# RADIAN

......e••••oM MBMORAHDUM 

## TO: Mary Tom Kissell FROM: 

## Kristine Pelt DATE: 

## February 1, 1994 

# A-90-23 IV-B-7

SUBJECT: Steam Stripper Total Capital Investment and Total Annual Costs
This memorandum discusses the**equation~** 

## and assumptions used to**devel~p** 

## total capital investment (TCI) and total annual cost {TAC) for the HON wastewater design steam stripper. A 

# LOTus• spreadsheet was developed to calculate these costs, and a copy of this spreadsheet is attached.**T~e** 

## design basis of the·steam stripper will**b~ ~iscussed**  

## in detail in a separate steam stripper design memorandum.l
.. That steam stripper design memorandum will include a discussion of steam-to-feed ratio, column diameter, number of trays, and .column height, which are all inputs to the Lotus• cost program. Therefore, these parameters are not discussed in detail in this memorandum. The algorithms for TCI and TAC developed in this memorandum were used to optimize the stream to feed ratio for the design steam stripper.2 Once the steam to feed ratio was optimized, the new steam to feed ratio (0.04 kg steam per kilogram of wastewater) was**~sed** 

## in the.Lotus spreadsheet to generate the cost equations that would be used in the**f~amework** 

## to generate cost impacts for wastewater.3

## Th~s**memora~du~ W~S·Written**  to document the assumptions used in the Lotus spreadsheet·and does not necessarily reflect the final design parameters. Sections 1. 0 and· 2
.. 

# o present in detail the TCI' and· 

## TAC for an 

## so gpm (300 tpm) steam stripper system. A steam stripper witn an 80**gp~** 

## flow rate of wastewater was chosen as**a~** 

## example because this flow rate is the median of the five flow rates which were used to develop cost equations for TCI and 

## TAC. Section 3.0 presents a summary and comparison of the TCI and TAC for steam stripper systems designed for five dift:erent wastewater feed flow rates ranging from 10 to 200 gpm (40 to 760 tpm).·

### 1.0 

## TOTAL CAPITAL INVESTMENT Table 1-1 

## presents the TCI for an 80 gpm (300 

## tpm) steam stripper system. Total capital investment is the sum of the basic equipment cost (BEC), the purchased equipment cost (PEC), and the direct and indirect installation costs. The BEC includes the cost of the steam stripping column, feed tank, feed preheater, overheads condenser, overheads decanter, and pumps, and is discussed in Section 1.1. The PEC includes flame arrestors, instrumentation, sales tax, and freight,**~nd** 

## is discussed in Section 1.2. Direct and indirect installation costs are discussed in Section 1.3 and include costs such as foundations, painting, and engineering. 1.1 

## BASIC EQUIPMENT COST The**~est** 

## of each piece of**e~ipment'included** 

## in the BEC, as well as the material of const·ruction and size of the equipment are presented in Table**1-~.** 

## Each individual piece of equipment is discussed in this section and the detailed calculations used to develop TCI are presented in Attachment 1. 1.1.1 Steam Stripping Column The cost of the column was based on the average cost calculated using an equation·from Chemical Engineering Magazine,4 and an equation from Peters and**Ti~erhaus,5** 

## assuming the steam· stripper column cost was constructed of 304 stainless steel (304SS). 

## The equation from Chemical Engineering Magazine was used to estimate the cost of a carbon steel column including the shell, skirt, nozzles, and manholes. A factor**(X~ol)** 

## was then**u~ed** 

## to estimate the cost of an equivalent stainless steel column as shown below. Cost of Stainless Column 

# = Cost of Carbon Column 

# * Xcol The costs of stainless steel**~rays** 

## and carbon steel platforms and ladders were added to the cost of the 304 stainless steel column.

mgm40:fnlmemo.kas 

### 2

### TABLE 1-1. SUMMARY OF TOTAL CAPITAL INVESTMENT

Cost Component Direct Equipment Costs Base Equipment Cost (BEC) Flame arrestor lnstrumentaton Sales Tax and Fretght Purchased Equipment ·cost (PEC) Direct Installation Costs**P~ptng** 

