORS - ELEVATORS - ELEVATORS - ELEVATORS - ELEVATORS - MOTORS - MOTORS - MOTORS - MOTORS - MOTORS - MOTORS - MOTORS - MOTORS - MOTORS - Motors 0000011081 0000011082 0000011083 0000011084 0000011085 0000011086 0000011087 0000011088 0000011089 PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 Dust Collectors 0000011091 0000011092 744 PROCESS SPECS, DUST COLLECTR01 REV PROC SPECS, DUST COLLECTR01 IPS Appendix A: Engineering and Procurement Activity Numbers 0000011093 0000011094 0000011095 0000011096 0000011097 0000011098 0000011099 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 DUST COLLECTRDUST COLLECTRDUST COLLECTRDUST COLLECTRDUST COLLECTRDUST COLLECTRDUST COLLECTR- Filters 0000012001 0000012002 0000012003 0000012004 0000012005 0000012006 0000012007 0000012008 0000012009 PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 FILTERS - FILTERS - FILTERS - FILTERS - FILTERS - FILTERS - FILTERS - FILTERS - FILTERS - PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, CENTRIFUGES - CENTRIFUGES - CENTRIFUGES - CENTRIFUGES - CENTRIFUGES - Centrifuges 0000012011 0000012012 0000012013 0000012014 0000012015 IPS Appendix A: Engineering and Procurement Activity Numbers 745 0000012016 0000012017 0000012018 0000012019 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 CENTRIFUGES - CENTRIFUGES - CENTRIFUGES - CENTRIFUGES - PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 MIXERS - MIXERS - MIXERS - MIXERS - MIXERS - MIXERS - MIXERS - MIXERS - MIXERS - PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 COOLING TOWER- Mixers 0000012021 0000012022 0000012023 0000012024 0000012025 0000012026 0000012027 0000012028 0000012029 Cooling Towers 0000012031 0000012032 0000012033 0000012034 0000012035 0000012036 746 COOLING TOWERCOOLING TOWERCOOLING TOWERCOOLING TOWERCOOLING TOWER- IPS Appendix A: Engineering and Procurement Activity Numbers 0000012037 0000012038 0000012039 APPROVE VENDOR, COOLING TOWER01 APPROVE REQNS, COOLING TOWER01 REISSUE REQNS, COOLING TOWER01 Misc. Equipment 0000012041 0000012042 0000012043 0000012044 0000012045 0000012046 0000012047 0000012048 0000012049 PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 MISC EQUIP - MISC EQUIP - MISC EQUIP - MISC EQUIP - MISC EQUIP - MISC EQUIP - MISC EQUIP - MISC EQUIP - MISC EQUIP - PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, PACKAGE ITEMS- Package Items 0000012051 0000012052 0000012053 0000012054 0000012055 0000012056 0000012057 0000012058 0000012059 PACKAGE ITEMSPACKAGE ITEMSPACKAGE ITEMSPACKAGE ITEMSPACKAGE ITEMSPACKAGE ITEMSPACKAGE ITEMSPACKAGE ITEMS- IPS Appendix A: Engineering and Procurement Activity Numbers 747 01 Packings and Linings 0000012061 0000012062 0000012063 0000012064 0000012065 0000012066 0000012067 0000012068 0000012069 PROCESS SPECS, 01 REV PROC SPECS, 01 MECH DESIGN, 01 PREPARE REQNS, 01 OBTAIN QUOTES, 01 SELECT VENDORS, 01 APPROVE VENDOR, 01 APPROVE REQNS, 01 REISSUE REQNS, 01 PACK&LININGS PACK&LININGS PACK&LININGS PACK&LININGS PACK&LININGS PACK&LININGS PACK&LININGS PACK&LININGS PACK&LININGS - Detail Engineering Project Level CPM 0001000011 0001000012 UPDATE & ISSUE PROJECT CPM FINALIZE CPM FOR CONSTRUCTION Definitive Estimate 0001000021 0001000022 0001000023 0001000024 0001000025 DEFINITIVE ESTIMATE MTO PREPARE DEFINITIVE ESTIMATE REVIEW & ISSUE DEFIN ESTIMATE UPDATE DEFINITIVE ESTIMATE FINALIZE CONTROL ESTIMATE Site Development 0001001011 0001001012 0001001013 0001001014 0001001015 748 CIVIL DESIGN,LAYOUT STUDIES PREP SITE GRADING DRAWINGS DRAFT & CHECK SITE GRADING DWGS PREP SITE DEVELOPMENT DETAILS DRAFT & CHECK SITE DEVEL DETAILS IPS Appendix A: Engineering and Procurement Activity Numbers 0001001016 0001001017 CLIENT APPROVE SITE DEVEL DWGS REV & ISSUE SITE DEVELOPMT DWGS Equipment Layout 0001002001 0001002010 0001002011 UPDATE EQUIPMENT LIST EQUIPMENT LAYOUT STUDIES REVIEW EQUIP LAYOUTS & FREEZE Line List 0001003000 PREPARE & ISSUE LINE LIST Piping Model (if specified) 0001003010 0001003011 0001003012 0001003015 PREPARE MODEL PROJECT REVIEW,UPDATE MODEL CHECK & IFC MODEL REVISE & REISSUE PFDS Civil 0001004000 0001004001 0001004002 0001004003 0001004004 PREP & ISSUE BUILDING SPECS REBAR, CONCRETE BULK MTO PREPARE & ISSUE REBAR REQNS CLIENT APPROVE REBAR REQNS MTO & REQN EARLY UNDERGRND MATL Structural 0001005002 PRELIM STRUCTURAL MTO Control System 0001006004 0001006007 0001006070 0001006071 0001006072 0001006073 MTO & REQN JUNC BOX, MAJOR CABLE INSTRUMENT CABLE TRAY STUDY PREP CONTROL ROOM/CONSOLE DWGS DRAFT&CHK CONTRL RM/CONSOLE DWGS APPROVE CONTROL RM/CONSOLE DWGS REV CONTROL RM/CONSOLE DWGS Electrical 0001007000 0001007001 0001007002 0001007003 0001007004 0001007007 UPDATE ELECTRICAL LOAD LIST MTO & REQN ELEC BULK MATLS MTO & REQN MINOR ELEC EQUIP MTO & REQN CABLE TRAY, HARDWARE MTO & REQN ELEC TRACING MATL ELEC CABLE TRAY STUDY IPS Appendix A: Engineering and Procurement Activity Numbers 749 0001007008 0001007009 ELEC HEAT TRACING STUDY LIGHTING STUDY Insulation 0001008000 0001008001 0001008002 PREP & ISSUE INSULATION SPECS CLIENT APPROVE INSULATION SPECS REV & ISSUE INSULATION SPECS Paint 0001009000 0001009001 0001009002 PREP & ISSUE PAINTING SPECS CLIENT APPROVE PAINT SPECS REVISE & ISSUE PAINTING SPECS Detail Engineering – Variable by Contractor Equipment Layout (GA’s) 0001011022 REV,IFD EQUIP LAYOUT DWGS 01 - User-Specified Drawings – General 0001011080 0001011081 0001011082 0001011085 0001011086 0001011087 0001011090 0001011091 0001011092 0001011095 0001011096 0001011097 DRAFT & CHECK, APPROVAL, REVISE & IFC, DRAFT & CHECK, APPROVAL, REVISE & IFC, DRAFT & CHECK, APPROVAL, REVISE & IFC, DRAFT & CHECK, APPROVAL, REVISE & IFC, USER USER USER USER USER USER USER USER USER USER USER USER DWG DWG DWG DWG DWG DWG DWG DWG DWG DWG DWG DWG (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) (XX) Rotating Equipment 0001012012 ROTATING EQP STRESS ANALYSIS 01 Piping 0001013001 0001013002 0001013003 0001013017 750 BULK PIPING MTO (80%) 01 PREP PIPING REQNS (80%) 01 PREP REMOTE SHOP REQNS 01 REVISE & ISSUE P&IDS - IPS Appendix A: Engineering and Procurement Activity Numbers 0001013021 0001013022 0001013023 0001013031 0001013032 0001013033 0001013041 0001013042 0001013043 0001013045 0001013051 0001013052 0001013055 0001013060 0001013061 0001013062 0001013063 0001013071 0001013072 0001013073 01 PREPARE PIPING LAYOUT 01 UPDATE PIPING LAYOUT 01 PIPING STRESS ANALYSIS 01 DRAFT & CHECK PIPE ARNGMNT 01 CLIENT APPROVAL PIPE ARNGMNT 01 UPDATE,IFC PIPING ARNGMNT 01 DRAFT & CHECK ISOMETRICS 01 CLIENT APPROVAL ISOS 01 REVISE & ISSUE ISOS 01 FINALIZE LINE INDEX 01 PREPARE PIPE TEST SCHEDS 01 CHECK,IFC PIPE TEST SCHEDS 01 FINALIZE UTILITY P&IDS 01 DESIGN SPECIAL HANGERS 01 DRAFT & CHECK ENG HANGERS 01 APPROVE HANGER DRAWINGS 01 REV & ISSUE HANGER DWGS 01 DRAFT & CHECK STM TRACING DWG01 APPROVE STEAM TRACING DWGS 01 REV,IFC STEAM TRACING DWGS 01 User-Specified Drawings – Piping 0001013080 DRAFT & CHECK, USER DWG (XX) - IPS Appendix A: Engineering and Procurement Activity Numbers 751 0001013081 0001013082 0001013085 0001013086 0001013087 0001013090 0001013091 0001013092 0001013095 0001013096 0001013097 01 APPROVAL, 01 REVISE & IFC, 01 DRAFT & CHECK, 01 APPROVAL, 01 REVISE & IFC, 01 DRAFT & CHECK, 01 APPROVAL, 01 REVISE & IFC, 01 DRAFT & CHECK, 01 APPROVAL, 01 REVISE & IFC, 01 USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) - Civil 0001014010 0001014011 0001014012 0001014013 0001014020 0001014021 0001014022 0001014023 0001014030 752 DESIGN EQUIPMENT FOUNDATIONS 01 DRAFT & CHECK EQUIP FDN DWGS 01 APPROVAL, EQUIP FDN DWGS 01 REV & IFC,EQUIP FDN DWGS 01 DESIGN STEELWORK FOUNDATIONS 01 DRAFT & CHECK STEELWORK FDNS 01 APPROVE STEELWORK FDN DWGS 01 REV & IFC STEELWORK FDN DWGS 01 DESIGN PAVING - IPS Appendix A: Engineering and Procurement Activity Numbers 0001014031 0001014032 0001014033 0001014040 0001014041 0001014042 0001014043 0001014050 0001014051 0001014052 0001014053 01 DRAFT & CHECK, PAVING DWGS 01 APPROVAL, PAVING DWGS 01 REV & IFC PAVING DWGS 01 DESIGN MISC. CONCRETE 01 DRAFT & CHECK, MISC CONC DWGS01 APPROVAL, MISC CONCRETE DWGS 01 REV & IFC MISC CONCRETE DWGS 01 PREP UNDERGROUND PIPE LAYOUT 01 DRAFT & CHECK U-GRND PIPING 01 CLIENT APPROVE U-GRND PIPING 01 REV & ISSUE U-GRND PIPING 01 Buildings 0001014060 0001014061 0001014062 0001014063 0001014071 0001014072 0001014073 PREP BUILDING PLANS,ELEVNS 01 DRAFT&CHECK BLDG PLANS,ELEVNS01 APPROVE BLDG PLANS,ELEVNS 01 REV,IFC BLDG PLANS,ELEVNS 01 DRAFT & CHECK ARCH DETAILS 01 APPROVE ARCH DETAILS 01 REV & ISSUE ARCH DETAILS 01 User-Specified Drawings – Civil/Building 0001014080 0001014081 DRAFT & CHECK, USER DWG (XX) 01 APPROVAL, USER DWG (XX) 01 IPS Appendix A: Engineering and Procurement Activity Numbers 753 0001014082 0001014085 0001014086 0001014087 0001014090 0001014091 0001014092 0001014095 0001014096 0001014097 REVISE & IFC, 01 DRAFT & CHECK, 01 APPROVAL, 01 REVISE & IFC, 01 DRAFT & CHECK, 01 APPROVAL, 01 REVISE & IFC, 01 DRAFT & CHECK, 01 APPROVAL, 01 REVISE & IFC, 01 USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) - Steelwork 0001015010 0001015011 0001015012 0001015013 0001015021 0001015022 0001015023 0001015031 0001015032 0001015033 754 STRUCTURAL STEEL DESIGN 01 DRAFT & CHECK STRUCT DWGS 01 CLIENT APPROVE STRUCT DWGS 01 REV & ISSUE STRUCT DWGS 01 DRAFT & CHECK MISC STEEL 01 APPROVE MISC STEEL DWGS 01 REV & ISSUE MISC STEEL 01 DRAFT & CHECK GRATING DWGS 01 APPROVE GRATING DWGS 01 REV & IFP GRATING DWGS 01 - IPS Appendix A: Engineering and Procurement Activity Numbers 0001015034 0001015035 MT0 & REQN GRATING 01 APPROVE GRATING REQNS 01 - User-Specified Drawings – Steelwork 0001015080 0001015081 0001015082 0001015085 0001015086 0001015087 0001015090 0001015091 0001015092 0001015095 0001015096 0001015097 DRAFT & CHECK, 01 APPROVAL, 01 REVISE & IFC, 01 DRAFT & CHECK, 01 APPROVAL, 01 REVISE & IFC, 01 DRAFT & CHECK, 01 APPROVAL, 01 REVISE & IFC, 01 DRAFT & CHECK, 01 APPROVAL, 01 REVISE & IFC, 01 USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) - Instrumentation 0001016000 0001016001 0001016003 0001016010 0001016011 0001016012 0001016013 PREPARE, IFC INSTR INDEX 01 FINALIZE, IFC INSTR INDEX 01 MTO & REQN TAGGED ITEMS 01 DESIGN LOOP DIAGRAMS 01 PREP LOOP DIAGRAMS, IFP 01 APPROVE INSTR LOOP DGS 01 REVIEW LOOP DIAGRAMS IPS Appendix A: Engineering and Procurement Activity Numbers - 755 0001016014 0001016021 