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ER Estimate Plan Guideline Template
May 2011
Project Management Office Department/Estimating Services Division
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ER Estimate Plan Guideline Template
USE OF TEMPLATE Template is intended to be used as a guideline and reference to help the project team prepare an ER Estimate Plan which will meet Saudi Aramco specified requirements and its purpose as a key estimate planning tool. Objective is to establish an integrated ER Estimate Plan incorporating Saudi Aramco and supporting Project Proposal (Preliminary Engineering) Contractor(s) best practice development processes, procedures and requirements.
REFERENCE SAEP‐25 Estimate Preparation Guidelines Section 3.3.1.1 Initial Kick‐off Meeting “The initial kick‐off meeting will be conducted before the 30% completion of Project Proposal. An ER Estimate Plan, as described in Section 3.3.2, shall be prepared and completed prior to the Kick‐off Meeting.” Section 3.3.2 ER Estimate Plan “SAPMT shall be responsible for developing an ER Estimate Plan which will be reviewed and discussed during the initial kick‐off meeting…”
GENERAL NOTES: Draft copy of the project ER Estimate Plan document is to be prepared and made available prior to the initial ER Estimate Kick‐off Meeting, as a key planning document forming the basis for review, discussion and estimating team(s) alignment Estimate Plan is to have a Cover Sheet (indicating Project Name, Budget Item Number, Document Number, Revision Control, Review & Approval status) and a Table of Contents Additional comments, to provide further clarity, are highlighted in italicized gray color font The following TEMPLATE indicates “typical format & content” for use as a guideline and reference in the development of the project’s integrated ER Estimate Plan:
1.0
PURPOSE 1.1
ER Estimate Plan
Clearly communicate the development basis and approach to prepare, review and approve the Expenditure Request (ER) Estimate in full compliance with Saudi Aramco requirements & establish uniformity among the project team(s) members and stakeholders. Estimate Plan forms Project Management Office Department/Estimating Services Division
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ER Estimate Plan Guideline Template the baseline reference throughout development and becomes the starting point for subsequent conversion into the final detailed Basis of Estimate (BOE) document (generally maintaining common format/elements).
1.2
ER Estimate
A primary document required in support of Saudi Aramco funding process to achieve official project sanction/Expenditure Request Approval (ERA). Expected accuracy is +/‐10% of the actual Total Project Cost at Close‐out/Expenditure Request Completion (ERC).
2.0
ROLES AND RESPONSIBILITIES Reference: SAEP‐25, Section 4.3.1 Saudi Aramco Project Management Team • Responsible for preparation of the ER estimate and providing project documents required to complete the ER Estimate. • Work with the Engineering Contractor to ensure the cost estimate is complete and accurate in accordance with the project scope as described in the approved Project Proposal. Saudi Aramco Project Management Office Department/Estimating Services Division • Assign lead and support estimators who take an active role in defining/communicating Saudi Aramco ER Estimate preparation requirements. • Work to ensure that SAPMT and Engineering Contractor adhere to established ER Preparation and project development guidelines. • Perform final Saudi Aramco review, validation, endorsement and issue of ER Estimate. Project Proposal (Preliminary Engineering Contractor) • Assist SAPMT in the preparation of a complete and accurate ER cost estimate. • Provide dedicated and experienced Estimators and other resources as required for the preparation of the ER Estimate. • Implement an estimate quality plan and assign a QA/QC Estimator separate from the estimating team to perform periodical audits to ensure compliance with the guidelines. Reference Appendix ‐___ for the detailed Project Estimate Team Organization
3.0
APPLICABLE REFERENCE DOCUMENTS Latest edition of the following Saudi Aramco Engineering Procedures: • SAEP‐12 Project Execution Plan • SAEP‐14 Project Proposal • SAEP‐25 Estimate Preparation Guidelines • SAEP‐26 Capital Project Benchmarking Guidelines Include any Project Proposal (Preliminary Engineering) Contractor applicable documents
Project Management Office Department/Estimating Services Division
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ER Estimate Plan Guideline Template
4.0
PROJECT SCOPE SUMMARY State the purpose & primary type of project (Process, Civil/Structural, E&I, Communications, new green‐field, existing revamp, etc) and location(s). Major scope elements by summary level Project Work Breakdown Structure such as Process Units, Off‐sites, Utilities, Demolition, Site Development, etc. Identify capacities, major equipment and component, etc.
5.0
PROJECT EXECUTION STRATEGY Project Execution Plan (PEP) or Simplified Contracting & Procurement Plan developed in accordance with SAEP‐12, shall establish the planning basis for the estimate. Include summary description of contracting strategy: • Project Proposal preliminary engineering phase • Detail Engineering‐Procurement‐Construction phases Include summary description of procurement strategy: • Saudi Aramco Direct Charge (DC) and Contractor Supply Material Plan • Long Lead Material Requirements (e.g. Novation) Prior Approval Expenditure Request (PAER) Requirements
Project Key Milestone Dates Reference Appendix ‐___ for the PEP / Simplified Contracting/Procurement Plan & the Overall Project Summary Schedule.
6.0
ESTIMATE SCHEDULE Key Milestones include: • Project Proposal Start – • Draft Estimate Plan – • Estimate Kick‐off Meeting – • Estimate Plan Approval by Contractor & Saudi Aramco – • Estimate Package Interim Review‐1 w/ Saudi Aramco – • Estimate Package Interim Review‐2 (final pre‐submittal review) w/ Saudi Aramco • Submit Estimate Package to Saudi Aramco PMOD/ESD – • Submit Estimate to Saudi Aramco FPD Budget Director Office – • ERA –
Reference Appendix ‐___ for the detailed ER Estimate Development Schedule
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ER Estimate Plan Guideline Template
7.0
ESTIMATE METHODOLOGY 7.1
General
Application of industry best practice detail estimating methods & techniques supplemented with forced detail & factored methods for minor undefined project scope items, as applicable & described in this plan. Estimate shall reflect the Total Project Cost (TPC) incorporating all Contractor and Saudi Aramco owner elements for engineering, materials, construction, commissioning & start‐up, in accordance with SAEP‐25 requirements. Project Proposal (Preliminary Engineering) Contractor shall clarify and clearly define with Saudi Aramco SAPMT what project elements are to be included within Saudi Aramco Owner costs, in alignment with the project execution plan & strategy, to ensure proper scope & cost allocation to the engineering, procurement and construction contractor(s) component of the estimate.