### Foundations and Supports Electrical Erection and Handling Painting Insulation TOTAL DIRECT INSTALLATION COST •Indirect .lnstallatton Costs**~ngtneertng** 

### and**Su~ervtston**



### Construction 

### &Field Expense Construction 

### Fee Start-up and Testtng Contingency Cost Factor

$112.00 /arrestor**0.1*[BEC+Arres~or]** 

### (b) 0.08*[BEC+Arrestor +Instrumentation]

3DX 

### of PEC (b) 

### 12X of PEC (b) 

### IX of PEC (b) 401 of PEC (b) IX of PEC (b) lX of PEC (b)

lOX of PEC (b) lOX of PEC (b) lOX of PEC (b) 2X of PEC (b) 3X of PEC (b) (b)**~nent**



### . Cost (a)

. $288,796 $112 $28,890 $25,420 $343,218
$102,970

$41,190

$3,430 $137,290

$3,430 $3,430 $291,740

$34,320 $34,320 $34,320

$6,860 $10,300 TOTAL INDIRECT INSTALLATION COST $120,120 Percent of Total Capital Investment
38.2 0.015

3.8 3.4

13.6 5.5 0.5 18.2 

### 0.5 0.5

4.5 4.5 4.5 0.9 1.4
TOTAL CAP.ITAL INVESTMENT (TCI) $755,078 100.0**-----~------~---------~-----------------------------------------------------------------------------------~-~----------** (1) 

### July 1989 Dollars (b) OAQPS Control Cost Manual

mgm40:fnlmema.kas 

### 3

## TABLE 

## i-2. SUMMARY OF BASIC EQUIPMENT COSTS
Equipment Estimated Price year Price index Equipment Equipngnt Construction**c~t** price costs, she material July 1989a Feed tanks 48,515 1st qtr. 1979 230.9 74,800 960**~** Carbon steel Feed 34,638 July 1989 356**34,~38 240·~**  Carbon steel preheater with copper (shell and tubes tube) Steam 69,703 1st qtr. 1979 230.9 107,467 0.76 m 304 Stainless stripping diameter, steel colum 8.8 m hefght Primary 9,831 July 1988. 343 10,203 21.7 

## rtf. 304 Stainless condenser steel (water cooled, shell and tube) Overhead 9,n2 Jan. 1979 225.9 15,320 3.8**~** 304 Stainless collection steel decanter**P~s** (4) 52,022 Nov. 1988 347.8 53,24? 8,800 total Stainless watts steel Total base 295,677 equipment cost (SEC)**~orrected** using the July 1989 price index of 356.

ased on wastewater flow to the steam stripper.

mgm40:fnlmemo.kas 

### . 4

## Based on vendor**inform~tion,.the** 

## calculated cost factor (Xcol) for 304ss·was 3.1. Details regarding the estimation of the value**f~r** 

## Xcol are shown in Attachment 2. The second method used to estimate the cost of a 304SS · column was taken from Peters and Timmerhaus.S Shell, manhole, nozzle, tray,**platform~** 

## ladder, handrail, and insulation costs were included in the Peters and Timmerhaus column cost. The trays and shell were stainless steel, and the manholes, nozzles, platforms, ladders, and handrails were carbon steel. The cost of the column calculated using the· Peters and Timmerhaus equation was averaged with the cost of the column · calculated using the Chemical Engineering Magazine equation to obtain the final cost of the column. Both of the methods used to calculate the cost.of the steam stripping column are based on the weight of the col.umn, which is dependent on the diameter of the column.4,5 For simplicity, it was assumed that the diameter of the column was dependent only on the flow rate of the wastewater to the steam stripper. Fer the design of the steam stripper, it was assumed that the column diameter was dependent on both the flow rate of the wastewater to the steam. stripper and the flow rate of the steam to the steam stripper.1 The diameter that was estimated using only the flow rate of the wastewater to the steam stripper is 25 percent higher than the diameter estimated using both flow rates.**~owever,** 

## an increase in the diameter of the column results in only a slight increase in the ·total capital cost of the steam stripper, because the cost of the column is either a logarithmic or an exponential function of the weight of the column.4,5 ·Furthermore, the cost of the column is less than fifteen percent of·the total capital investment.**1~1.2** 