0001016022 0001016023 0001016031 0001016032 0001016033 0001016041 0001016042 0001016043 0001016051 0001016052 0001016053 0001016061 0001016062 0001016063 01 REVISE,IFC LOOP DIAGRMS 01 DRAFT&CHECK INSTR LOCN PLANS 01 CLIENT APPROVAL INSTR LOCN 01 REV & IFC INSTR LOCN PLANS 01 DRAFT & CHECK 2-WIRE DIAGRAMS01 APPROVE 2-WIRE DIAGRAMS 01 REV & IFC 2-WIRE DIAGRAMS 01 DRAFT&CHECK INSTR SCHEMATICS 01 APPROVE INSTRUM SCHEMATICS 01 REV & IFC INSTR SCHEMATICS 01 DRAFT&CHK CONN DIAG/JBOX DWGS01 APPROVE CONN DIAG/JBOX DWGS 01 REV & IFC CONN DIAG/JBOX DWGS01 PREP,CHECK CABLE SCHEDULES 01 APPROVAL, CABLE SCHEDS 01 REV & ISSUE CABLE SCHEDS 01 User-Specified Drawings – Instrumentation 0001016080 0001016081 0001016082 0001016085 756 DRAFT & CHECK, 01 APPROVAL, 01 REVISE & IFC, 01 DRAFT & CHECK, USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) - IPS Appendix A: Engineering and Procurement Activity Numbers 0001016086 0001016087 0001016090 0001016091 0001016092 0001016095 0001016096 0001016097 01 APPROVAL, 01 REVISE & IFC, 01 DRAFT & CHECK, 01 APPROVAL, 01 REVISE & IFC, 01 DRAFT & CHECK, 01 APPROVAL, 01 REVISE & IFC, 01 USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) - Electrical 0001017010 0001017011 0001017012 0001017013 0001017015 0001017016 0001017017 0001017018 0001017020 0001017021 0001017022 0001017023 0001017025 PREPARE LIGHTING DWGS 01 DRAFT & CHECK LIGHTING DWGS 01 APPROVE LIGHTING DWGS 01 REV & IFC LIGHTING DWGS 01 PREPARE GROUNDING DWGS 01 DRAFT & CHECK GROUNDING DWGS 01 APPROVE GROUNDING DWGS 01 REV & IFC GROUNDING DWGS 01 PREPARE CABLE TRAY DRAWINGS 01 DRAFT & CHECK CABLE TRAY DWGS01 APPROVE CABLE TRAY DRAWINGS 01 REV & IFC CABLE TRAY DWGS 01 REV,IFD ELECTRICAL ONE LINES - IPS Appendix A: Engineering and Procurement Activity Numbers 757 0001017026 0001017027 0001017030 0001017031 0001017032 0001017040 0001017041 0001017042 0001017050 0001017051 0001017052 0001017060 0001017061 0001017062 0001017065 0001017066 0001017070 0001017071 0001017072 0001017073 758 01 CLIENT APPROVE ELEC ONE LINES01 FINALIZE ELECTRICAL ONE LINES01 PREPARE ELECTRICAL SCHEMATICS01 DRAFT ELECTRICAL SCHEMATICS 01 APPROVE ELECTRICAL SCHEMATICS01 PREPARE POWER DISTRIBUTION 01 DRAFT POWER DISTRIBUTION DWGS01 APPROVE POWER DISTRIB DWGS 01 PREPARE CIRC SCHD & CONN DIAG01 DRAFT CIRC SCHD & CONN DIAG 01 APPROVE CIRC SCHD & CONN DIAG01 PREPARE SUBSTATION LAYOUT 01 DRAFT SUBSTATION LAYOUT DWGS 01 APPROVE SUBSTATN LAYOUT DWGS 01 ASSEMBLE,CHECK POWER PKG 01 REV & ISSUE ELEC POWER PKG 01 PREPARE ELEC TRACING DWGS 01 DRAFT&CHECK ELEC TRACING DWGS01 APPROVE ELEC HEAT TRACING 01 REV & IFC ELEC TRACING DWGS 01 IPS Appendix A: Engineering and Procurement Activity Numbers User-Specified Drawings – Electrical 0001017080 0001017081 0001017082 0001017085 0001017086 0001017087 0001017090 0001017091 0001017092 0001017095 0001017096 0001017097 DRAFT & CHECK, 01 APPROVAL, 01 REVISE & IFC, 01 DRAFT & CHECK, 01 APPROVAL, 01 REVISE & IFC, 01 DRAFT & CHECK, 01 APPROVAL, 01 REVISE & IFC, 01 DRAFT & CHECK, 01 APPROVAL, 01 REVISE & IFC, 01 USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) USER DWG (XX) - Procurement Fixed Activities 0002001000 0002002000 0002002009 0002003000 0002004000 ASSEMBLE,IFC SITE DEVL DWGS ASSEMBLE,IFC EQUIPMENT DWGS EXPEDITING -EQUIP DELIVERY ASSEMBLE,IFC,PIPING DWGS ASSEMBLE,IFC,CIVIL DRAWINGS Control System Procurement 0002004011 0002004012 0002004013 0002004014 0002004016 0002004017 0002005000 0002006000 OBTAIN REBAR QUOTES TAB & RECOMMEND REBAR VENDOR CLIENT APPROVE REBAR VENDOR ISSUE BLANKET P.O., REBAR QUOTE & PURCHASE U-GRND MATL DELIVER EARLY U-GRND PIPING ASSEMBLE,IFC STRUCTURAL DWGS ASSEMBLE,IFC C0NTROL SYSTEM DWGS IPS Appendix A: Engineering and Procurement Activity Numbers 759 0002006011 0002006012 0002006013 0002006014 0002006015 0002006016 0002006017 0002006021 0002006022 0002006023 0002006024 0002006025 0002006026 0002006027 0002006028 0002006031 0002006032 DIGITAL CONTROL SYSTEM QUOTES SELECT DIGITAL CONTRL SYSTEM APPROVE DIGITAL CONTROL SYSTEM PURCHASE DIGITAL CONTROL SYSTEM RECEIVE VENDOR DATA,DIG CTRL SYS REVIEW VENDOR DATA,DIG CTRL SYS FAB & DELIVER DIG CONTROL SYS CONTROL PANEL QUOTES TAB & RECOMMEND PANEL VENDOR CLIENT APPROVE PANEL VENDOR ISSUE P.O., CONTROL PANEL RECEIVE VENDOR DATA, PANEL REVIEW VENDOR DATA, PANEL FABRICATE CONTROL PANEL INSTALL PANEL INSTRMTS & SHIP PURCHASE JUNC BOX, MAJOR CABLE DELIVER JUNC BOX, MAJOR CABLE Electrical 0002007000 0002007011 0002007012 0002007013 0002007014 0002007015 0002007021 0002007022 0002007023 0002007024 0002007025 0002007031 0002007032 0002007033 0002007034 760 ASSEMBLE,IFC ELECTRICAL DWGS OBTAIN QUOTES, ELEC BULKS TAB & SELECT VENDOR, ELEC BULKS CLIENT APPROVE ELEC MATL VENDOR PURCHASE ELECTRICAL BULK MATLS DELIVER ELECTRICAL BULK MATLS OBTAIN QUOTES,MINOR ELEC EQUIP TAB&SELECT VENDOR,MINOR ELEC EQ APPROVE VENDOR, MINOR ELEC EQ PURCHASE MINOR ELEC EQUIPMENT DELIVER MINOR ELEC EQUIPMENT ISSUE MAJOR ELEC EQUIP P.O. RECV VENDOR DATA,MAJOR ELEC EQ REVIEW,RETURN MAJOR ELEC EQ DATA FAB,DELIVER MAJOR ELEC EQUIP IPS Appendix A: Engineering and Procurement Activity Numbers 0002007041 0002007042 0002007043 0002007044 0002007045 0002007071 0002007072 0002007073 0002007074 0002007075 OBTAIN QUOTES, CABLE TRAY TAB & SELECT VENDR,CABLE TRAY APPROVE VENDOR, CABLE TRAY PURCHASE ELEC CABLE TRAY DELIVER ELEC CABLE TRAY OBTAIN QUOTES, ELEC TRACING TAB & SELECT VENDOR,ELEC TRACING APPROVE VENDOR,ELEC TRACING PURCHASE ELEC TRACING MATERIAL DELIVER ELEC TRACING MATL Insulation 0002008000 ASSEMBLE,IFC,INSULATION SPECS Paint 0002009000 ASSEMBLE,IFC,PAINTING SPECS Procurement – By Contractor 0002010001 0002010002 0002010003 0002010004 0002010005 PREPARE MECHANICAL BID PACKAGE APPROVE MECHANICAL BID PACKAGE BID CYCLE, MECHANICAL CONTR APPROVE MECHANICAL CONTRACTOR MOBILIZE, MECHANICAL CONTRACTOR Procurement – By Equipment Class Contract Vessels 0002010011 0002010012 0002010013 0002010014 0002010015 ISSUE P.O., PRESS 01 REC VENDOR DATA,PRESS 01 REVIEW DESIGN, PRESS 01 APPROVE DESIGN, PRESS 01 FAB & SHIP PRESS 01 VESSELSVESSELSVESSELSVESSELSVESSELS- Towers 0002010021 0002010022 0002010023 0002010024 ISSUE P.O., TOWERS 01 REC VENDOR DATA,TOWERS 01 REVIEW DESIGN, TOWERS 01 APPROVE DESIGN, TOWERS IPS Appendix A: Engineering and Procurement Activity Numbers - 761 0002010025 01 FAB & SHIP 01 TOWERS - Storage Tanks 0002010031 0002010032 0002010033 0002010034 0002010035 ISSUE P.O., 01 VENDOR DATA 01 REVIEW DESIGN, 01 APPROVE DESIGN, 01 FAB & SHIP 01 STORAGE TANKSSTORAGE TANKSSTORAGE TANKSSTORAGE TANKSSTORAGE TANKS- Pumps 0002010041 0002010042 0002010043 0002010044 0002010045 ISSUE P.O., PUMPS 01 REC VENDOR DATA,PUMPS 01 REVIEW DESIGN, PUMPS 01 APPROVE DESIGN, PUMPS 01 FAB & SHIP PUMPS 01 - ISSUE P.O., COMPRESSORS 01 REC VENDOR DATA,COMPRESSORS 01 REVIEW DESIGN, COMPRESSORS 01 APPROVE DESIGN, COMPRESSORS 01 FAB & SHIP COMPRESSORS 01 - - Compressors 0002010051 0002010052 0002010053 0002010054 0002010055 - Turbines 0002010061 0002010062 762 ISSUE P.O., TURBINES 01 REC VENDOR DATA,TURBINES - IPS Appendix A: Engineering and Procurement Activity Numbers 0002010063 0002010064 0002010065 01 REVIEW DESIGN, TURBINES 01 APPROVE DESIGN, TURBINES 01 FAB & SHIP TURBINES 01 - Heat Exchangers 0002010071 0002010072 0002010073 0002010074 0002010075 ISSUE P.O., HEAT 01 REC VENDOR DATA,HEAT 01 REVIEW DESIGN, HEAT 01 APPROVE DESIGN, HEAT 01 FAB & SHIP HEAT 01 EXCHNGRSEXCHNGRSEXCHNGRSEXCHNGRSEXCHNGRS- Boilers 0002010081 0002010082 0002010083 0002010084 0002010085 ISSUE P.O., BOILERS 01 REC VENDOR DATA,BOILERS 01 REVIEW DESIGN, BOILERS 01 APPROVE DESIGN, BOILERS 01 FAB & SHIP BOILERS 01 - Furnaces 0002010091 0002010092 0002010093 0002010094 0002010095 ISSUE P.O., FURNACES 01 REC VENDOR DATA,FURNACES 01 REVIEW DESIGN, FURNACES 01 APPROVE DESIGN, FURNACES 01 FAB & SHIP FURNACES 01 - Air Coolers 0002011001 ISSUE P.O., 01 AIR COOLERS IPS Appendix A: Engineering and Procurement Activity Numbers - 763 0002011002 0002011003 0002011004 0002011005 REC VENDOR DATA,AIR 01 REVIEW DESIGN, AIR 01 APPROVE DESIGN, AIR 01 FAB & SHIP AIR 01 COOLERS - COOLERS - COOLERS - COOLERS - REFRIG - REFRIG - REFRIG - REFRIG - REFRIG - Pkg Refrigeration 0002011011 0002011012 0002011013 0002011014 0002011015 ISSUE P.O., PKG 01 REC VENDOR DATA,PKG 01 REVIEW DESIGN, PKG 01 APPROVE DESIGN, PKG 01 FAB & SHIP PKG 01 Generators 0002011021 0002011022 0002011023 0002011024 0002011025 ISSUE P.O., ELEC 01 REC VENDOR DATA,ELEC 01 REVIEW DESIGN, ELEC 01 APPROVE DESIGN, ELEC 01 FAB & SHIP ELEC 01 GENERATRGENERATRGENERATRGENERATRGENERATR- Air Dryers 0002011031 0002011032 0002011033 0002011034 0002011035 764 ISSUE P.O., AIR 01 REC VENDOR DATA,AIR 01 REVIEW DESIGN, AIR 01 APPROVE DESIGN, AIR 01 FAB & SHIP AIR DRYERS - DRYERS - DRYERS - DRYERS - DRYERS - IPS Appendix A: Engineering and Procurement Activity Numbers 01 Conveyors 0002011041 0002011042 0002011043 0002011044 0002011045 ISSUE P.O., CONVEYORS 01 REC VENDOR DATA,CONVEYORS 01 REVIEW DESIGN, CONVEYORS 01 APPROVE DESIGN, CONVEYORS 01 FAB & SHIP CONVEYORS 01 - Mills 0002011051 0002011052 0002011053 0002011054 0002011055 ISSUE P.O., MILLS 01 REC VENDOR DATA,MILLS 01 REVIEW DESIGN, MILLS 01 APPROVE DESIGN, MILLS 01 FAB & SHIP MILLS 01 - ISSUE P.O., FANS 01 REC VENDOR DATA,FANS 01 REVIEW DESIGN, FANS 01 APPROVE DESIGN, FANS 01 FAB & SHIP FANS 01 - - Fans 0002011061 0002011062 0002011063 0002011064 0002011065 - Elevators 0002011071 0002011072 0002011073 0002011074 ISSUE P.O., ELEVATORS 01 REC VENDOR DATA,ELEVATORS 01 REVIEW DESIGN, ELEVATORS 01 APPROVE DESIGN, ELEVATORS 01 IPS Appendix A: Engineering and Procurement Activity Numbers - 765 0002011075 FAB & SHIP 01 ELEVATORS - Motors 0002011081 0002011082 0002011083 0002011084 0002011085 ISSUE P.O., MOTORS 01 REC VENDOR DATA,MOTORS 01 REVIEW DESIGN, MOTORS 01 APPROVE DESIGN, MOTORS 01 FAB & SHIP MOTORS 01 - Dust Collectors 0002011091 0002011092 0002011093 0002011094 0002011095 ISSUE P.O., DUST 01 REC VENDOR DATA,DUST 01 REVIEW DESIGN, DUST 01 APPROVE DESIGN, DUST 01 FAB & SHIP DUST 01 COLLECTRCOLLECTRCOLLECTRCOLLECTRCOLLECTR- Filters 0002012001 0002012002 0002012003 0002012004 0002012005 ISSUE P.O., FILTERS 01 REC VENDOR DATA,FILTERS 01 REVIEW DESIGN, FILTERS 01 APPROVE DESIGN, FILTERS 01 FAB & SHIP FILTERS 01 - Centrifuges 0002012011 0002012012 766 ISSUE P.O., CENTRIFUGES 01 REC VENDOR DATA,CENTRIFUGES 01 - IPS Appendix A: Engineering and Procurement Activity Numbers 0002012013 0002012014 0002012015 REVIEW DESIGN, CENTRIFUGES 01 APPROVE DESIGN, CENTRIFUGES 01 FAB & SHIP CENTRIFUGES 01 - ISSUE P.O., MIXERS 01 REC VENDOR DATA,MIXERS 01 REVIEW DESIGN, MIXERS 01 APPROVE DESIGN, MIXERS 01 FAB & SHIP MIXERS 01 - - Mixers 0002012021 0002012022 0002012023 0002012024 0002012025 - Cooling Towers 0002012031 0002012032 0002012033 0002012034 0002012035 ISSUE P.O., COOLING 01 REC VENDOR DATA,COOLING 01 REVIEW DESIGN, COOLING 01 APPROVE DESIGN, COOLING 01 FAB & SHIP COOLING 01 TOWERTOWERTOWERTOWERTOWER- Misc. Equipment 0002012041 0002012042 0002012043 0002012044 0002012045 ISSUE P.O., MISC 01 REC VENDOR DATA,MISC 01 REVIEW DESIGN, MISC 01 APPROVE DESIGN, MISC 01 FAB & SHIP MISC 01 EQUIP - EQUIP - EQUIP - EQUIP - EQUIP - Package Items 0002012051 0002012052 ISSUE P.O., PACKAGE ITEMS01 REC VENDOR DATA,PACKAGE ITEMS- IPS Appendix A: Engineering and Procurement Activity Numbers 767 0002012053 0002012054 0002012055 01 REVIEW DESIGN, PACKAGE ITEMS01 APPROVE DESIGN, PACKAGE ITEMS01 FAB & SHIP PACKAGE ITEMS01 Packing and Linings 0002012061 0002012062 0002012063 0002012064 0002012065 ISSUE P.O., PACK&LININGS 01 REC VENDOR DATA,PACK&LININGS 01 REVIEW DESIGN, PACK&LININGS 01 APPROVE DESIGN, PACK&LININGS 01 FAB & SHIP PACK&LININGS 01 - Activities Variable by Contractor Piping – Material Vendor 0002013011 0002013012 0002013013 0002013014 0002013015 0002013016 0002013017 PIPING (80%) QUOTES 01 TAB & RECOMMEND VENDOR 01 APPROVE PIPING VENDOR 01 ISSUE P.O., PIPING(80%) 01 DELIVER PIPING (80%) 01 ISSUE P.O., FINAL PIPING 01 DELIVER FINAL PIPING 01 - Piping – Remote Shop 0002013021 0002013022 0002013023 768 PIPE FAB SHOP QUOTES 01 TAB & RECOMMEND PIPE SHOP 01 CLIENT APPROVAL, PIPE SHOP - IPS Appendix A: Engineering and Procurement Activity Numbers 0002013024 0002013025 0002013026 -01 ISSUE PO, PIPE FABRICATION 01 FAB & SHIP SPOOLS (80%) 01 FAB & SHIP FINAL SPOOLS 01 - Civil Contract 0002014001 0002014002 0002014003 0002014004 0002014005 PREP CIVIL&STRUC BID PACKAGE APPROVE CIVIL&STRUC BID PACKAGE BID CYCLE, CIVIL & STRUCTURAL APPROVE CIVIL&STRUC CONTRACTOR MOBILIZE, CIVIL CONTRACTOR Civil 0002014015 0002014021 0002014022 0002014023 0002014024 0002014025 0002014026 0002014027 FAB & DELIVER,REBAR,INBEDS 01 PREPARE BID PKG,BUILDINGS 01 APPROVE BID PKG, BUILDINGS 01 OBTAIN BIDS, BUILDINGS 01 SELECT CONTRACTOR,BUILDINGS 01 APPROVE CONTRACTOR,BUILDINGS 01 SIGN CONTRACT,BUILDNGS 01 MOBILIZE,BUILDING CONTRACTOR 01 - Steel 0002015006 0002015007 0002015008 0002015009 0002015010 0002015011 QUOTE,SELECT STEEL FABRICATOR01 RECEIVE SHOP DWGS, STRUCTURAL01 REVIEW SHOP DWGS ,STRUCTURAL 01 FAB & SHIP STRUCTURAL STEEL 01 MISC STEEL SHOP DRAWINGS 01 REVIEW SHOP DWGS, MISC STEEL - IPS Appendix A: Engineering and Procurement Activity Numbers 769 0002015012 0002015020 0002015021 01 FAB & SHIP MISC STEEL 01 QUOTE & PURCHASE GRATING 01 DETAIL,FAB & DELIVER GRATING 01 Instrumentation 0002016041 0002016042 0002016043 0002016044 0002016045 QUOTE INSTR TAGGED ITEMS 01 SELECT VENDORS,TAGGED ITEMS 01 APPROVE VENDORS,TAGGED ITEMS 01 PURCHASE INSTR TAGGED ITEMS 01 DELIVER INSTR TAGGED ITEMS 01 - Insulation Contract 0002018001 0002018002 0002018003 0002018004 0002018005 PREPARE BID PACKAGE, INSULATION APPROVE BID PACKAGE, INSULATION BIDS,SUPPLY & INSTALL INSULATION APPROVE INSULATION CONTRACTOR MOBILIZE, INSULATION CONTRACTOR Painting Contract 0002019001 0002019002 0002019003 0002019004 0002019005 770 PREPARE BID PACKAGE, PAINT APPROVE BID PACKAGE, PAINT OBTAIN BIDS, PAINTING APPROVE PAINTING CONTRACTOR MOBILIZE, PAINTING CONTRACT IPS Appendix A: Engineering and Procurement Activity Numbers Appendix B: Site Development and Construction Activity Numbers Numbering Conventions The table below illustrates IPS Site Development and Construction activity ID’s as they are described below. The first seven characters of the ten-character activity ID indicate the functional source of the activity (for example, a pipe-rack or a particular item of equipment), and the last three characters indicate the type of work, with a standard description. The first seven characters contain variables, as described below:  The first and second characters indicate the schedule Area number, 01 through 90; and other project-level items, such as substations, control panel and power transmission lines, which always use 91.  The third through fifth characters contain the user-specified tag number (columns 5 - 7) from the estimating system input for equipment items and plant bulks. For substations, the fourth and fifth characters contain the substation reference number (01-99) specified by the user or, if not specified, the System default reference number of 00.  The sixth and seventh characters contain an IPS Equipment Code corresponding to the Equipment Symbol (see Appendix D). Appendix B: Site Development and Construction Activity Numbers 771 All other activities have a fixed identifier in positions six and seven of the activity number, as listed in the table on the following page.  The eighth through tenth characters always refer to the type of work performed in the activity. These last three characters generate a standard activity description, as listed in the Activity ID’s list. Note: For Control Centers or Operations Centers, the fifth and sixth characters contain the Center reference number (01-99) specified by the user. Site Development and Construction – Activity Numbering Conventions Category Range Construction – Areas Equipment Items AA-XXX-YY-2-00-NN through AA-XXX-YY2-35 Plant Bulks, Buildings, Area SD items AA-XXX-91-1-00-NN through AA-XXX-919-35 Area Bulks AA-XXX-91-3-00-NN through AA-XXX-919-35 Construction – project-level Unit Substation 91-OBB-00-4-00-NN through 91-OBB-007-27 Main Substation 91-1BB-00-4-00-NN through 91-1BB-007-27 Control Center 91-20C-C0-6-00-NN through 91-20C-C06-35 Operations Center 91-21C-C0-6-00-NN through 91-21C-C06-35 Transmission Line 91-300-00-7-29-NN through 91-300-007-30 Elec. Hookup and Testing 91-300-00-7-31-NN through 91-300-007-33 Demobilize Project 91-450-00-0-80-NN only AA – Schedule area number BB – Substation reference number CC – Control or operation center reference number NN – Contractor number 772 Appendix B: Site Development and Construction Activity Numbers XXX – Component reference number YY – Equipment type List of Activity Numbers The following Site Development and Construction Activity Numbers are listed by the last three characters only of the 10character Activity Number. The first seven characters will be listed according to numbering conventions discussed above. Note: A blank description or * indicates no logic provided by Aspen Capital Cost Estimator. 126 CURB, GUTTER, Site Development SIDEWALK 100 EARLY SITE 127 TRENCH AND STRUCTURAL DEVELOPMENT COMPLETE EXCAVATION * 101 DELIVER SITE MATERIAL 128 HAND EXCAVATION 102 SUBCONTRACT SITE 129 RAILROADS DEVELOPMENT 130 MASONRY AND CONCRETE 103 WALLS 104 131 FENCING 105 SOIL BORINGS 132 LANDSCAPING 106 DEMOLITION 133 107 CLEAR SITE 134 SITE DEVL USER 108 DEWATERING SUPPLIED ITEM 109 PILING 135 MISCELLANEOUS SITE 110 DEVELOPMENT 111 Equipment Setting 112 WATER WELLS 113 RETAINING WALLS 200 EQUIPMENT SETTING 114 SITE FILL AND * 201 DELIVER EQUIPMENT COMPACTION 202 SUBCONTRACT EQUIPMNT 115 HAULING EARTH 203 FIELD FABRICATE 116 BULK EXCAVATION VESSEL 117 EMBANKMENTS AND DIKES 204 FIELD FABRICATE TOWER 118 SOIL STABILIZATION 205 SET VESSEL IN 119 ROCK EXCAVATION STRUCTURE 120 206 SET TOWER IN 121 DRAINAGE SYSTEMS STRUCTURE 122 BASE PREPARATION 207 SET EXCHANGER IN 123 SUBPAVING STRUCTURE 124 ASPHALT PAVING 208 PUMP SETTING 125 CONCRETE PAVING 209 DRIVER SETTING Appendix B: Site Development and Construction Activity Numbers 773 774 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 VESSEL SETTING TOWER SETTING SETTING COOLING TOWER SETTING PACKAGE BOILER FIELD ERECT EQUIPMENT SETTING STORAGE TANK FIELD ERECT STORAGE TANK TURBINE SETTING FURNACE SETTING REACTOR SETTING COMPRESSOR SETTING HEAT EXCHANGER SETTING AIR COOLER SETTING CONVEYOR SETTING FAN/BLOWER SETTING STACK/FLARE SETTING MILL/CRUSHER SETTING CRANE/HOIST SETTING BLENDER/MIXER SETTNG EQUIPMENT SETTING INSTALL LININGS INSTALL PACKINGS EQUIPMENT USER SUPPLIED ITEM MISCELLANEOUS EQUIPMENT SETTING Piping 300 * 301 302 * 303 304 305 306 PIPING WORK DELIVER PIPING MATERIAL SUBCONTRACT PIPING DELIVER PREFABRICATION PIPE FIELD SHOP PIPING 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 * 334 335 FABRICATION FABRICATE PIPE SUPPORTS ERECT PIPE SUPPORTS ERECT PIPING FIELD WELD PIPE, FITTINGS ERECT VALVES BOLT UP CONNECTIONS MAKE THREADED CONNECTION UTILITY PIPING BURIED PIPE COAT AND WRAP PIPE PROCESS DUCTWORK STEAM TRACING PIPING SYSTEM TESTNG PIPING USER SUPPLIED ITEM MISCELLANEOUS PIPING Civil 400 * 401 402 403 404 CIVIL WORK DELIVER CIVIL MATERIAL SUBCONTRACT CIVIL EXCAVATE FOUNDATION Appendix B: Site Development and Construction Activity Numbers 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 * 430 431 432 433 434 435 504 EXCAVATE TRENCH BACKFILL AND COMPACT SHORING EXCAVATIONS GRADE AND COMPACT BASE FIELD FABRICATE FORMWORK INSTALL FORMWORK STRIP AND CLEAN FORMWORK FIELD FABRICATE REBAR INSTALL REBAR FIELD MIX CONCRETE POUR AND FINISH CONCRETE CONCRETE CURING TIME SET ANCHOR BOLTS GROUT BASE PLATE BUILDING STRUCTURAL BUILDING PLUMBING BUILDING ELECTRICAL SAND MAT FOUNDATION INSTALL PRECAST UNIT CONCRETE STRUCTURES MISCELLANEOUS CONCRETE CIVIL USER SUPPLIED ITEM MISCELLANEOUS CIVIL WORK Steel 500 * 501 502 503 STRUCTURAL STEELWORK DELIVER STRUCTURAL STEEL SUBCONTRACT STEELWORK Appendix B: Site Development and Construction Activity Numbers 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 UNLOAD AND HANDLE STEEL ERECT STEEL STRUCTURE ERECT PIPERACK STEEL EQUIPMENT SUPPORT STEEL GRATING, STAIRS, AND SO ON STEEL USER SUPPLIED ITEM MISCELLANEOUS STEELWORK Instrumentation 600 * 601 602 603 604 INSTRUMENTATION DELIVER INSTRUMENTS SUBCONTRACT INSTRUMENTS INSTALL LOCAL 775 776 605 606 607 608 609 610 * 611 * 612 613 614 615 616 617 618 619 620 621 622 623 624 625 626 627 628 629 630 631 632 633 634 635 INSTRUMENTS INSTALL INSTRUMENT PIPING INSTALL INSTRUMENT WIRING INSTALL JUNCTION BOXES INSTALL CONTROL PANEL CONNECT PANEL INSTRUMENTS COMPUTER INSTALLATION COMPUTER TEST RUNS INSTRUMENT TESTING INSTALL TUBE BUNDLES