7.2
Project Work Breakdown Structure (WBS)
Estimate shall be developed, compiled and organized according to the project WBS and Saudi Aramco Code of Accounts (COA). Reference Appendix ‐ ___ for the detailed project WBS • WBS reflects the physical and contractual boundaries of the work and provides the framework to develop and summarize the estimate.
7.3
Estimating Software System Tools
Estimate shall be developed, compiled and presented utilizing the following estimating software systems: • Indicate both primary estimating and secondary support estimating systems used for detail development and summary level reporting such as: o Aspen Capital Cost Estimator (ACCE) for oil and gas facilities o Martin Ryan Application Programming Interface (API) MS Excel templates for loading process equipment & bulks into ACCE o Microsoft Excel in‐house developed tool and data base for… o Others as proposed and described o Confirm the estimate formats & presentation for the submittal of each component in accordance with the WBS and including items such as: o E&I & Comms and Civil/Structural estimates in accordance with defined Saudi Aramco support estimate format requirements (e.g. MS Excel format, linked worksheets, hyper‐linked quotations, etc.) o Detail level & Overall Summaries
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ER Estimate Plan Guideline Template
7.4
Currency
Estimate base currency shall be in USD Specify exchange rates for other applicable currency conversions & cut‐off date basis.
7.5
Units of Measure
Estimates prepared in MS Excel format shall indicate material quantities in METRIC units. Aspen Capital Cost Estimator (ACCE) software file submittals shall have data input basis in IMPERIAL units (including Martin Ryan Excel Templates). Output reporting (only) to be set to METRIC units for interface functionality with Saudi Aramco Enterprise Management System.
8.0
ESTIMATE TECHNICAL BASIS Approved Project Proposal Package establishes the overall basis for ER Estimate and is the baseline from which all subsequently considered scope changes are measured.
9.0
ESTIMATE COST BASIS (APPLIED METHODOLOGY)
9.1
Material & Construction Labor
Develop BY DISCIPLINE, as applicable, in accordance with the Project WBS.
9.1.1 Material Quantification Direct field equipment and bulk material scope quantification shall be in accordance with the project detailed Material Take‐off (MTO) Methodology and in alignment with the Project WBS.
Reference Appendix ‐ ___ for detailed MTO Methodology
Demolition/Mothball • •
Reference SAEP‐25, section 3.3.3.6, sub‐section “a” for inclusion of detailed requirements. Scope shall be quantified, priced and included under discipline construction costs with corresponding COA. Shall be based preferably upon sub‐contract quotes or other as specified.
9.1.2 Material Pricing Direct field equipment and bulk material pricing shall be developed based upon… • Reference SAEP‐25, section 3.3.3.5 for inclusion of detailed requirements. Project Management Office Department/Estimating Services Division
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ER Estimate Plan Guideline Template • • •
Quotations shall be technically & commercially evaluated and presented in Bid Tabulation format with recommended selection and justification if not the lowest quote. Where ACCE is utilized the major equipment costs will be replaced by quotations and/or validated in‐house pricing per requirements. Where ACCE is utilized to generate pricing for bulk materials, the pricing will be indexed to current market conditions based on quotations and/or validated in‐house pricing per requirements.
9.1.3 Construction Labor Man‐hours Direct field construction labor man‐hours shall be developed based upon… • Third Party Software database (ACCE, Richardson, etc), In‐house historical Database. • Specify the base geographic location such as United States Gulf Coast (USGC), company specific USGC, Eastern Province Saudi Arabia, etc. • Specify method for development of direct field “Pre‐commissioning” labor hours such as % factored, database generated, etc. Recommended Labor productivity factor(s) shall be developed and applied to the base location man‐hours to adjust to a site‐specific Saudi Arabian work location, as applicable. • Labor productivity factor(s) shall address all items that may require adjustments to the base productivity such as geographic site location, green‐field, brown‐field, revamp, labor quality & availability, facility complexity, work schedule, overtime, etc. • Provide a table showing labor productivity factor(s) build‐up and how it will be applied in the estimate.
9.1.4 Construction Labor Rate A recommended “All‐in” average hourly construction labor rate(s) shall be developed and applied to the direct field construction labor man‐hours, based upon the execution planning requirements, including all wages, benefits, burdens, base indirect field costs, overhead and profit. • Based on project specific execution planning requirements for type/size of project, etc. Typically this is known as “All‐in” sub‐contract labor rate with separate costs such as prime contractor (e.g. EPC, LSTK, etc), if applicable, covered under Construction Management & Other Indirect Field Costs • Provide detailed construction labor rate(s) build‐up and supporting basis, information, exclusions, etc.
9.2
Construction Management & Other Indirect Field Costs
Construction Management (CM) and other indirect field costs shall be developed, as applicable, based upon the project execution planning requirements.