## Feed Tanks Feed tank costs are based on 1979 cost equations from Chemical Engineering Maqazine.6 Because the reference equations are more than 5 years old, additional information was used to verify that the scale-up of the feed tank costs to July 1989**~O:fnlmemo.kas** 

### 5

## dollars was valid. Feed tank costs obtained from Richardson's Manual7 and a vendor representative verified that the 1979 

## cost equation**ga~e** 

## an adequate cost estimate (see Attachment 3). 1.1.3 

## Condenser Because the overheads condenser· was operated at elevated temperatures, the material of construction used in the cost estimate was 304SS. 

## The equation for condensers calculated the cost in carbon steel and multiplied by a factor, Xcond, to obtain the cost in stainless steel. The cost equation for the condenser and the factor, Xcond' were**obta~ned** 

## from Chemical Engineering Magazine.B The factor for the condenser was variable and dependent on the area of the condenser. Therefore, the appropriate Xcond factor equation was used to develop the Xcond factor for the condenser, instead of using the.factor developed for the steam stripper column. 1.1. 4 

## Preheater Preheater costs were based on vendor data.9 A linear relationship was developed between feed tank cost in July 1989 

## dollars and the flow rate of water to the preheater. Detailed calculation·s are shown in Attachment 4. 

### 1.1.5 

## Decanter The overheads decanter operated at elevated temperatures and therefore, the material of construction used in the cost estimates was 304 

## stainless steel. The cost equation for decanters was obtained from Peters and Timmerhaus.10 Detailed calculations are. shown in Attachment l. 1.1.6 

## Pumps The operation of the steam stripper**r~quire~** 

## four pumps including a .pump for wastewater transfer to**an~** 

## from the feed tank, an overheads pump, and a bottoms pump. The pump cost equations were obtained· from Chemical Engineering MAgazine,& and the cost was based on 316 stainless steel construction.**D~tailed** 

## pump cost calculations are shown in Attachment 1 •. 1.2 PURCHASED EQUIPMENT COSTS 

## The 

## PEC is based on the 

## BEC and is the sum of the 

## BEC, the flame arrestor. cost, the instrumentation cost, and sales tax and freight. The cost of·the flame arrestor is $112.11 The mgm40:fnlmemo.kas 6

## instrumentation cost is 1 percent of the sum of.the BEC and the cost of the flame arrestor. The sales tax and freight is 8 percent of the sum of the BEC, 

## the cost of the.flame arrestor, and the cost of the instrumentation. All PEC cost equations with the exception of the flame arrestor cost were obtained from the Office of Air Quality Planning and Standards Control Cost Manua1.12**Purc~ased** 

## equipment cost for a steam stripper with a flow rate of 80 gpm {300 tpm) is shown in Table 1-1. 1.3 INSTALLATION COST Direct and indirect installation costs.are all expressed as a percentage of the PEc.12 The direct**inst~llation cost~**  

## include piping, foundations and supports, electrical, erection and**h~ndling,** 

## painting, and**in~ulation** 

## costs. Indirect installation costs include engineering and supervision, construction and field

- 0 

## expenses, start-up and testing, and contingency costs. Direct and indirect installation costs for a steam stripper with a flow rate of 80 gpm (300 tpm) are shown in Table 1-1. 2.0 TOTAL ANNUAL COST Th.is section describes the TAC associated with the operation of the design steam**stripper~** 

## This cost is the sum of the direct and indirect annual costs, which are**pre~ented** 

## in Sections 2.1 · and 2.2, respectively. Direct, indirect, and total annual costs .for a steam stripper sized for a flow rate of 

## so gpm (300 tpm) are presented in Table 2-1. ·2 . 1 TOTAL DIRECT ANNUAL COST The direct annual cost includes the cost of utilities, labor, and maintenance. Utilities include electricity, steam, and water costs, and these cost calculations are shown in Attachment 1. The heat loss in the steam**~tripper** 

## was assumed to ·be five percent of the heat input (see**A~tachment** 

## 5)". Steam cost is discussed in detail in a s.eparate memorandum.13 Primary condenser cooling water costs were**base~** 