PULL MULTICORE RUNS INSTALL TERMINATION CABINETS INSTALL RELAY/PC CABINETS INSTALL DATA HIGHWAY INSTALL CONSOLE/VDU Electrical 700 * 701 702 703 704 705 706 707 708 709 710 711 712 713 714 715 716 717 718 719 720 721 INSTRUMENT CONTINUITY CHECK CONTROL SYSTEM TEST INSTRUMENT USER SUPPLIED ITEM MISCELLANEOUS INSTRUMENTION 722 723 724 * 725 726 727 728 729 ELECTRICAL WORK DELIVER ELECTRICAL MATERIAL SUBCONTRACT ELECTRICAL INSTALL BURIED CABLE INSTALL CABLE TRAYS CABLE IN TRAYS INSTALL CONDUIT/FITTINGS PULL WIRE IN CONDUIT ELECTRICAL TRACING RECEPTACLES AND SWITCHES INSTALL PANELBOARDS INSTALL LIGHT FITTINGS PUSH BUTTON, PILOT LIGHT BUS DUCT SUBSTATION STEEL STRUCTURE INSTALL SWITCHGEAR INSTALL SUBSTATION DISCONNECT INSTALL TRANSFORMER INSTALL MOTOR CONTROL CENTER BUILDING LIGHTING INSTALL CATHODIC PROTECTION GROUNDING SYSTEM TRANSMISSION TOWERS Appendix B: Site Development and Construction Activity Numbers 730 731 732 733 734 735 TRANSMISSION LINES ELECTRICAL POWER HOOK-UP ELECTRICAL CIRCUIT CHECK ELECTRICAL SYSTEM TEST ELECTRICAL USER SUPPLIED ITEM MISCELLANEOUS ELECTRICAL Insulation 800 * 801 802 803 804 805 806 807 808 809 810 811 812 813 814 815 816 817 818 819 * 820 821 822 823 824 825 826 827 828 829 INSULATION WORK DELIVER INSULATION MATERIAL SUBCONTRACT INSULATION PIPE INSULATION EQUIPMENT INSULATION FIREPROOFING ACID RESISTANT TILE Appendix B: Site Development and Construction Activity Numbers 830 831 832 833 834 835 INSULATION USER SUPPLIED ITEM MISCELLANEOUS INSULATION Paint 900 * 901 902 903 904 905 906 907 908 909 910 911 912 913 914 915 916 917 918 919 920 921 922 923 924 925 926 927 928 929 930 931 PAINTING WORK DELIVER PAINT MATERIAL SUBCONTRACT PAINTING SURFACE PREP STEELWORK PAINT STEELWORK SURFACE PREP EQUIPMENT PAINT EQUIPMENT SURFACE PREP - PIPING PAINT PIPING 777 778 932 933 * 934 935 PAINT USER SUPPLIED ITEM MISCELLANEOUS PAINTING  Appendix B: Site Development and Construction Activity Numbers Appendix C: Equipment Class Definitions Equipment Class Number Vessels 01 Towers 02 Storage Tanks 03 Pumps 04 Compressors 05 Turbines 06 Heat Exchangers 07 Boilers 08 Furnaces 09 Air Coolers 10 Package Refrigeration 11 Generators 12 Air Dryers 13 Conveyors 14 Mills 15 Fans 16 Elevators 17 Motors 18 Dust Collectors 19 Filters 20 Centrifuges 21 Mixers 22 Cooling Towers 23 Miscellaneous Equipment 24 Package Items 25 IPS Project Schedule Settings 779 Packings and Linings 780 26 Appendix C: Equipment Class Definitions Appendix D: Equipment Codes The Equipment Code identifies the component. In addition, equipment codes can include non-equipment items. The Equipment Codes are as follows. Equipment Item Symbol Description Equipment Code AC Air Compressor 01 AD Air Dryer 03 AG Agitator 72 AT Agitated Tanks 04 BL Blender 06 C Condenser 07 CE Crane 09 CO Conveyor 10 CP Centrifugal Pump 11 CR Crusher 12 CRY Crystallizer 13 CT Centrifuge 14 D Dryer 16 DC Dust Collector 17 DD Drum Dryer 18 DDT Double Diameter Tower 15 E Evaporator 19 EG Electric Generator 20 EJ Ejector 21 EL Elevator 22 F Filter 24 FE Feeder 26 IPS Project Schedule Settings 781 FL Flaker 27 FLR Flare 28 FN Fan 29 FU Furnace 70 GC Gas Compressor 32 GP Gear Pump 34 HE Heat Exchanger 36 HO Hoist 37 HT Horizontal Tank 38 HU Heating Unit 39 K Kneader 42 LIN Lining 73 M Mill 43 MOT Motor/Motor Reducer 68 MX Mixer 44 P Pump 45 PAK Packing 74 R Reactor 48 RB Reboiler 69 RD Rotary Drum 49 RU Refrigeration Unit 50 S Scale 52 SE Separation Equipment 54 ST Stock Treatment 53 STK Stack 55 T Thickener 57 TDS Tray Drying System 58 TUR Turbine 71 TW Single Diameter Tower 60 VP Vacuum Pump 62 VS Screen 63 VT Vertical Tank 64 WFE Wiped Film Evaporator 65 WTS Water Treatment System 66 Other 76 Non-Equipment Codes Open Steel Structure and Mill Building 782 00 Appendix D: Equipment Codes Pipe Rack 01 Pad 02 Shell 03 None 04 Buildings 11-20 Supplemental Bulks Area Bulks 91 31-80 IPS Project Schedule Settings 783 784 Appendix D: Equipment Codes Appendix E: Tutorial In this appendix, a brief tutorial for modifying and preparing the IPS project schedule settings is discussed. Under the tree node IPS Project Schedule Settings => Schedule Appearance Adjustments, the Title of the IPS project is the first input. The default P3E project title (that is,, IPS project title) is the same as the scenario name of the Aspen Capital Cost Estimator project. Typing the IPS project name results in a P3E project with the same name, and the corresponding P3E Enterprise Project Name has also the same name. The EPS project name and EPS Id can be modified using the input provided under Primavera Information => Project Manager Information. Modification of activity description is performed using Description Modification node of the input tree. As an example, consider a detailed engineering activity, (variable by contractor) under civil account with an activity id 0001014013 with an internal description REV & IFC,EQUIP FDN DWGS. The user may wish to change to a less detailed description “PREPARE CIVIL DRAWINGS” as shown above. All the input is entered from the activity number, and the new activity description is entered. Several similar examples are provided above. Description modification for construction is very similar. IPS Project Schedule Settings 785 Adjustments to calculated durations for the generated activities may be performed using the schedule adjustment by duration node. Duration for the engineering and procurement activities can be adjusted as shown below. All three phases may be zeroed out; if the detailed engineering durations are zeroed out, basic engineering activities are automatically set to zero; and if procurement activities are set to zero, basic and detailed engineering activities are zeroed out. In a similar manner, duration of construction activities may be modified as shown below. The durations of construction activities are adjusted by account. Duration of procurement activities are modified by providing the fabrication and ship time of equipment as shown in the next page. 786 Appendix E: Tutorial The IPS-generated activities may be replaced or combined to generate activities as per the user requirements using the activity modifications node. As an example, the figure below shows engineering activity modification screen, and item 1 shows the use of * (in the contract number, activity sequence number and account group number) for the source activity, to combine all basic engineering activities into one single activity with an id of 000003013. Item 2 shows that all IPS Project Schedule Settings 787 detailed civil engineering activities (0001014010 through 0001014097) have been combined into one single civil design activity 0001**4013. Item 3 shows how steel activities are combined into one. If activities are modified and combined, it becomes necessary to generate logic for created activities. In the figure given below, logic modification for several detailed engineering activities are listed, owing to the fact that all basic engineering activities have been combined to one. As an instance, activity 1**2011 (design equipment and piping layout) is assigned a predecessor 1**6007 (Instrument cable tray study) in item 2 of the figure shown below. Existing predecessors for 1**6007 are removed in item 1. 788 Appendix E: Tutorial The remaining schedule adjustments by crew size and crafts have been described in the main section; to be noted is that craft adjustment is simply used to replace the system craft code and description by the users, and des not serve to modify the schedule duration. IPS Project Schedule Settings 789 790 Appendix E: Tutorial Index 2 2/3 rule 202, 386 A About command Help menu 53 Absolute Basis streams 313 Account allocation Code of Accounts 118 ACCUM, escalation 98 Activate Custom Model option Preferences 62 Activity modification IPS project schedule settings 178, 723 Add a Construction Workforce 113 Add Area command 319 Add button Engineering Discipline Info form 103 Pipe Details form 339 Add Contractor command 142 Add Project Component command 326 Add Stream button toolbar 313 Add Stream command View menu, PFD 309 View menu, PFD 313 Add Trend Data to Database command Trend menu, Aspen Icarus Reporter 624, 646 adding templates 32 Adding areas 319, 320 barchart items 158 COA sets 116 contractor sets 146 contractors 142 custom pipe specs 84 drawing types 104 EML items 478, 480 Equipment rental items 129– 132 lines to pipe volumetric model 338 loop to instrument volumetric model 342 power distribution items 133 process control items 137 project components 324–326 project directories 63–67 rental days 130 simulation units 187 streams 228, 235–238, 362– 366 UCL items 485, 488 Adjusting schedule and barcharts IPS Project Schedule Settings 791 project execution schedule settings 155– 156 Air coolers design criteria specifications 201 Air supply instrumentation loop 343 Allow Docking command 46 Allow Pipeline Areas General Project Data dialog box 28 Alternate project directories 65 Analyzer importing from 29–30 Analyzer Scale-Up Module (ASM) 499–504 Anchor bolts civil installation bulk 340 Apply 2/3 Rule for Design Pressure Design Criteria 202 Apply button Component Specifications form 679 Develop Stream specifications form 229, 364 Installation Bulks form 333 Interactive Sizing form 370 Mat'l Man-hour Adjustments form 335 Preferences dialog box 58 Area icons 35 List view display of items 38 mapping 285 simulator 277, 286, 292, 305 Area Information dialog box 319 Area Insulation 321 Area title 321, 324 792 Areas adding 319, 320 deleting 351 dimensions 321, 324 electrical specifications 321, 324 equipment specifications 321, 324 importing 345 index manhours 322, 324 index material costs 322, 324 insulation specifications 321, 324 linking to Consets 147 linking to unit substations 135 paint specifications 321, 324 piping specifications 321, 324 pop-up menu 326 re-numbering 351 steel specifications 321, 324 title 321, 324 type definition 319, 321, 324 ASM See Analyzer Scale-Up Module (ASM) Aspen Icarus Project Scheduler (IPS) using in Kbase environment 160 Aspen Icarus Reporter Data trending 645 Excel reports 637–44 HTML reports 635–36 importing data 649 Management reports 637–40 menu bar 623 report mode 624 standard reports 624–35 Aspen Plus Index link to IPE 266 map specs 190, 191 models used in sizing towers 392 AspenTech