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ER Estimate Plan Guideline Template
9.2.1 Construction Management Field office staff including supervision, administrative, support personnel, etc Specify the planned basis of development (manpower projection support plan, etc). Typically provided by the prime contractor (LSTK, etc) Generally excludes lower tier subcontractor field office staff, as defined & included in the “All‐in” average hourly construction labor rate(s)
9.2.2 Other Indirect Field Costs Specify items to be included & planned basis for their development. Typical items: Temporary Construction & Utilities (Site offices CM/SAPMT & supplies, etc) Temporary Camp Facilities (Catering/Accommodations) • Construction Management Contractor • SAPMT, as identified • Construction Labor (if not covered by sub‐contract labor rate) Equipment Rental (Heavy lifts) Major Scaffolding Vendor Field Representatives (up to and including pre‐commissioning)
9.3
Detailed Engineering and Home Office Services
Reference SAEP‐25, section 3.3.3.6, sub‐section “q” for inclusion of detailed requirements
9.4
Other Material Costs
Specify the planned basis for each item (e.g. quotation, % factor of __, based on historical, etc.) Freight, Shipping, Handling (i.e. Delivery to jobsite/Lay‐down in field)) • Reference SAEP‐25, section 3.3.3.5, sub‐section “a,6” Custom Duties • Reference SAEP‐25, section 3.3.3.6, sub‐section “m” for inclusion of detailed requirements. Commissioning & Start‐up Spare Parts • Reference SAEP‐25, section 3.3.3.6, sub‐section “k” for inclusion of detailed requirements Capital Spare Parts • Reference SAEP‐25, section 3.3.3.6, sub‐section “k” for inclusion of detailed requirements, if applicable Catalyst, Precious Metals, Chemicals, etc. (Initial fill for start‐up) • Reference SAEP‐25, section 3.3.3.6, sub‐section “l” for inclusion of detailed requirements, if applicable
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ER Estimate Plan Guideline Template
9.5
Allowances
List any Recommended Allowances in tabular format and define what each is intended to cover and specify the planned basis for each item (e.g. % factor of __, based on historical, etc.) Typical: Contractor Overhead & Profit (Contract Fee) • Specify basis as applicable (LSTK Prime Contractor, % of TIC, etc.) Contract Change Order Allowance • for design or field changes, within the terms of the contract, historically experienced on similar type contracts.
9.6
Late Changes
Specify how any late changes, subsequent to estimate input preliminary engineering design deliverables freeze/cut‐off date & associated baseline revision number, will be estimated and included (e.g. change register/log, incorporating 90% Review Package comments from technical review meeting, etc.)
9.7
Commissioning & Start‐up
Specify the planned basis for each item (e.g. manpower projection support plan, % factor of __ based on historical, quotations, etc.) Typical: Construction Support Services (Craft labor, tools & equipment, supervision, management for activities such as blinding/purging/steaming/flushing/etc and any other support services/sub‐contracts such as loading required for initial fill catalyst & chemicals, baseline instrument scraper runs for cross‐ country pipelines, etc.) Miscellaneous costs (Utilities for grass roots facilities such as inert gas, chemicals for flushing & cleaning, lubricants, etc.)
9.8
Saudi Aramco Owner Costs
Typical: Project Proposal Preliminary Engineering • Reference SAEP‐25, section 3.3.3.6, sub‐section “p” for inclusion of detailed requirements. • Shall be based upon released contract(s), as applicable, including latest committed cost and remaining forecast. • Provide copy of latest revision of Project Proposal Engineering Contract Release Document in the Owner Costs Section of ER Package Submittal. Project Management Office Department/Estimating Services Division
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ER Estimate Plan Guideline Template Licensor Scope & fees • Reference SAEP‐25, section 3.3.3.6, sub‐sections “o” for inclusion of detailed requirements. • Shall be based upon actual released contract(s), quotation, etc. • Provide copies of all Licensor Engineering Contract Cost Documents in the Owner Costs Section of ER Package Submittal. SAPMT & Support • Reference SAEP‐25, section 3.3.3.6, sub‐sections “r” for inclusion of detailed requirements. • Shall be based upon detailed support/projection plans & build‐ups. Saudi Aramco Overhead Prorate • Shall be based on latest provided historical % factor.
9.9
Escalation (Cost Trends)
Recommended annual forward escalation shall be applied through the duration of project and shall be based upon current forecast of market conditions. Specify the basis and methodology utilized to determine the recommended escalation indices / percentages.
9.10 Contingency & Risk Analysis Specify the basis and methodology utilized to determine the recommended project contingency. Market Outlook Study & Project Risk Assessment • Reference SAEP‐25, section 3.3.3.4 for inclusion of applicable detailed requirements
10.0
QUALIFICATIONS & ASSUMPTIONS All planned estimate qualifications and assumptions shall be listed with supporting explanation.
11.0
EXCLUSIONS All planned estimate exclusions shall be listed with supporting explanation.
12.0
BENCHMARKING 12.1 Estimate Key Metrics
Compare overall estimate metrics, ratios, and factors with historical data to validate the estimate. Project Management Office Department/Estimating Services Division
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ER Estimate Plan Guideline Template Preliminary Engineering Contractor shall provide a Key Metrics analysis of quantities, costs, labor, etc. Reference Appendix ‐ ___ for Key Metrics Report
12.2 Internal & External (Third party) Benchmarking As identified and requested by Saudi Aramco, reference SAEP‐25, section 3.3.4 & SAEP‐26 for inclusion of applicable detailed requirements
13.0
ESTIMATE QUALITY ASSURANCE 13.1 General Integrated estimate quality plan shall be developed, incorporating Project Proposal (Preliminary Engineering Contractor) processes/procedures/requirements and Saudi Aramco requirements, to ensure the completeness and accuracy of the estimate. Any deviation or waiver from SAEP‐25 requirements shall necessitate a written confirmation from Saudi Aramco Estimating Services Division (ESD) and in case of any conflict SAEP‐25 shall govern.
13.2 Reviews List all planned Preliminary Engineering Contractor internal quality review requirements such as: • Engineering Review • Procurement Review • Construction Review • Estimating Team Review • Project Team Review • Management Review List all Saudi Aramco quality review requirements referencing SAEP‐25, section 3.3.1 • Interim Review(s) (pre‐ER Estimate package submittal) • Final Review (PMOD/ESD processing) 13.3 Estimate Package Submittal SAPMT shall validate the final estimate package contents, complete the associated ER Estimate Package Requirements‐Submittal Validation Sheet and provide an authorized copy of same with the submittal. Project Management Office Department/Estimating Services Division
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ER Estimate Plan Guideline Template Reference Appendix ‐ ___ for ER Estimate Package Requirements‐Submittal Validation sheet.