## on a recirculating water system. The losses of cooling water were due to evaporation, drift, and blowdown, and these losses were · 4 percent of the cooling water flow·to the primary condenser.
mgm40:fnlmemo.kas 7TABLE 2-1. TOTAL ANNUAL COST CALCULATIONS



## --------------------------------------------------------------------------------------------------------------------------------- Cost Canponent Cost Factor Annual Cansa.nptton Annual Cast(a) Percent of Tot Annual Cost**----------------------------------------------------------------------------~---------------------------------~------------------** 

### Direct Annual Costs Uttlit1es Electricity Steam Water (cooling) labor Operating Labor Supervision &Admin Maintenance labor Materials TOTAL DIRECT ANNUAL COST (TDAC) Indirect Annual Costs

. Overhead

Property Taxes Insurance**Adm1nistrativ~** 

### Charges Capital**Recover~** 

### (CR) TOTAL INDIRECT ANNUAL COST (TJAC) TOTAL ANNUAL COST (TAC) ANNUAL WASTE THROUGHPUT (AWT) 

### COST PER UNIT WASTEWATER ($/Mg) $0.0590 

### /kwh (a) ' $9.26 /Mg (c) 0.0528 /1000 1 (a) $22.50 

### /hr lSX of Op. labor (a) $22.50 

### /hr lOOX of 

### Maintenance Labor (a) 73,092 kWhr (b). 6,363 Mg (d) 21,999,767 

### ltters (e)
530 

### hrs 

### (fl

530 

### hrs (f)

&OX 

### of labor and maintenance materials (a) lX of TCI (a)

. 1X of 

### TCI (a)

2X of 

### TCI (a) lOX I 15 yrs (a)



### TDAC + 

### TIAC 151,444 Mg/yr



### TAC/AVT $4,310 $58,920

$1,160 $11,930

$1.790 $11.930 $11,930 $101,970

$22,550

$7,550 $7,550 $15,100 $99,270 $152,020 L7 23.2

0.5
4.7 0.7
4.7 4.7

8.9 3.0 3.0
. 5.9 39.1
S2s3,99o 1oo.o
$1.68 

### COST PER LITER WASTEWATER FEED ($/1) 

### TAC/FLOW 1BD,DDO.OOD 1/yr 0.00159**--------------~----------------------------------------------------~-------------------------------------------------------------** 

### a OAQPS Contro1 Cost 

### Manua1 

### b · 240 

### kWhr/day. 351 

### days/yr c Steam Costs, August 23,1993 

### d 21,200 

### kg/day, 351 

### days/yr e 73,000 

### ltters/day, 351 

### days/yr (based on 

### recirculating cooling water) f Based 

### on 1/2 

### hr shtft.**~** 

### •htfts per day, 

### and 351 

### day/yr.**~O:fnlmemo.kaa** 

### 8

### Detailed calculations of cooling water losses are shown in Attachment 6. Operating and maintenance labor rates were estimated at $22.50 per hour, based on the labor rate used in Subpart 

## H of the Hazardous Organic NESHAP for equipment leaks. The information in Attachment· 7 

### ·indicates that this value for operating and maintenance**lab~r** 

### rates is reasonable. The number o.f· hours of labor required**~or** 

### maintenance and operation of the steam stripper was assumed to be 530 hours per year. This estimate was based on the general quideline given by the OAQPS Control Cost · Manual:12 30 minutes per shift, 3 shifts per day, and 351 days per year. These labor hours are not specific to steam strippers. Supervision and administrative labor was assumed to be 15_percent of operating labor.12**Maintenan~e** 

### material costs were assumed to be equal to maintenance labor costs.12 2.2 TOTAL INDIRECT ANNUAL COST Total indirect annual cost includes overhead, property taxes, insurance, and administrative charges. overhead is 60 percent of the sum of operating, supervision, and maintenance labor, and maintenance materials. Property taxes, insurance, and administrative charges are a percentage of TCI. Capital recovery is estimated assuming a 10-percent interest rate and an equipment life of 15**years.~2**