Aspen Plus simulator program 190, 191 AspenTech support 18 AspenTech Support Center 18 Auto Filter 644 Automatic Item Evaluation checked command Tools menu 52, 679 Automatic task backup 61 B Backup/Recovery options Preferences 61 Barcharts custom-designed bars 158– 159 project component activity bars 157 Schedule Adjustments specifications form 155– 156 Base stream 230 Base Stream Develop Streams dialog box 313 BaseCase, default scenario name 24, 697 Basic engineering 100 Basis Map dialog box 286 streams 313 Basis for Capital Costs Code of Accounts 115–120 construction workforce 107– 111 contingency and miscellaneous project costs 96 contracts 140 design basis 81 equipment rental 129–132 escalation 97–99 indexing 122 input units of measure 75 introduction 75 libraries 239 output (reports) units of measure customization 79 systems 132–140 BFD See Block Flow Diagram (BFD) Block Flow Diagram (BFD) displaying 279 Drag & Find feature 280 introduction 279 right-click commands 281 View menu 283 Zoom commands 282–283 Bottom sump height towers, design criteria 202 Buildings 317 C Cached project information 55 Cancel button Develop Stream specifications form 229 Capacity changing 499 Capacity over-design factor See Pump overdesign factor Capital Cost errors 608 Capital Costs depreciation 216–217 escalation 217 investment parameters 217 reports 59 View command 284, 307, 308 Capital Costs View IPS Project Schedule Settings 793 View menu 51 CARBONST.DAT 82 Cascade command Window menu 37, 53 Cash Flow Summary reports, Icarus Editor 615 Cashflow spreadsheet 662–70 CASHFLOW.ICS Cashflow spreadsheet 662– 70 ChemCAD map specs 192 simulator report preparation 267–269 Civil installation bulk 340 material costs and manhours 334 specs, design basis 85 Clear All Saved Trends command Trend menu, Aspen Icarus Reporter 645 Close command File menu 49 COA See Code of Accounts (COA) Code of Accounts (COA) adding a COA set 116 allocating costs to 118 allocating UCL item costs to 486 exceptions to account allocations 119 introduction 115 Codes of Accounts (COA) instrumentation field hookup 255 Cold Inlet Stream field 370 Cold Insulation Schedule 322 Cold Outlet Stream field 370 794 Color coding Component Specifications form 331 Component Map Information 290, 292 Component Name 291 Component Specifications form accessing 330 color coding 330, 331 Options button 331, 332 P&ID button 337, 341 Component Status 291 Components See Project components Components view Palette 41, 43 Compressors design criteria specifications 198 sizing 361 Computer name scenario information 31 Configuration options mapping 288, 292 Connectivity, stream explanation 234 Consets adding 146 deleting 151 editing 149–150 linking 147 unlinking 148 Construction equipment rental 129–132 management 97, 101, 155 manpower, escalation 97 schedule 155, 617 workforce 107–111, 142 Construction workforce number 108 Contingencies Index Project Summary spreadsheet (PROJSUM.ICS) 660 Contingency and miscellaneous project costs 96 Contract scope definitions 145–151 exceptions 150 Contractor adding 142 assigning engineering drawings 106 definition, editing 143 deleting 144 linking to workforces 142 reports 617 sets 145–151 unlinking from workforce 143 Contracts Contractors tree diagram 141–145 introduction 140 Scope tree diagram 145–151 Control center adding 137–139 instrument volumetric models 342 introduction, power distribution 137 linking to area 139 linking to Consets 147 linking to power distribution items 135 Control Center button bar 563 Control centers instrumentation loop 343 Control signal instrumentation loop 343 Control valve instrumentation loop 343– 344 Conversion factor input units of measure 26, 78 simulator units of measure 186 Conversion rate currency 28 Copy command project components 347 Cost libraries deleting 497 duplicating 496 Equipment Model Library (EML) 476–482 importing 495 introduction 475 Unit Cost Library (UCL) 483– 493 Costs total direct cost, Equipment Summary (EQUIP.ICS) 654 total project cost, Cashflow spreadsheet (CASHFLOW.ICS) 663 Country Base 27 CPM barchart project schedule 154 CPM Schedules 16 Craft code 112 Craft names modifying 114–115 Craft rates construction workforce specifications 110–112 Craft Wage rate 112 Create New Project dialog box 23, 29, 67, 695 Create New Trend in Excel command Trend menu, Aspen Icarus Reporter 624, 647 Create Stream dialog box 235, 237, 363, 365 Create tab view IPS Project Schedule Settings 795 Develop Streams dialog box 235 Create User Database command File menu, Aspen Icarus Reporter 623, 650 Create User Database dialog box Aspen Icarus Reporter 651 creating line sizing equations 442 Creating project scenario 23–28, 23– 28 streams 228, 235–238, 362– 366 creating projects by importing templates 33 Crew mixes modifying 113–114 Crew size IPS project schedule settings 167, 711 Currency Conversion Rate 28, 74 Project Summary spreadsheet (PROJSUM.ICS) 656 Currency Name 27 Currency Symbol 27 Project Summary spreadsheet (PROJSUM.ICS) 656 Current Map List Project Component Map Specifications dialog box 189 Custom Model instructions 351–356 Preferences 62 Custom P&ID's 796 attaching to a component 448 setting as component’s default in active project only 449 setting as component's default 445 Custom piping specs design basis 81–85 Custom Tasks command Tools menu 52 Customer External Files selecting in project 153 customer support 18 Customized External Steel Costs File Exporting 249 customizing instrument field hook ups 252 Customizing Steel Costs Using an External File 245 Cut command project components 348 Cyclone inlet linear velocity design criteria specifications 210 D Data trending Aspen Icarus Reporter 645 Decision Analyzer command Run menu 50 DEFAULT.DAT 82 Delete a Construction Workforce 113 Delete button Pipe Details form 339 Delete Mappings command 292 Index Deleting areas 351 components 350 contractors 144 cost libraries 497 cost library items 494 mappings 292 power distribution items 136 process control items 140 projects and project scenarios 54 specification files 245 streams 238 Delivery times equipment classes 156 project components 157–158 Density Develop Stream specifications form 231 Depreciation method Cashflow spreadsheet (CASHFLOW.ICS) 663, 667, 670 Project Summary spreadsheet (PROJSUM.ICS) 658 Depreciation Method investment parameters 216 Design allowance 321 Design basis editing 95 introduction 81 Design Criteria specifications, project basis 196–210 Design deflection 321 Design engineering 154 Design pressure applying 2/3 rule for 202, 386 design criteria specifications 196 sizing agitators 380 sizing heat exchangers 387 sizing towers 400 utility specifications 213 Design temperature design criteria specifications 197 sizing agitators 380 sizing heat exchangers 387 sizing towers 400 utility specifications 213 Desired rate of return Cashflow spreadsheet (CASHFLOW.ICS) 663 Executive Summary spreadsheet (EXECSUM.ICS) 672 Project Summary (PROJSUM.ICS) spreadsheet 658 Desired Rate of Return investment parameters specifications 216 Detail engineering 100 Develop Equipment Library Model form 479 Develop Product Specifications dialog box 225 Develop Schedule command Run menu 50 Develop Stream specifications form 229, 364, 365 Develop Streams dialog box 235, 236, 363, 364 Develop Utiltiy Specifications dialog box 211 Diameter option 321 Dimensions, areas 321, 324 Direct costs instrument field hook-ups 252 Directories project, locations Preferences 63–67 Disciplines IPS Project Schedule Settings 797 engineering 102 Disconnect command streams 316 Disconnected Streams dialog box 315 Discounted Cash-Flow Rate of Return See Internal Rate of Return (IRR) Display results after evaluation Preferences 59 Docking 46 Documentation 18 Double-jointed pipe requirement pipeline area specifications 325 Draw Disconnected Stream button toolbar 315 Draw Disconnected Stream command View menu, PFD 315 Draw Disconnected Stream command View menu, PFD 309 Drawing count engineering workforce specifications 105 Drawing number 105, 106 Drawing type engineering workforce specifications 104 Duct installation bulk 340 Durations IPS project schedule settings 169, 713 E e-bulletins 18 Economic Life of Project investment parameters 216 798 Economy - local and world, escalation 97 Edit Connectivity button toolbar 310, 311 Edit Connectivity command View menu, PFD 309, 310 editing external steel material file 246 EI (escalation indices) 98 Electrical installation bulk 344 material costs and manhours 334 specs, areas 321, 324 specs, design basis 88 Electricity operating unit costs specifications 220 E-mail reports 636, 638, 643 EML See Equipment Model Library (EML) Engineering assigning responsibility for 149 disciplines 102 drawings 104 management 101 phases 100 schedule 617 workforce 142 Engineer-Procure-Construct (EPC) period Cashflow spreadsheet (CASHFLOW.ICS) 663 investment parameters 217 Project Summary spreadsheet (PROJSUM.ICS) 657 EQUIP.ICS Index investment analysis spreadsheets 654 Equipment adding 324–326 class delivery times 156 item delivery times 157 number 130, 131 rental 129–132 specifications, areas 321, 324 specs, design basis 81 Equipment Model Library (EML) adding an item to 478 adding EML item as a component 480 creating 476 definition 475 Equipment Rental Summary report 131 Equipment Summary investment analysis spreadsheets 654 ERROR message 608 Escalating library costs 494 Escalation Cashflow spreadsheet (CASHFLOW.ICS) 663 investment parameters 217 Project Summary spreadsheet (PROJSUM.ICS) 658 specifications 97–99 Estimate Class 74 Estimate Date 75 EU country base 27–28 Euro currency, General Project Data 28 Evaluate button Component Specifications form 331, 678 Evaluate Item command 678 Evaluate Project button toolbar 48, 607 Evaluate Project command Run menu 50, 607 Evaluation item 678 Preferences 59 project 607 Evaluation Engine 390, 650 Excavation and backfill civil installation bulk 340 Excel Custom Model files 351– 356 Excel reports Auto Filter 644 descriptions 640 opening 641 EXECSUM.ICS 670–73 Executive Summary spreadsheet 670–73 Exit command Kbase File menu 52–53 EXOPEN 319 Export to Excel Trending Report dialog box Aspen Icarus Reporter 647 Export to Excel Workbook dialog box Aspen Icarus Reporter 638, 642 Export to Icarus SPECS File command File menu 49 Export Trend