14.0
APPENDICES Project Estimate Team Organization • Key Estimating Team Personnel Organization Chart • Estimate Responsibility Matrix • Single Point Contacts for Contractor and Saudi Aramco ER Estimate Development Schedule • Reference attached template of typical Project Execution Plan or Simplified Contracting/Procurement Plan & Project Summary Schedule • Inclusive of project life cycle activities per SAEP‐14 Section 3.4.1
Project WBS MTO Methodology • Reference attached template of typical Key Metrics Report ER Estimate Package Requirements‐Submittal Validation Sheet • Reference attached
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ER Estimate Plan Guideline Template
TEMPLATE OF TYPICAL
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ER Estimate Plan Guideline Template
TEMPLATE OF TYPICAL MATERIAL TAKE‐OFF (MTO) METHODOLOGY GENERAL This methodology shall be utilized to generate the direct field material MTO for all discipline Scope of Works. The quantity calculations shall be based on the Project Proposal (Preliminary Engineering) design deliverables and the associated freeze/cut‐off date & baseline revision number, as defined in the ER Estimate Plan. Material take‐off shall be based on NEAT quantities as shown on project design drawings, documents and 3D computer model, as applicable. Any recommended or required allowances, such as rounding off, cut/waste, etc. shall be identified as separate line item(s).
PROCESS EQUIPMENT Item
Material Take‐off Method
Equipment MTO based on of the following documents: 1. Sized Equipment List 2. P&ID’s 3. PFD’s 4. Technical Specifications 5. Equipment Data Sheets All equipment shall be quantified manually as per the sized equipment list and verified in accordance with above deliverables.
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ER Estimate Plan Guideline Template
Items highlighted in Bold are Minimum Equipment Data Required to Load Aspen Capital Cost Estimator (ACCE)
Heat Exchangers Type: (U‐tube, Floating head, Fixed head, Plate & Frame, etc) TEMA Type Bare Tube Surface Area Design Conditions: (Pressure, Temperature) Operating Conditions: (Pressure, Temperature) Material ‐ ASME Designation: (Shell, Tube Sheet, Channel, Tubes) Wall Thickness: (Shell, Tube Sheet, Channel, Tubes) Tracing: (Type / Quantity) Insulation: (Type & Thickness ‐ Default Calculated From Operating Temperature)
Air‐coolers Bare Tube Surface Area Design Conditions: (Pressure, Temperature) Operating Conditions: (Pressure, Temperature) Material ‐ ASME Designation: (Tubes) Number of Bays / Bundles, Tube Length, Bay Width Number of Fans / Bay (2 Defaults) Fan Power Tracing: (Type / Quantity) Insulation: (Type & Thickness ‐ Default Calculated From Operating Temperature)
Columns Type: (Double Diameter, Single Diameter) Dimensions: Diameter and T‐T (Per Section) Type of Internals: (Trays / Packing) Number of Trays or Packing Height & Number of Tray / Packing Sections Design Conditions: (Pressure, Temperature) Operating Conditions: (Pressure, Temperature) Material ‐ ASME Designation: (Shell, Cladding, Trays) ASME Design Basis: (ASME Div.1 or ASME Div.2) Wall Thickness Skirt Height Tracing: (Type / Quantity) Insulation: (Type & Thickness ‐ Default Calculated From Operating Temperature)
Vessels Type (Horizontal, Vertical, Boot) Dimensions: (Diameter and T‐T) Design Conditions: (Pressure, Temperature) Project Management Office Department/Estimating Services Division
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ER Estimate Plan Guideline Template Operating Conditions: (Pressure, Temperature) Material ‐ ASME Designation: (Shell, Cladding, Trays) ASME Design Basis: (ASME Div.1 or ASME Div.2) Wall Thickness Skirt Height Tracing: (Type / Quantity) Insulation: (Type & Thickness ‐ Default Calculated From Operating Temperature)
Tanks Capacity or Dimensions: (Diameter and T‐T) Design Conditions: (Pressure, Temperature) Operating Conditions: (Pressure, Temperature) Material ‐ ASME Designation Wall Thickness Roof Type Tracing: (Type / Quantity) Insulation: (Type & Thickness ‐ Default Calculated From Operating Temperature)
Compressors Type (Centrifugal‐horizontal, Centrifugal, Recip., Fan, etc.) Actual inlet capacity Design Inlet Pressure Design Outlet Pressure Material ‐ ASME Designation Driver Type: (Motor, VSDS, Turbine) Driver Power: (HP) Number of Stages Lube Oil System: (Yes / No) Tracing: (Type / Quantity) Insulation: (Type & Thickness ‐ Default Calculated From Operating Temperature)
Filters Type (Cartridge, Plate and Frame, etc) Flow Rate Design Conditions: (Pressure, Temperature) Operating Conditions: (Pressure, Temperature) Material ‐ ASME Designation Tracing: (Type / Quantity) Insulation: (Type & Thickness ‐ Default Calculated From Operating Temperature)
Furnaces Type (Vertical Cylindrical, Box type, etc) Duty Project Management Office Department/Estimating Services Division
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ER Estimate Plan Guideline Template Standard Gas or Liquid Flow Process Type (Gas / Liquid) Design Conditions ‐ Process Side: (Pressure, Temperature) Operating Conditions: (Pressure, Temperature) Material ‐ ASME Designation: Tubes Tracing: (Type / Quantity) Insulation: (Type & Thickness ‐ Default Calculated From Operating Temperature)
Pumps Type (Centrifugal, API 610, Recip., Multi‐stage, Metering, Gear, etc.) Capacity Head Design Conditions: (Pressure, Temperature) Operating Conditions: (Pressure, Temperature) Material ‐ ASME / API Designation Driver Type: (Motor, VSDS, Turbine) Driver Power: (HP) Primary Seal Plan Secondary Seal Plan Cooling Water Seal Plan Tracing: (Type / Quantity) Insulation: (Type & Thickness ‐ Default Calculated From Operating Temperature)
Flare Type (Derrick Supported, Guyed, Self Supported, Horizontal Ground) Gas Flow Rate Dimensions: (Diameter and T‐T for Each Section) Design Conditions: (Pressure, Temperature) Operating Conditions: (Pressure, Temperature) Material ‐ ASME / API Designation Tracing: (Type / Quantity) Insulation: (Type & Thickness ‐ Default Calculated From Operating Temperature)
Packaged Equipment Type Capacity Design Conditions: (Pressure, Temperature) Operating Conditions: (Pressure, Temperature) Material ‐ ASME Designation Weight Dimension: (Length, Width, Height) Details: (Scope of Supply) Tracing: (Type / Quantity)
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ER Estimate Plan Guideline Template
PIPING Item A/G Pipes Fittings Valves
Material Take‐off Method Taken off on the basis of the following documents: 1. Piping Line Lists 2. P&ID’s 3. Piping Material Specifications & Classes 4. Plot Plans 5. 3D Model (as applicable) 6. Piping Assembly 7. Piping Line Routing Diagrams/Sketches/Layouts/Elevations (if 3D model not applicable) 8. Pipeline alignment / plan & profile drawings (as applicable) Large Bore Diameter (>2”): MTO for pipe lengths, fittings and valve quantities shall be generated utilizing a combination of 3‐D Model (as applicable) and manual material take‐offs (for lines where 3D model is not applicable) Small Bore Diameter (≤2”): Small bore piping including fittings and valves shall be factored as a percentage of the large bore piping (if not reflected in engineered deliverables requirements, otherwise shall utilize manual material takeoffs). Recommended factors applied are to be included in the Basis of Estimate document. Take‐offs will be by line number as per P&IDs. Each line will be broken down as per Work Breakdown Structure (WBS) requirements indicating whether the piping is shop fabricated or field run.