### · 3.0 TOTAL CAPITAL INVESTMENT AND TOTAL ANNUAL COST VERSUS FLOW 

### RATE Using the equations in the LOTUS 8 

### spreadsheet,**va~ues** 

### for TCI and TAC were calculated for the design steam stripper at 5 different flow rates (tpm): 40, 150, 300, ·455, and 760. These selected wastewater flow rates provide a representative range of flow rates of wastewater to ·a steam stripper. The results are**sho~n** 

### in Table 3-1 and are graphed in Figures 3-1 and 3-2.

mgm40:fnlmemo.kas 

### 9

### TABLE 3-1. ·SUMMARY OF TCI AND TAC FOR A STEAM STRIPPER


## Flow rate (tpm) (gpm) 

## TCI TAC

760 201 1,199,296 638,310 455 120 925,338 441,210 300 79.3 773,069 339,660 150 39.6 580,641 233,090 40 10.6 363,272 142,070

mgm40:fnlmemo.kas 

### 10

# I 0 

# ..
.... 

# i**~** 

### a CIJ Cll 

### t.l t.l t.7 t.l 

# lu tA

...t.a &t.a**~**

# I~**~**



# - 

# t=

... Ju u 

# ...
.... CLt

0 

# •• . 

# .**--~~···**

# .... • Qdan

.... 0 

### 1Cif
.....



# .. ..... ---·······



# m 

# conan.-o - a.•+

# m.e (lpm)



### .410
. 100



### . ........., ...Rile**~pm)** 

## Rgure 3-1. 

## Summary oftotal capital Investment versus wastewater 

## feed rate for 

# steam lbtpping unit 

## ....**----~**

100 

# I

# i
0 

# .. ... 

# i u· 

## "" C» liD 

### CL7



## u 

# (


# .. ·!

...

.... 

# J N 

# Ju


# .....
at



# • • 

# ....,.,

# ..... • c.tlaft

.... 

### OTAC,...._



### TACfltr'nln•
.....

## fllr •121.1R1 

## +882.4 Clpm).



### TAC (cMion
....• 

### 72,112 

## + 131.1 (lpm)



# .. 40D



### . ......., ....,... &lpm) 

## F'gure 3-2. Total annual 

# cost versus**~ater** 

## feed rate for steam stripping unit 100 

# I

## REFERENCES 1. Memorandum from Bagley, 

# c., Radian Corporation, to Kissell, M., EPA/SOB. Design Steam Stripper -·Background, Basis, and Proposed Changes. February 7, 1994. 2. Memorandum from Allen, 

# c., Research Triangle Institute, to Manninq,·E., EPA/CPB. Evaluation of Cost Effectiveness of Steam Stripping Wastewater streams. February 2, 1994. 3. 

## Memorandum·from Pelt, K., Radian Corporation, to Kissell, M., EPA/SOB. Total Capital Investment and Total Annual Cost Equations Used in the Framework for steam Stripping Wastewater. February 1, 1994. 4. Mulet, A., A.B. Corripio, and.L.B. Evans. Estimate Costs of Distillation and Absorption Towers via Correlations. Chem. Eng. December 28, 1981. p. 180. 

# s. Pet.ers, M.S., and K.D •. Timmerhaus. Economics for Chemical Engineers. McGraw-Hill Book Company. 1980. Plant Design and Third· Ed. New York, pp•.768-773 •. 6. Corripio,· A.B., K.S. Chrien, and L.B. Evans.**Estim~te** 

## Costs of Heat Exchangers and Storage Tanks via Correlations. Chem. Eng. January 25, 1982. pp. 144-146. 7. Richardson Engineering Services, Inc. Process Plant Construction Estimating Standards, Volume 3. Mesa, 

## AZ. 1988.
. 

# a. Hall, R.S., W.M. Vatavuk, and J. Matley. Estimating**P~ocess** 

## Equipment Costs. Chem. Eng. November 21, 1988. pp.**66~75.** 

## 9. Scott, K.A., Radian Corporation with Ambassador Heat Transfer company.· May 12, 1993. Cost of Heat Exchangers. 10. Peters, M.S., and K.D. Timmerhaus. Economics for Chemical Engineers. McGraw-Hill Book Company. 1980. Plant Design and Third Ed. New York, p. 572. 11. Telecon. Gitelman, A., Research Triangle Institute with Hoyt Corporation. September 

# a, 1986. Cost of 

## flame arrestors. 12. 

# u.s. Environmental Protection Agency, ·Office of Air Quality Planning and Standards. OAQPS Control Cost Manual. Fourth Edition. ·EPA-450/3-90-006. Research Triangle Park, NC. · January 1990. 13. 