Data into Excel dialog box Aspen Icarus Reporter 647 Exporting a Customized External Steel Costs File 249 External Simulation Import Tool 52 External Simulation Import Tool command Tools menu 271–274 External Steel Costs File IPS Project Schedule Settings 799 Exporting customized 249 external steel file using 245 external steel material file editing 246 F Facility Type investment parameters 218 FATAL message 608 Field instrumentation, process control 137 supervision, project schedule 155 Field hook-up assembly and parts 251–260 Fieldbus system instrumentation specs, design basis 86 short-circuit protection 86 Fields group 60 File menu Aspen Capital Cost Estimator menu bar 49 Aspen Icarus Reporter menu bar 623 Fireproofing insulation specs 88 Fit into one page Zoom dialog box 282 Float in Main Window command 46 FLOOR 320 Flow rate units product specifications 227 Fluid classes utility streams 212 Foaming tendency trayed towers, design criteria 204 800 Form work civil installation bulk 340 Fraction basis 232 Freeze Content button Properties Window 45 Fuel operating unit costs specifications 221 Furnace fractional efficiency heat exchanger design criteria 201 G G and A expenses Cashflow spreadsheet (CASHFLOW.ICS) 663 Project Summary spreadsheet (PROJSUM.ICS) 657, 659 G and A Expenses investment parameters 218 Galvanizing (for steel) civil/steel specs, design basis 85 paint installation bulk 344 General and administrative costs Cashflow spreadsheet (CASHFLOW.ICS) 663 investment parameters 218 Project Summary spreadsheet (PROJSUM.ICS) 657, 659 General materials, escalation 97 General Project Data creating a new project scenario 27 defining the Project Basis 73 General rates Index construction workforce specifications 107–110 General Wage Rate/Productivity specifications form 108 GRADE 320 Gray borders Component Specifications form 331 Green borders Component Specifications form 331 Grid Settings command View menu, PFD 308, 309 Grids viewing in Block Flow Diagram (BFD) 284 viewing in Process Flow Diagram (PFD) 309 Grids Visible command View menu, BFD 284 Grout civil installation bulk 340 H Heat exchangers design criteria specifications 202 sizing 385–389 utility specifications 210 help desk 18 Help menu 53 HETP (height equivalent of a theoretical plate) packed towers, design criteria 204 Hook-ups customizing 251–260 extra wire for 86 instrumentation 86, 251–260 Hot Inlet Stream field 368 Hot Insulation Schedule 321 Hot Outlet Stream field 370 HTML reports descriptions 635 Item Report 59 opening 636, 637 HYSIM map specs 193 models used in sizing towers 392 simulator report preparation 269–271 HYSYS map specs 194 models used in sizing towers 392 simulator report preparation 271–274 I Icarus Editor printing report section 610 reviewing results 609–19 toolbar 611 Tools menu 52 Icarus Evaluation Engine (IEE) 390, 650 Icarus interface 33–47, 33–47 Icarus Project Component Selection dialog box 290, 480, 488, 490 Icarus Project Scheduler (IPS) See Aspen Icarus Project Scheduler (IPS) icziputil.exe 69 IEE See Icarus Evaluation Engine (IEE) Import command File menu 49 Libraries view, Palette 242, 495 Import Connected Streams option Preferences 62 IPS Project Schedule Settings 801 Import Data command File menu, Aspen Icarus Reporter 623 File menu, Aspen Icarus Reporter 649 Import Installation Bulks option Preferences 62 Import Selection dialog box Aspen Icarus Reporter 650 Importing areas 345 components 345 project from previous version 29–30 scenarios 346 specification files 242 Inasmbly.dat 252 Inch-Pound (IP), units of measure 25, 240, 242 Incomplete items 39 Indexing Project Basis specifications 122 Indicating signal instrumentation loop 343 Indices escalation (EI) 98 system base 98 user base 98 Indirect costs general wage rates 109 Project Summary spreadsheet (PROJSUM.ICS) 660 reports 660 Unit Cost Library (UCL) 476 Indirects field Wage General Info specifications form 109 INFOmational message 608 802 Inparts.dat 252, 253, 254 Input units of measure customization 25–27, 75– 79 Input Units of Measure Specifications dialog box 25, 78 INSCLD##.DAT 89 INSHOT##.DAT 89 Installation bulks accessing 332 civil 340 duct 340 electrical 344 instrumentation 340 insulation 344 introduction 332 material man-hour additions 336 paint 344 pipe details 337 pipe spec 336 Preferences 60 steel 340 Installation Details report 252 Installation guide 18 Installation, assigning responsibility for 149 Instrument air operating unit costs specifications 221 instrument field hook-ups customizing 252 Instrument field hook-ups 251–260 Instrument volumetric model adding loop to 342 deleting loop on 342 instrument bulk items 340– 344 replacing loop on 342 Index Instrumentation customizing field hook-ups 251–260 Fieldbus system 86 installation bulk 340 loop adjustments 343–344 material costs and manhours 334 specs, design basis 85 Insulation installation bulk 344 material costs 334 specs, design basis 88 Insulation Equivalent Length library 90 Interactive sizing 359–372 Interactive Sizing form 287, 291, 367, 370 Interface layour customizing 46 Interface layout Save Window States option 59 understanding 33–47, 33–47 Internal Rate of Return (IRR) Cashflow spreadsheet (CASHFLOW.ICS) 662, 669 Investment Analysis project specifications 214– 227 Investment Analysis View View menu 51, 654 Investment Analysis View command View menu 654 Investment Parameters project specifications 214 IP, units of measure 25, 240, 242 IPE 5.0/5.1 importing from 29–30 IPS Also See Aspen Icarus Project Schedulaer (IPS) IPS project schedule settings activity adjustments 178, 723 appearance adjustments 161, 706 displaying Also See Aspen Icarus Project Schedulaer (IPS) duration adjustments 167, 711 logic adjustments 172, 716 IRR See Internal Rate of Return (IRR) Item evaluation automatic 679 running 678 sample item report 681 Item Report instructions for running 678 Preferences 59 sample 681 Item Report command 678 J Japan country base, General Project Data 27 Job Number field 74 JP country base 27–28 Junction boxes 137 instrumentation loop 343 K Kbase Project Workflow 16 KbaseLog.txt Preferences, Logging 68 Known Issues 18 K-Yen (KY) currency, General Project Data 28 L Labor cost per unit Unit Cost Library (UCL) 486 IPS Project Schedule Settings 803 Labor hours per unit Unit Cost Library (UCL) 486 Labor Unit Costs operating unit costs specifications 220 Laboratory charges Project Summary spreadsheet (PROJSUM.ICS) 657 Laboratory Charges investment parameters 217 Ladders, steel - installation bulks 340 Large CCP Reports splitting 652 Length of delivered pipe section pipeline area specifications 325 Length of Start-up Period investment parameters 219 Libraries Basis for Capital Costs 75, 239 cost libraries 351–497 Equipment Model Library (EML) 476 moving to another directory 251 specification libraries 239– 245 Unit Cost Library (UCL) 483 view 41 line sizing equation creating 442 Line Sizing Equations 441 Line sizing Tutorial 440 Link Area command process control 139 scope definitions 147 Link Control System command 804 power distribution 135 Link to Const. Work Force command 142 Link to Engg. Work Force command 142 Linking contractor sets to areas 147 contractor sets to power distribution 147 contractor sets to process control 147 Liquid entrainment method 207, 408 List view description 38 mapped components 291 relationship to Project Explorer 38 simulator file name 277 Status column 291, 328 Load Data button toolbar 277 Load Data command Run menu 277 Local economy, escalation 97 Locations preferences 64 Logging Preferences 68 Logic modification IPS project schedule settings 172, 716 Loops instrumentation field hookups 253 instrumentation installation bulks 340 modifications 343–344 M Magnification Index Block Flow Diagram (BFD) 282–283 Main Area default report group 318 Main substations adding 133–134 Main Window display options 46 interface, default position 34 printing 49 understanding 36–37 Management reports 637–40 Man-hour indexing 122 Manpower Productivity Expert (MPE) Tools menu 52 Map All Items option Map dialog box 286 Map command pop-up menu 285 Map dialog box 286 Map Items button toolbar 285 Map Items command Run menu 50, 285 Map Selected Item(s) option Map dialog box 286 Mapping simulator models design criteria 196–210 instructions 285–292 specifications 190 units of measure mapping specs 185–188 unsupported models 62 Mass flow Develop Stream specifications form 231 Material adjustments indexing, area level 322, 324 Material and man-hour additions 336 Material and man-hour adjustments 333 installation bulks 354 Material and man-hour indexing 122 Material cost per unit Unit Cost Library (UCL) 486 Material costs code of account allocations 119 escalation 255 indexing 122 inparts.dat file 255 Material Index Info form 123 Material piping specs 81 Material streams product specifications 224 Mean temperature difference (MTD) 387 Menu bar Aspen Capital Cost Estimator 52–53 Aspen Icarus Reporter 623 Kbase 34 Merging Areas Into Projects 152 Merging Projects 152 Metric, units of measure 25, 240, 242 Microsoft Access Database (.mdb) file 650 Mixture button Develop Stream specifications form 229 Mixture Specs developing streams 231 Modify command simulator block 278 streams 315 Modify tab view Develop Streams dialog box 228 MODULE 320 Monthly Rate field equipment rental specifications 130, 132 IPS Project Schedule Settings 805 MTD See Mean temperature difference (MTD) Multi-core runs instrumentation loop 343 MUSE design criteria specifications 201 N Net Present Value (NPV) Cashflow spreadsheet (CASHFLOW.ICS) 668 Net Rate of Return (NRR) Cashflow spreadsheet (CASHFLOW.ICS) 669 New command File menu 23, 29, 49, 695 New Component Information dialog box 327 New Mapping button Project Component Map Specifications dialog box 189 New Project button toolbar 23, 48, 695 NPV See Net Present Value (NPV) NRR See Net Rate of Return (NRR) Number of Periods for Analysis investment parameters 215 Number of shifts 109 Number of Weeks per Period investment parameters 215 O OK button Develop Stream specifications form 229 Installation Bulks form 60, 333 806 Mat'l Man-hour Adjustments form 336 OPEN 320 Open button toolbar 31, 48, 698 Open command File menu 31, 49, 698 Palette Projects view 32 Open Existing Project dialog box 31 Open Workbook command File menu, Aspen