U/G Pipes Fittings Valves
Taken off on the basis of the following documents: 1. P&ID’s 2. Piping Material Specifications & Classes 3. Plot Plans 4. Piping Assembly 5. 3D Model (as applicable) 6. U/G Piping Layout/Line Routing Diagrams/Sketches (if 3D model not applicable) 7. Pipeline alignment / plan & profile drawings (as applicable) MTO for pipe lengths, fittings and valve quantities shall be generated utilizing 3‐D Model (as applicable) or manual material take‐offs (for lines where 3D model is not applicable)
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ER Estimate Plan Guideline Template
Gaskets & Bolts
Taken off on the basis of the following documents: 1. P&ID’s 2. Piping Material Specifications & Classes 3. 3D Model (as applicable) Bolts and Gaskets quantity shall be generated by Aspen Capital Cost Estimator (ACCE) based on the flange count, valve count, and equipment nozzle count. For other systems shall be generated manually or by recommended in‐house historical factor.
Supports Taken off on the basis of the following documents: 1. P&ID’s 2. Piping Material Specifications & Classes Support quantity shall be generated by Aspen Capital Cost Estimator (ACCE) based on the pipe line classification, pipe diameter, and length. For other systems MTO shall be generated manually or by recommended in‐house historical factor. Spring Material Take Off will be done manually using 3D Model (as applicable) as a Supports reference and stress analysis calculations of critical lines. Piping Taken off on the basis of the following documents: Painting 1. Piping Line Lists Coating & 2. P&ID’s Insulation 3. Piping Material Specifications & Classes 4. Insulation Specification 5. Paint & Coating Technical Specifications The piping paint and insulation quantity shall be generated by Aspen Capital Cost Estimator (ACCE) based on the requirements defined on the piping line lists. The requirements (e.g. paint code, prime/intermediate/finish coat thickness, internal/external, insulation type, insulation thickness, and jacketing) shall be input into ACCE for each line to calculate the paint/coating and insulation quantities. For other systems MTO shall be generated manually. Piping Internal Lining
Drawings are used to extract from complete piping Material Take Off report listing the total length of pipe to be lined together with the total number of fittings and flanges, each of these split per size.
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ER Estimate Plan Guideline Template
The following attributes shall be populated on the Piping Material Take‐off (MTO): 1. Work Breakdown Structure (WBS) 2. P&ID Number 3. P&ID Revision 4. Line Identification (line number) 5. Pipe Specification 6. Size 7. Wall thickness 8. Item Description 9. Quantity 10. Unit of Measure (UOM) 11. Paint Requirement 12. Insulation Requirement 13. Insulation Type 14. Insulation Thickness 15. Tracing Requirement (steam tracing – ST, glycol tracing – GT, electric tracing – ET) 16. Number of Tracers 17. Location (on‐module, off‐module, underground, vendor supplied) CIVIL Item
Material Take‐off Method Minimum Design Requirements: Earth works 1. Plot Plans General earthwork ‐ 2. Geotechnical/Topographical Survey rough grading & site 3. Grading plans preparation 4. Earthwork Cross Sections Drawings Excavation and fillings Manual Take‐offs on the basis of the above drawings generated mainly works by volume as well as some by area Minimum Design Requirements: Trench excavation for 1. Detail Foundation Drawings U/G networks and 2. Detail Piping Layouts foundations pits/basin 3. Concrete works: formwork drawings Manual Take‐offs of excavation volumes through evaluation of surface areas and depth of excavation on the basis of the above drawings. Roads
Paving
Manual Take‐offs on the basis of the surfaces shown on Plot plans, roads general layout, road details, civil specifications and geotechnical report. Manual Take‐offs on the basis of road surfaces shown on Plot plans, Paving details, Paving plans civil specifications and geotechnical report.
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ER Estimate Plan Guideline Template
Site Finishing Concrete Foundations
Manual calculation of surface areas on the basis of plot plan, site finishing plan and details. Manual Take‐offs based on formwork & reinforcement details, foundation plans and other detail foundation drawings.