## Memorandum from Bagley, 

# c., Radian Corporation, to Kissell, 

## M., EPA/SDB. Steam Costs. March 17, 1993.

mgm40:fnlmemO.kaa 

## 13

### ATTACHMENT 1 TOTAL CAPITAL INVESTMENT AND UTILITY CALCULATIONSSTEAM**~TRIPPER** aJSTII&' PROC£DURE : BASED 

## a. ASPDI ,_IITOUT

- 300LPII (ao&PM} CASE STEM/FIED RATIO. IC& STEMIIC& W : VASTtVATEI FtED RATE. &PII:

. TAC : FlOW RATES Ttl :



### ------·--·------ FIED FlOW. IC&/
..: BOTTCMS FLOW. IC&/HR :

STEAM FlOW. IC&/HR : OVEAHEAD FlOW.IC&/HR :

PRJ COifD H20. IC&/S :
EQUIPMEIT



## --------------- PREHEATER AREA. M-2: 11974.67 17803
. 8412 1ni
.511M 2083
.54141 18
. 1012112

238
.910552 21
. 6846841 0.096 0
. 801164098 79
. 3000 $401.550 TOAC $870.974 TIAC 6PII: 6PII: ICJ/hr:

&PM : &PM :

n · 2: n·2 : 79.3 78.5 5359430
. 2 9
. 2 287.5

2581
. 1

233.3 

# 1 228.650 171.800 DEISITl H20 • 8
. 331b/ga1 DDISITl Stella • 8
. 00lb/gal ktlogr•. kg • 2
. 205 lb

WATT-9
.486E-04 BTU/S 1
. 750 baaed 

### on telecon with Rob &ol-.. of 

## r..nta**·** PRJ 

### COlD AREA. M·2:

. 0.13 ft

- 2 area baaed on· 2
. 9 telecon with Rob 6oldnan of Ect.arda Engineering
. aJLIIUI DIAME TER. M: 0.75865892 FT: 

### ITU : 16
. 25 NO

. OF aJLUMII TRAYS : 10

ACTIVE HEI&HT. 

### FT:
. 15

TOTAL HEI&HT• FT : 29 *************•· · · · ······ · · · ········*****······· ·· ··· ••*****••• • • • • ••• • ••*******•••••· ············ A

. CAPITAL COSTS 1) Stela S t ripper Col1111n Di • inside di-ter. ft • 

## u. n •.tangent-to-tang length. ft• Ta • eat
. wall thickness. ft • rha(aa304). lb/ft• s • V.ight of the col1111n: 

## va • pi*Di( 

## n + o. 811&*Di)Ta*rho 

## va. lb· · 7 .473 501 Z
. 9 29
. l 0
. 0521

BE SURE WEI6HT. DIAMETER. AND**TOW~** H£16HT ARE WITHIN THE LIMITS

FOR All EQUATIOIIS The weight equation for calculating steam st ripper column coat h the Sllll8 for carbon and stainless steel. but the deni ttiea of the t.o •tala are different
.