Icarus Reporter 623, 645 Opening an existing project 697 Operating and Maintenance Labor Escalation Cashflow spreadsheet (CASHFLOW.ICS) 663 investment parameters 217 Project Summary spreadsheet (PROJSUM.ICS) 658 Operating charges Cashflow spreadsheet (CASHFLOW.ICS) 663 investment parameters 218 Project Summary spreadsheet (PROJSUM.ICS) 659 Operating costs Cashflow spreadsheet (CASHFLOW.ICS) 665 Executive Summary spreadsheet 672 investment parameters 217 product specifications needed to evaluate 226 Project Summary spreadsheet (PROJSUM.ICS) 657, 659 Index raw material specifications needed to evaluate 222 Operating hours per period Project Summary spreadsheet (PROJSUM.ICS) 657 total operating labor cost calculation 661 total product sales calculation 660 total supervision cost calculation 661 Operating Hours per Period investment parameters 219 Operating labor and maintenance costs investment parameters 218, 220 Operating Mode investment parameters 218 Operating supplies Project Summary spreadsheet (PROJSUM.ICS) 657 Operating Supplies investment parameters 217 Operating Unit Costs project specifications 219– 221 Operator center adding 137–139 introduction, power distribution 137 Options button Component Specifications form 331, 332 Options menu Component Specifications form 60 Options sub-menu Tools menu 52 Order Number 350 Output (reports) units of measure customization 79 Overall column efficiency design criteria specifications 206 tower sizing 401 Overdesign factor 371 heat exchangers 202, 387 pumps 198 Overwrite Project Backups option 59, 61 P P&ID See P&ID button; P&ID Libraries; P&ID Editor; Piping and instrumentation drawings (P&ID’s) P&ID button 337, 341, 444 P&ID Editor 440 P3 setup 68 Packed towers design criteria specifications 203 sizing 405, 406 PAD 320 Paint material costs 334 specs, areas 321, 324 specs, design basis 95 Palette Components view 41, 43, 326 cost libraries 476–497 deleting a project from 55 description 40–43 docking and undocking 46 dragging components from 326 floating in Main Window 46 hide/display 43 interface, default position 34 Libraries view 41, 239–245, 476–497 opening projects 32 IPS Project Schedule Settings 807 Projects view 32, 40, 43, 55, 57, 65 Recent Items folder 326 specification libraries 239 unlocking projects from 57 View menu 51, 307 Paste command project components 347 Period Description investment parameters 215 Phases engineering 99 Pipe Details installation bulk 337 Pipe Spec installation bulk 336 Pipeline Also see Pipeline area; Pipeline project; P&ID Editor; Piping and instrumentation drawings (P&ID’s) fluid type, pipeline area specifications 325 internal lining type, pipeline area specifications 325 title, pipeline area specifications 325 Pipeline area adding 325 allowing 28 editing 325 specifications 325 Pipeline project creating 28 description 28 Piping installation bulks 336, 337–339 material costs and manhours 334 specs, design basis 81–85 808 volumetric model \r 338 Piping and instrumentation drawings (P&ID’s) Editor 440 manual 337, 341 printing 444 sending through electronic mail 444 Piping specifications areas 321, 324 Piping volumetric model adding lines to 338 changing lines on 339 deleting lines on 339 replacing lines on 339 Plant bulks 317 Plant capacity changing 499 Plant overhead Cashflow spreadsheet (CASHFLOW.ICS) 663 Project Summary spreadsheet (PROJSUM.ICS) 657, 659 Plant Overhead investment parameters 218 Platforms, steel - installation bulks 340 PLC (Programmable Logic Control) center adding 137–139 introduction, power distribution 137 Ports Visible button toolbar 310 Ports Visible command View menu, PFD 308 Potable water operating unit costs specifiations 220 Index utilities costs, Project Summary spreadsheet (PROJSUM.ICS) 662 Pounds (PS) currency, General Project Data 28 Power distribution adding items 133–134 deleting items 136 introduction 132 linking to Consets 147 links to areas 135 links to control systems 135 Power supply frequency electrical specs 88 Precooler suffix for mapping 289 tower configurations 293, 395, 398 Preferences accessing 58 Backup tab view 61 buttons 58 description 58 General tab view 58 introduction 58 Locations tab view 63–67 Logging tab view 68 Process tab view 62 prompts 58 saving window states 59 Schedule 68 Spreadsheet Views tab 60 Tools menu 52 Prepared By field General Project Data 74 Primary fluid component 230, 232, 363 Primavera Information 183, 727 Primavera user name 68 Prime contractor 141 Print command Kbase File menu 49 Print Preview command File menu 49 Print Setup command File menu 49 Printing Aspen Icarus Reporter 629 forms and reports in Main Window 49 Icarus Editor 610 Pro/II map specs 195 models used in sizing towers 392 R/R minimum 202 simulator report preparation 274–275 Problem description SimSci report preparation 274 Process connection intrumentation loop 343 Process control adding items 137–139 deleting items 140 editing items 138 introduction 136–137 linking to a contractor set 147 linking to contractor sets 147 links to areas 139 Process Design specifications 159–214 Process equipment 317 Process Flow Diagrams (PFD) 305–316 Process Fluids investment parameters 219 Process options Preferences 62 Process Stream field product specifications 226 raw material specifications 223 IPS Project Schedule Settings 809 Process vessel height to diameter ratio design criteria specifications 206 vessel sizing procedure 411, 413 Procurement engineering phases 100 schedule settings 154 Product specifications investment analysis specifications 224–227 Productivity adjustments 109 Products Escalation Cashflow spreadsheet (CASHFLOW.ICS) 663 investment parameters 217 Project Summary spreadsheet (PROJSUM.ICS) 658 Profitability Index (PI) 670 Programmable Logic Control (PLC) centers adding 137–139 introduction, power distribution 137 Project areas See Areas Project Basis Basis for Capital Costs 75– 159 default specifications 239 General Project Data 73 introduction 71 Investment Analysis 214– 227 Process Design 159–214 Project Properties 72 specification libraries 239 Streams 228–239 view 35 Project Capital Escalation 810 Cashflow spreadsheet (CASHFLOW.ICS) 663 investment parameters 217 Project Summary spreadsheet (PROJSUM.ICS) 658 Project component connecting to stream 311 Project Component Map Preview dialog box 287, 290, 292 Project Component Map Specifications dialog box 188 project specifications, Process Design 188–196 Project components adding 326 component specifications 329 copying 347 deleting 350 Equipment Model Library (EML) items 480 importing 345 installation bulks 332 re-numbering 350 scheduling 157–158 Unit Cost Library (UCL) item 488 Project Data Sheet reports, Icarus Editor 613 Project Description Project Summary spreadsheet (PROJSUM.ICS) 655 Project Description field Project Properties 25, 73, 697 Project directories alternate directories 64 Index copying 57 default, setting 66 Project evaluation Preferences 59 running 607 scan for errors 59, 608 Project execution schedule settings project basis specifications 154–159 Project Explorer 34, 35 docking and undocking 46 floating in Main Window 46 interface, default position 34 relation to Palette 40 View menu 51, 307 Project in use - message 56 Project Indirect Summary report equipment rental items 131 Project menu Contracts command 140 Project Name Aspen Plus - IPE simulator link 266 Project Summary spreadsheet (PROJSUM.ICS) 655 Project Name field creating a new project 24, 696 Project Properties creating a new project 25, 697 defining the Project Basis 72 Project scenarios creating new 23–28, 23–28 deleting 54 importing 346 opening existing 697 salvaging 55 saving 53 unlocking 56 Project Schedule Data Sheet reports, Icarus Editor 616 Project Summary reports, Icarus Editor 613 spreadsheet, reviewing investment analysis 655– 62 Project Title 656 General Project Data 74 Project Type Executive Summary spreadsheet 673 Project Summary spreadsheet (PROJSUM.ICS) 656 Project view 36 projects creating from imported templates 33 Projects copying 57 creating 23–28, 23–28 deleting 54 opening existing 697 view 40, 43 PROJSUM.ICS spreadsheet description 655–62 Prompts Preferences 59 Properties Window description 44 docking and undocking 46 floating in Main Window 46 Freeze Content button 45 interface, default position 34 relationship to specifications form 44, 330 View menu 51, 307 PROVISION See SimSci's Pro/II with PROVISION Pump overdesign factor design criteria specifications 198, 390 sizing procedures 389, 390 Pumps IPS Project Schedule Settings 811 design criteria specifications 198 sizing 361 Q Question mark in Status column 328, 330 component specifications 291 Quoted cost item mapping overhead/bottoms split to 394 mapping unsupported models to 62 Quoted cost items mapping unsupported models to 190 Quoted equipment 317, 332 R Rate field product specifications 226 raw material specifications 223 Rate Units field product specifications 227 raw material specifications 223 Raw material costs, project specifications 224 escalation 217 project specifications 221– 224 Raw Material Costs Executive Summary spreadsheet 672 Project Summary spreadsheet (PROJSUM.ICS) 659, 660 Raw Material Escalation 812 Cashflow spreadsheet (CASHFLOW.ICS) 663 investment parameters 217 Project Summary spreadsheet (PROJSUM.ICS) 658 Raw Material Specifications investment analysis, project basis 221–224 Rebar civil installation bulk 340 Recent Items folder 326 Reconnect Sink command stream, Process Flow Diagrams (PFD) 316 Reconnect Source command streams, Process Flow Diagram (PFD) 316 Red borders Component Specifications form 331 Refrigerant 368 Relation attributes 650 Relative Basis streams 313 Remarks field project properties 25, 73 Rental action code 130, 132 Rental Days Required field equipment rental specifications 130, 132 Re-number command Run menu 50, 350, 351 Re-numbering areas 351 project components 350 Report Editor 52 Report files Reporting Assistant 674 Report groups adding 318 Index deleting 318 Preferences, deletion prompt 59 Preferences, display 60 renaming 318 showing, Preferences option 36 Report templates Reporting Assistant 675 Reporter See Aspen Icarus Reporter Reporting Assistant 674–78 Reports customizing 674–78 data trending 645–48 Excel 637–44 HTML 635–36 Item report 678 Management reports 637 producing 678 