Concrete Pits & Basin Minimum Engineering Requirements 1. Formwork & reinforcement details (Pits, Manholes, 2. Foundation plans Basins and Above 3. Piping/Electrical/Instrument layouts grade canal) Manual calculation of the volumes, surfaces areas or quantity of each component on the basis of the above mentioned documents. Minimum Engineering Requirements Concrete Firewalls 1. Formwork & reinforcement details (Transformer 2. Substation plans firewalls) Manual calculation for volumes, surfaces areas or quantity on the basis of the above mentioned documents. Sewer and Drainage Minimum design requirements: 1. Drainage system details (Sewer & drainage) 2. Sanitary sewer network layouts 3. Rainwater drainage layouts Manual quantification based on above documents. Typically these are systems without metal or plastic pipe and cover items such as concrete pipe, catch basins, manholes, culverts, open channels, trenches, etc. Minimum Design Requirements: Fencing 1. Civil works general layout (Fencing and Gates) 2. Plot plan 3. Fencing details Manual calculation of the length of each fence & quantity & type of gate on the basis of the above mentioned documents. Minimum Design Requirements: Piling 1. Piling Plan / Layouts 2. Piling Specification/material description Manual Take‐off quantities by type and size.
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ER Estimate Plan Guideline Template
The following attributes shall be populated on the Civil Material Take‐off (MTO): 1. 2. 3. 4.
Work Breakdown Structure (WBS) Drawing Number Drawing Revision Item Identification (equipment tag number, building tag number, component ID – for concrete) 5. Item Description (ACCE foundation type – for concrete) 6. Quantity STRUCTURAL STEEL Item Material Take‐off Method Minimum Design Requirements: • Pipe racks 1. Pipe racks plans & details • Cable racks 2. Cable racks plans & details • Platform & 3. Platforms plans & details walkways 4. Shelters plans & details • Shelters 5. Equipment Structure plans & details • Equipment 6. Steel frames & supports details structure 7. Walkways/stairs plans & details • Steel frames & Manual calculation of the weight (tonnes) of structure (bracing and connection supports plates included), surface area of cladding, weight of ladders, handrails, grating • Stairs and quantity of self closing gates, based on characteristic of the structure, • Ladders required bearing capacity and on the above mentioned documents. Total steelwork weight will be shown in below categories: • Extra‐Light steel structures • Light steel structures • Medium steel structures • Heavy steel structures • Extra‐Heavy steel structures • Handrail • Cladding • Ladders • Self closing gates for ladders • Grating non‐Shaped panels • Grating treads
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ER Estimate Plan Guideline Template
(Cont’d)
For steel structures the unit rate of the components shall be inclusive of all materials, welds, work, consumables, surface treatments; for ladders and cladding, all connecting fitting and accessory (i.e. clamps, bolts, screws, flushing, downspouts, etc.), laboratory tests, inspections, certificates, shop drawings, installation instructions, packing, profits, etc. to supply components complete ex‐factory.
The following attributes shall be populated on the Structural Steel Material Take‐off (MTO): 1. Work Breakdown Structure (WBS) 2. Drawing Number 3. Drawing Revision 4. Item Identification 5. Size (length, width, height) 6. Weight by Category (Quantity) 7. Unit of Measure (UOM) 8. Paint Requirements 9. Location (on‐module, off‐module, vendor supplied BUILDINGS Item Material Take‐off Method Minimum Design Requirements: Buildings 1. Building List 2. Architectural building drawings (Plans, Elevations, Sections, Details) 3. Structural building drawings (including foundations) 4. HVAC system drawings 5. Electrical system drawings 6. Fire & Smoke Detection system drawings 7. Telecommunication system drawings 8. Plumbing system drawings Building quantities based on size (SF, length, width, height, levels), type (control building, substation, compressor shelter, analyzer building, PIB, field erected versus pre‐fabricated, etc) and key materials. The following attributes shall be populated on the Building MTO: 1. Work Breakdown Structure (WBS) 2. Drawing Number 3. Drawing Revision 4. Item Identification (building tag number) 5. Item Description 6. Size (length, width, height) 7. Quantity Project Management Office Department/Estimating Services Division
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8. Unit of Measure (UOM) 9. Building Classification, Utilities, HVAC, and Services 10. Construction Type (stick built, pre‐engineered) INSTRUMENTATION Item Control Valves On‐off Valves (pneumatic and electric)
Method of Material Take Off Valve MTO shall be based on: • Instrument Installation Schedule ‐ Valves • P&ID’s Quantification shall be based on Instrument Installation Schedule and verified according to the P&ID’s.
Analyzers
Analyzers MTO shall be based on: • Instrument Installation Schedule – Analyzers • P&ID’s Quantification shall be based on Instrument Installation Schedule and verified according to the P&ID’s.
Flow Instruments
Flow Instruments MTO shall be based on: • Instrument Installation Schedule – Flow instruments • P&ID’s Quantification shall be based on Instrument Installation Schedule and verified according to the P&ID’s.
Pressure Instruments
Pressure Instruments MTO shall be based on: • Instrument Installation Schedule – Pressure instruments • P&ID’s Quantification shall be based on Instrument Installation Schedule and verified according to the P&ID’s.
Level Instruments
Level Instruments MTO shall be based on: • Instrument Installation Schedule – Level instruments • P&ID’s Quantification shall be based on Instrument Installation Schedule and verified according to the P&ID’s.
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Temperature Instruments
Temperature Instruments MTO shall be based on: • Instrument Installation Schedule – Temperature instruments • P&ID’s Quantification shall be based on Instrument Installation Schedule and verified according to the P&ID’s.
Miscellaneous Instruments
Miscellaneous Instruments MTO shall be based on: • Instrument Installation Schedule – Miscellaneous instruments • P&ID’s Quantification shall be based on Instrument Installation Schedule and verified according to the P&ID’s.
Fire Detectors and Fire Alarm Panels
Fire and smoke detector sensors and Fire Alarm Panels MTO shall be based on: • Buildings Fire Detection System Layout.
Interface Panels
Interface Panels shall be quantified based on the number of electric substations and the number of I/O to be connected on each.
Single Pair Cables
Single Pair cables (from instrument to JB) MTO shall be based on: • Electric and electronic Instrument and valve List.
Home‐run (Multicore) Cables
Home‐run multi‐core cables MTO shall be based on: • Instrument Cable List • Instrument Cable routing layout Quantification shall be based on Instrument Cable List and verified according to Instrument Cable routing layout.