- densi ty of carbon steel • 490 lb/ft

- 3

- density of stainless steel • 501 lb/ft

- 3

### a. Challical Engineering Magazine, DecedJer 28, 1981, pg. 180.

.. COST 

### INDEX • '• 230.9 -Shell, skirts, nozzles, and manholes Cbs • exf[6.823 + 

### 0.14178 (ln Vs) + 

### 0.02468 (ln Vs)A2] 9020 b < 

### Vs < 

### 2,470,000 lb. VEI&HT TOO SMALL
. Cbs $ • 

### 23,175 Cbsl304ss), $ • 

### Cbs*Fm • 69158 

### Fa,304ss • 3.01 (Based on 

### Vendor data) -Platfon=s and Ladders
. Cbp • 151.Bl*Dt·o.6331&*Lt·o.8D1&1 3 ftc 01 < 

### 24 ft : 57.5 ft < 

### Lt c 

### 170 ft DIAMETER TOO SMALL LENGTH TOO SHORT 

### Cbp, $ • 

### 4441 -Cost of**Tr~ys** 

### - 304 stainless sieve trays Cbt • (Number of trays)*278.38*exp[0.1739*D] 2 ft c 

### Dc 

### 16 ft DIAMETER OKAY
. Cbt, $ • 

### 4,604 Total column Cost: Column cOst (304 ss) • Cbs(304ss) + 

### Cbp + 

### Ftm*Ftt*Cbt COLUMN COST. $ • 

### 79, 505 where Ftt(Steve Trays)

- Table V• Ftm(304Stainless)• (1.189 +0.0577*0) • 0.85 1.36b. Peters and Tt11111arhaus Che Plant Design pg 768

- 773.

. COST**~NDEX** • 225.9 -Shell Ftg 15-24 Shell cast • 133.4&*VS·o.6347 1000 lb < Vs < 70,000 lb VEI&HT OKAY Shell cast, 

### S • 38,359 -Manholes Fig 15-25 (SU&GEST USIN& 10 MANHOLES

- OHE FOR EACH TRAY) Manhole cast • (no. of manhales)*(internal diameter, tn)* (53.83 + 40.71*(ta.er-.a11 thtckness,tn)) 0.375 inches < Ts < 2 inches THICKNESS OKAY no. of manholes • tnt. dta, tn • Manhole cast, 

## S• 10 18 (THIS IS INHERENT IN THE CURVEJ 14,269 -Nozzles Fig 15-25 (SU&&EST USING: ONE,& inch(averheads); ONE,4 inch(feed); TV0,4 tnch(steam); and ON£,4 tnch(battCIIIS) Nozzles cost • SUM[(na. of nozzles)*(inches of nozzle)]* (24.57 +**3S.94*(t~r** .all thickness, in)) 0.375 tnches < Ts < 2 inches THICKNESS OKAY
. sum[(na. noz)(in noz.)] • [(4*4")+(1*6")] • 22 Nozzles cast. 

### S • 1,035 -Trays Fig**~5-26** 304 stainless only Trays cast • (no. of trays)*214.54*exp(0.2075*Di) 2 ft < Di < 12.5 ft DIAMETER OKAY Trays cost, 

### S • 3,911 -Ladders Table 9 $.43/lb of ladder, 30lb/ft of ladder Ladder height • column height • 29 Ladder cost. 

### S • 374.1 -Platforms and Handrails Table 9 $.43/lb ( d-4ft, 1700lb ) Assume a ltnear relationship

- 425 lb/ft of diameter P and Hcost, 

### S • 528.81 -Insulation Fig 15-27 Use fDBTUlass (ave) Assume 3 thick (ave) $10/ft2 A (ft.2)• 142.28125 Insulation cost, 

### S • 1422.8125Total column cost, 

## S• 59,900 TOTAL COLUMN COST, $ • 69,703 *************************************************************************************************2) Feed Tanks

- Clwltc:al Engineering Maaaztne January 25, 1982, P6 144-46
. COST IIID£l • 230
. 9 (1
.. CE Index (Jan-Apr/4))

or Cb • exp[2
. 331 + 1.3673 (ln V)

- 0
. 063088 (ln V)-2] 1,300 gal < V' < 21,000 gal Cb • exp[U.362

- · 0
. 6104 (ln V) + 0
. 045355 (ln ¥"2)] 21,000 gal < ' V < 11 , 000,000 

## v. gal • Cb,$• VOLlltE OKAY 253,760 (VOLlltE BASED ON 48 HOURS IETEITIOI) 48,515 -lnfol"'llltton obtained fn. vendors on the coat of feed tanks •• c:Gq)ared to the coat of t:he feed tanka fn. ChaDtc:al Engineering Magazine In J uly, 1989 dollars to wrtfy that acaltng coats fn. 1982 to 1989 Ia acc:urate
. It Ia .aaallllild that the tanlt Ia not CCIIIPletely