Standard reports 624–35 Reroute All Streams command Run menu 307 Reset button Develop Stream specifications form 229 Residence time design criteria specifications 204, 206, 207 sizing crystallizers 383 sizing vessels 407, 411, 413 Re-Size command project component pop-up menu 287, 361 Rotating equipment spares 321 Run menu 50 Run Report command File menu, Aspen Icarus Reporter 623 S Cashflow spreadsheet (CASHFLOW.ICS) 663, 664 Project Summary spreadsheet (PROJSUM.ICS) 659, 660, 661 Salvage Project As dialog box 56 Salvage Value Project Summary (PROJSUM.ICS) 658 Salvage Value (Percent of Initial Capital Cost) impact on depreciation 216 investment parameters 216 Salvaging project scenarios 55 Sample_Inasmbly.dat 252, 253 Sample_Inparts.dat 252, 254 Save As command File menu 49, 54 Save button toolbar 48, 53 Save command File menu 49, 53 Save Project As dialog box 54 Save Window States checkbox Preferences 59 Saving cached information 55 project scenarios 53 window states 59 SBI (System Base Indices), escalation 98 Scan for Errors before evaluation Preferences 59 Scan for Errors command Run menu 50 Scan Messages 608 Scenario Description Sales IPS Project Schedule Settings 813 Project Summary spreadsheet (PROJSUM.ICS) 656 Scenario Name field Create New Project dialog box 24, 29, 696 Save Project As dialog box 54 Scenarios creating 23–28, 23–28 deleting 54 importing 29, 346 opening existing 31–32 salvaging 55 saving 53 unlocking 56 Schedule Project Schedule Data Sheet 616 settings 154–159 Schedule Adjustments specifications form 155– 156 Scheduling and cost tracking user name, Preferences 68 Scope definitions 149–150 exceptions 150 Screens design criteria specifications 210 Seismic data civil/steel specs 85 Select a Suffix dialog box 289 Select command Project Basis pop-up menu 250 Select Import Type dialog box 30 Select Simulator Type dialog box 276 Sensor 814 instrumentation loop 343– 344 Separation factor design criteria specifications 207 sizing vessels 407, 408 Shop fab maximum diameter 321 Show Page Bounds View menu, BFD 284 View menu, PFD 308 Sieve tray design 403 Signal cabling, instrumentation - installation bulks 340 SimSci's Pro/II with PROVISION map specs 195 models used in sizing towers 392 R/R minimum 202, 406 SHORTCUT column operation 406 simulator report preparation 274–275 Simulation reports Aspen Plus 262–267, 392, 395 ChemCAD 267–269 HYSIM 269–271, 392, 395 HYSYS 271–274, 392, 395 loading 36 Pro/II 274–275, 392 selecting 276 Simulation units 187 Simulator data loading 275–278 mapping 285–292 mapping specifications 190 unsupported models 62 Simulator File Name Index project specifications, Process Design 276 Simulator Type Executive Summary spreadsheet 673 project specifications, Process Design 275 Project Summary spreadsheet (PROJSUM.ICS) 655 Simulator Units of Measure Mapping Specs project specifications, Process Design 185–188 Single Component Summary Report Preferences 59 Site development 317 Size button 360, 367 Size Icarus Project Component(s) options Map dialog box 287 Size Item option 312, 359 Sizing calculations 377–413 ChemCAD items 268 defaults 377–413 HYSIM items 270 mapped components 287, 291, 359 overview 359 parameters 196, 201, 203, 204, 207, 208, 210 requirements 377–413 Sizing Expert 211, 287, 312, 359–372 Sizing Method field Equipment Model Library (EML) 479 sizing parameter symbols 482 Slot Template dialog box 121 Snap to Grid checkbox Grid properties 309 Snap to Grid command View menu, BFD 284 View menu, PFD 308 Solids handling information design criteria specifications 210 Source Map dialog box 286 Spare parts equipment specs, design basis 81 SPC center adding 137–139 introduction, power distribution 137 Specialty center adding 137–139 introduction, power distribution 137 Specification basis product specifications 226, 227 raw material specifications 223 Specification files creating 240 deleting 245 duplicating 243 importing 242 introduction 239 modifying 242 moving to another directory 251 selecting 250 selecting for use in project 250 Specification libraries customizing 240 introduction 239 moving to another directory 251 specifying split file size 652 split file size specifying 652 IPS Project Schedule Settings 815 Splitting Very Large CCP Reports 652 SPREAD, escalation 98 Spreadsheet Views 60 Spreadsheets customizing 674–78 viewing investment analysis 653 SQL database exporting to Microsoft Access 650 Stairs, steel - installation bulks 340 Standard Basis file, changing location 67 file, selecting 250 input file, General Project Data 74 Standard reports descriptions 625 navigating 626 opening 625 printing 629 searching 628 Starting program 21, 694 Start-up period, length investment parameters 219 Startup, commissioning engineering phases 100 Status bar 34 View menu 51, 307 Status column List view 291, 328 Steam utility 368 Steel design basis specifications 85 fireproofing - insulation specs 88 galvanizing cost civil/steel specs, design basis 85 installation bulk 340 816 material costs and manhours 334 specifications, areas 321, 324 Streams absolute basis 236 adding 312 basis mode 236 connecting to equipment during sizing 366–372 connectivity, Process Flow Diagram (PFD) 310 creating 312 creating from Project Explorer 228, 235–238, 362–366 deleting 238, 316 material 224 modifying 228 process 226 product specifications 224 relative basis 236 Streams List command View menu, BFD 284 View menu, PFD 308 Stress relief option 321 structural steel members specifying weight breakdown for 248 Subcooling tower configurations 293 Subtype 120 Suffixes mapping 288, 289 Supervision costs, Project Summary spreadsheet (PROJSUM.ICS) 661 number of supervisors per shift, Project Summary Index spreadsheet (PROJSUM.ICS) 661 wage rate, Project Summary spreadsheet (PROJSUM.ICS) 661 support, technical 18 System Base Indices (SBI), escalation 98 System cost base data Project Summary (PROJSUM.ICS) 656 Systems power distribution 132–136 process control 136–140 T Tax Rate Cashflow spreadsheet (CASHFLOW.ICS) 663 investment parameters 216 Project Summary spreadsheet (PROJSUM.ICS) 658 technical support 18 Template files Reporting Assistant 675 templates adding 32 creating projects from 33 Templates Tab 45 Tile command Window menu 37, 53 Timed backup 61 Timed Recovery 61 Toolbar buttons 48 description 48 docking 48 interface, default position 34 View menu 51, 307 Tools menu 52 Total Manpower Schedule reports, Icarus Editor 614 Total pipeline length pipeline area specifications 325 Total project cost Cashflow spreadsheet (CASHFLOW.ICS) 663 Tower configurations mapping 288, 295–303, 394–398 Transducers instrumentation loop 343 Transmission lines adding 133–134 Transmitters, instrumentation - installation bulks 340 Trayed towers design criteria specifications 204 sizing 401, 402, 406 Tree diagrams Contractors 141–145 Power Distribution 132–136 Process Control 136–140 Scope 145–151 Trend menu, Aspen Icarus Reporter 624, 646, 647 Trending database reports 645–48 Trim cooler suffix for mapping 289 tower configurations 293, 395, 398 Type definition, area 321, 324 U UBI (User base indices), escalation 98 UCL See Unit Cost Library (UCL) UK country base 27–28 Unique Project Backup options 61 Unit Cost field IPS Project Schedule Settings 817 product specifications 227 raw material specifications 224 Unit Cost Library (UCL) adding an item to 485 adding UCL item to a project 488 creating 484 definition 476 Unit substations adding 133–134 linking to areas 135 United Kingdom country base, General Project Data 27 United States country base, General Project Data 27 Units of measure input customization 25, 75 output (reports) customization 79 project properties 25 Project Summary spreadsheet (PROJSUM.ICS) 656 scenario information 31 Unit Cost Library (UCL) 486 Units of Measure group 60 Units of Measure Specification dialog box 186 Unlink command contractors 143 power distribution 136 Unlock command 56 Unsupported simulator models Preferences 62 Update button Develop Stream specifications form 229 US country base 27–28 818 USD currency, General Project Data 28 User base indices (UBI), escalation 98 User Custom Model 351–356 User name scenario information 31 UserData folder 252 using external steel file 245 Utilities costs 662, 672 escalation 658, 663 list of availiable utility resources 368 usage estimation 233 Utilities Escalation Cashflow spreadsheet (CASHFLOW.ICS) 663 investment parameters 217 Project Summary spreadsheet (PROJSUM.ICS) 658 Utility costs heat-transfer utilities 213 non-heat transfer utilities 220 Utility Specifications project specifications 210– 214 Utility stream creating 211 modifying 211 Utility Unit Costs operating unit costs specifications (non-heat transfer utilities) 220 utility specifications (heattransfer utilities) 213 Index V Valve tray sizing 404 Valves Design Basis instrumentaton specs 85 instrumentation installation bulks 342 piping installation bulks 339 Vapor disengagement height towers, design criteria 203 Version scenario information 31 Vessel design criteria specifications 207–209 height to diameter ratio 206, 411, 413 sizing 361, 407 View Existing Trend Data command Trend menu, Aspen Icarus Reporter 624, 649 View menu 51, 307 Voltage levels electrical specs 88 Volumetric models instrumentation installation bulk 341–342 introduction, main features 15 piping installation bulk 338– 339 W Wages construction workforce 107– 111 WARNing message 608 web site, technical support 18 Weld efficiency 321 What-You-See-Is-What-YouGet Zoom dialog box 282 Wind data civil/steel specs 85 Wind design required 321 Window menu 53 Window states, saving 59 Wire distribution system electrical specs 88 Workbook mode understanding 36–37 View menu 51, 307 Workforce reference base General Wage Rates 109 Workforces construction 107–111 linking to contractors 142 Working capital Cashflow spreadsheet (CASHFLOW.ICS) 665 Working capital percentage Cashflow spreadsheet (CASHFLOW.ICS) 663 Project Summary spreadsheet (PROJSUM.ICS) 657 Working Capital Percentage investment parameters 217 World economy, escalation 97 WYSIWYG Zoom dialog box 282 Y Yen currency, General Project Data 28 Z Zoom Aspen Icarus Reporter 627 Block Flow Diagram (BFD) 282–283 IPS Project Schedule Settings 819

Aspen Capital Cost Estimator V7.3.1 User Guide

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