Junction Boxes
Junction boxes MTO shall be based on: • Instrument location layout.
Cable Trays
Cable trays MTO shall be based on: • Main cable routing layout • Main cable routing sections.
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Instrument Air Supply Bulk Materials
Instrument air bulk material MTO shall be based on: • Plot Plan with Pneumatic Instruments • Instrument installation details–Hook‐up for Pneumatic connection.
Process Connection Bulk Process connection bulk material MTO shall be based on: Materials • Instrument installation details – Hook‐up for Primary connection. Electric Connection Bulk Electric connection bulk material MTO shall be based on: Materials • Instrument installation details ‐ Hook‐up for Electrical connection. Minor Steel Structures Minor Steel Structures bulk material MTO shall be based on: • Instrument installation details ‐ Sketches for instrument supports. The following attributes shall be populated on the Instrumentation Material Take‐off (MTO): 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Work Breakdown Structure (WBS) P&ID Number P&ID Revision Line Identification (line number) Instrument Tag Number Item Description Size & Rating (in‐line instruments) Quantity Unit of Measure (UOM) Process Detail Pneumatic Detail Mounting Detail Unit Price Location (on‐module, off‐module, underground, vendor supplied)
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AUTOMATION Item
Method of Material Take Off
PCS
The PCS (DCS, ESD, VMS, Compressor Control, etc) scope and quantification is based on the project specifications, control system schematic/block diagram and I/O counts.
SCADA
SCADA scope and quantification based on the project specifications.
TELECOMMUNICATIONS Item PA/GA Equipment
Method of Material Take Off MTO shall be based on: • Control Cabinet & Extensions – Block Diagram • Internal Building–Telephones, loudspeaker & junction boxes location layout • Plant ‐ Telephones, loudspeakers and junction boxes location layout.
PA/GA multi/single pair signal cables and power cables
MTO shall be based on: • Overall Site Plant – Main cables layout from CCR to distribution points • Internal Building–Telephones, loudspeaker & junction boxes location layout • Plant ‐ Telephones, loudspeakers and junction boxes location layout.
PA/GA bulk installation material
MTO shall be based on: • Internal Building–Typical telephones, loudspeakers mechanical installation • Plant ‐ Typical telephones and loudspeakers mechanical installation.
CCTV Equipment
MTO shall be based on: • Central Control Supervision Station – Block Diagram • Overall Site Plant – Cameras location & Fiber Optic Cable Layout.
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Application Software shall be based on: • Specification for CCTV System. CCTV fiber optic MTO shall be based on: cables • Overall Site Plant – Cameras location & Fiber Optic Cable Layout CCTV bulk installation material
MTO shall be based on:
OSP
MTO shall be based on:
• Plant ‐ Typical cameras mechanical installation
• Fiber optic cable route layout • Trench layout (cable / conduit) • Fiber optic cable schematic layout / detail ISP
MTO shall be based on: • Floor plan equipment layout telecom room • Cable runway & structure telecom room • Grounding system telecom room • Internal building‐telephones, loudspeakers & junction boxes location layout • Plant‐telephones, loudspeakers & junction boxes location layout
Data/Voice/SD H Systems
MTO shall be based on: • Overall network architecture • Logic Diagram
Video MTO shall be based on: Teleconference • Typical block and level diagram System • VC system layout Wireless LAN System
MTO shall be based on:
Radio Systems
MTO shall be based on:
• Block and level diagram • Access point – indoor mounting • Access point ‐ outdoor • Equipment and component layout
• Block and level diagram • Antenna and transmission line layout • Equipment and component layout Project Management Office Department/Estimating Services Division
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IDAS (CCTV, MIDS, FOFSS)
MTO shall be based on:
Physical Security Systems
MTO shall be based on:
• Block and level diagram • Field devices layout • Equipment and component layout • Local monitoring station layout • Video wall system • FOC and terminations • IMUX/DATA network • Security control center
• Block and level diagram • Gate devices layout • Building access layout • Local monitoring station layout • Security control center layout
ELECTRICAL Item
Method of Material Take‐offs
Transformers, Cable The number of power transformers and the length of the cable busses Busses & Bus duct (if will be quantified on the basis of the followings documents/drawings: any) 1. Single Line Diagrams. 2. Electric Load List / Load Summary. 3. Plot Plan / Electrical Layout 4. Specification Sheet Equipment 5. Electrical Equipment List GIS System
GIS components will be quantified from single Line diagrams and equipment layout.
Switchgear
The number and components (number of circuit breakers, bus bare ratings, auxiliary circuits etc) of the switchgears will be quantified from single Line diagrams and electric Load List / Load Summary.
(Panels and Feeders number and type)
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AC / DC UPS
Feeder & Power Cables
MTO based on below listed documents/drawings: 1. Single Line Diagrams 2. Electric Load List / Load Summary 3. Specification sheet Equipment layout. Taken off on the basis of the followings documents/drawings: • Cable Route Plan/Layouts & elevation • Cable schedule Power cable quantities will be based on cable schedule. The quantities will be verified with Cable route plan and layout.
Control Cables
Taken off on the basis of the followings documents/drawings: • Cable Route Plan/Layouts & elevation • Cable schedule Control cable quantities will be based on cable schedule. The quantities will be verified with Cable route plan and layout.
Trenches Trays Conduit Ducts
Taken off on the basis of the followings documents/drawings: • Cable Route Plan/Layouts & elevation • Cable schedule Trenches volume, duct banks dimensions, cable trays and conduit pipes will be taken off from cable route plan and layouts.
Concrete Duct Banks Minimum design requirements: 1. Electrical/instrumentation layouts 2. Electrical/instrumentation duct banks details Manual calculation of the volumes of each component on the basis of the above mentioned documents. Underground Works Minimum Design Requirements: 1. Electrical/instrumentation cable laying details Electrical & 2. Electrical/instrumentation cable layouts Instrument Manual calculation of each component based on above mentioned documents.
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Grounding
Taken off on the basis of the followings documents/drawings: • Electrical Design Criteria & Calculation grounding system for S/S • Grounding Plan/Layouts • Grounding system installation details Grounding bulk materials and cables will be quantified on the basis on grounding plan/layout. Related bulk materials such as switchgears, transformer, etc will be based on Grounding installation details.
Lighting
Taken off on the basis of the followings documents/drawings: • Electrical Design Criteria & calculation • Lighting requirements • Lighting system installation details • Calculation for the illumination based on grid calculation • Lighting Plans / Layout Drawing Lighting materials (fixtures, poles, etc) will be quantified based on illumination requirements. Related bulk materials will be quantified on the basis of illumination requirements.
Remote Control Stations & Safety Switches Power Sockets
Remote control stations and switches will be quantified based on below documents/drawings: • Electrical Design Criteria • Electrical typical installation drawings • Electrical load list/SLDs Power sockets shall be counted on the basis of the followings documents/drawings: • Electrical Design Criteria • Electrical load list • Power system Layout/estimated Related materials necessary for the installations will be evaluated on the basis of the installation details
Local Power Distribution Panels
Local panel will be counted on the basis of the followings documents/drawings: • Electrical Design Criteria • Electrical typical installation drawings • Electrical load list • Cable route/ illumination requirements /Layouts & Power System Related materials necessary for the installations will be evaluated on the basis of the installation details
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Cable Glands HV and MV Cable Joints & Terminations Conduit Fittings
Cathodic Protection (package supply)
Cable gland will be counted and sized on the basis on Cable schedule. Terminations will be counted on the basis of cable schedule.
Taken off on the basis of the followings documents/drawings: • Electrical Design Criteria • Electrical typical installation drawings • Cable route/ illumination requirements /Layouts & Power System MTO is part of the Cathodic Protection sub‐contacting package (site survey, engineering, materials, commissioning) that a NACE certified selected Vendor will supply. The Material take‐off will be based on Purchase Order quantities. Material group.
The following attributes shall be populated on the Electrical Material Take‐off (MTO): 1. Work Breakdown Structure (WBS) 2. Item Description 3. Equipment Tag Number 4. Quantity 5. Unit of Measure (UOM) 6. Location (on‐module, off‐module, underground, vendor supplied)
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INSULATION & FIREPROOFING Insulation & MTO based on the following documents: Fireproofing 1. Sized Equipment List 2. Piping Line Lists 3. P&ID’s 4. PFD’s 5. Technical Specifications 6. Equipment Data Sheets 7. Piping Material Specifications & Classes 8. Fireproofing Specifications 9. Structural steel layout/plan/detail drawings The quantity for equipment and piping shall be generated by Aspen Capital Cost Estimator (ACCE) based on the requirements defined in above documents. Requirements (e.g. insulation/FP type, insulation/FP thickness, jacketing, shop or field) shall be input into ACCE for each equipment/piping item to calculate the insulation/FP quantity. For structural steel fireproofing and utilization of other estimating systems MTO shall be generated manually based on above documents. PAINT & COATING Paint & Coating
MTO based on the following documents: 1. Sized Equipment List 2. Piping Line Lists 3. P&ID’s 5. Paint & Coating Technical Specifications 6. Equipment Data Sheets 7. Piping Material Specifications & Classes 8. Structural steel layout/plan/detail drawings The quantity for equipment and piping shall be generated by Aspen Capital Cost Estimator (ACCE) based on the requirements defined in above documents. Requirements (e.g. paint/coating type, internal / external, prime / intermediate / finish coat & thickness, shop or field) shall be input into ACCE for each equipment / piping item to calculate the paint/coating quantity. For structural steel paint/coating and utilization of other estimating systems MTO shall be generated manually, as applicable.
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ER ESTIMATE PACKAGE REQUIREMENTS Submittal Validation Sheet BI Number: BI Title:
Item
SAEP‐25 Applicable Section
1.
2.
3.3.3.1
3.
3.3.3.2
4.
3.3.3.3
5.
3.3.3.4
6.
3.3.3.5 a
7.
3.3.3.5 b
8.
3.3.3.5 c,d
9.
3.3.3.6
Description
ER Estimate Package includes a hard‐bound copy and an electronic copy on a CD (including native working copy of estimate) with all required back‐up documents as specified in SAEP‐25 • Reference SAEP‐14 Section 3.4.5 Table of Contents, Approval Sheet and Revision Control Project Summary Basis of Estimate (BOE) Document Market Outlook & Project Risk Assessment • as applicable Material & Equipment Quotations • Bid tabulation format • Label quotes with unique identifier for referencing Material Take‐Off (MTO) • developed in accordance with approved ER Estimate Plan Material Sources Identified • Saudi Aramco DC / Contractor Supply ER Estimate • developed in accordance with approved ER Estimate Plan including all Contractor & Saudi Aramco Owner Cost elements • Saudi Aramco Owner Costs supporting back‐up including copies of Project Proposal contract release(s) and all
Project Management Office Department/Estimating Services Division
SAPMT Validation (Estimate Lead Project Engineer Initials)
Comments
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relevant Licensor Contract cost data, etc 10.
11.
12.
13.
14.
3.3.3.7
3.3.3.8
3.3.3.9
3.3.3.10
3.3.4
ER Estimate 56D Form • Draft SAPMT copy Project Proposal Package • in accordance with SAEP‐14 • approval sheet signed by SAPMT, FPD & Proponent Managers, as a minimum • drawings, specifications & other related design documents per approved deliverables list • DBSP Deviation List with cost/schedule impact • copies of approved Waivers • copy of final Technical Review Meeting Minutes Approved Project Execution Plan or Simplified Contracting/Procurement Plan • in accordance with SAEP‐12 Project Summary Schedule • in accordance with SAEP‐14 Section 3.4.1 Benchmarking • in accordance with SAEP‐26, as applicable
CONCURRENCE: __________________________ SAPMT Senior Project Engineer __________________________ SAPMT Project Manager
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