# .....**...!!ll~.:11~.::1tt.~.!:.~l1.!!!!~.1~.!2!.~!.!1:.~!1te**

# ............................. 3) Decanters

- Peters and Tl11111erh&ua 

### cna Plant Design pg 572, Fig 13-58 COST INOEI • 225.9 · Asauqttlona : 2 95X VOC reDDY al design 11 304 Stainless Steel 3 Retention tt• of ONE hour 4 Operation at 501 captclty Oec:ant Cap, gal • 1,005 Oec:anter coat • 216
. 8*(capactty, gal) · o . SS02 Oec:anter**coat ~**  $ • I,722

................... . ................... .. .. . .. . ........................ ************************** 4) Feed preheatera

- Teleccm
. Scott, K.A. , Radian· Corporation with Ambaaaador Heat Transfer Caqlany
. May
. 12, 1993
. Coat of Heat Exchanprs
. Coat In July 1989 Dollars Asa._ ·carbon ateel wtt:h copper tubes As..- 100 pat and 300 F Built to ASKE codes Coat of Preheater • [4213.357 * (Flo. Rate (gpmJr .5]

- 2882
. 31 Preheat coat, $ • 34,638**···························· ·····~··••** ******************************************************************5) Prt1111ry condensers

- ChaDtcal Engtneertng Mataztne ftov_.,.r 21, 1988. pg. 66

- 75, ftp
. 1 

## a 2. GOSt h
.. • 343

or Ass.- ftxed-tube, atngle shell, stngle pass exchangers and 12 foot length tutiea. Prt COnd coat • 2228.8*exp(0.00411*A,ftA 2) 150 ftA2 c A < 240 ftA2 Prt Cond coat • 5328.8*exp(0.0008762*A,ftA2) 240 ftA2 c A c 1500 ftA2 AREA OKAY Fm(304u) • .8193 +
. 15984(1nA) • 1.690794 Prt Cond cost, $ • 9,831 *************************************
...********************·····~·····•******************************** &)**~** - Chellltcal engtneertng Magazine Nov. 21, 1988, pg 66

- 75, F1g 11. ALL MPS ARE 316 STAINLESS STEEL. COST INDEX • 347
. 8 &roup A**p~s** - 10 to 150 

## !!'!': &roup 8 - 30 to 900 gp11. Group A 

### pump. - 0
. 5 to 10 

## 426 Group 8

- 3 to 24**~** 

# =**~:**

# :**f~1Xi~1mi'o~2~o** 

# :8up : Assume a 1M"' ta
. needed for the feed to and fi'GII the feed tank, the bottaDS,and the overheads
. An engtneertng eattmate of 122 feet of lllilter ts ass.-d for the head. Total pu111p efftctency ta aallllllld to be &41. Pump head,ft H20. 122
a . feed Tank KP • ffeed flow (gpa)*(122 ft H20}*(8.33 lb/gal)*(mtn/60 a)* (lbf/lb)/[0.64 *[(0.001341 np)/(0.7376 ft 1bf/a)] Feed Tank hp • 3.8 &ROUP A FLIII CIICAY FEm TANK PlllPS (2),
. 30,707 &ROUP A: HP OKAY &ROUP 8: HP OKAY b
. BottCIIII HP • [feed flow (gpm)*(122 ft H20)*(8.33 lb/gal )*(mtn/60 s)* (lbf/lb)/(0.64)*[(0.001341 hp)/(0.737& ft lbf/s)] BottCIIII hp • &ROUP A 3
. 8 FLOV OKAY BOTTCMS PiliP, $ • 15 , 353 GROUP 

### A: HP OKAY 

### GROUP 8: HP OKAY

c . overhead HP • [overhead flow(gpm)*(l22 ft H20)*(8.33 lb/gal)* (mtn/60 a)*(lbf/lb)/[0.64)*[(0.001341 hp)/(0.7376 ft lbf/s)] Overhead hp • GROUP A . 0.4 FLOW TOO SMALL OVERHEAD P\IIP, $ • 5 , 112 GROUP A: HP TOO SMAll GROUP B: HP TOO SMALL Total Cost of**P~s** • 11111 of (feed , bottOIIIS , overhead) TOT PUMP COST, $ • 52,022

### Converstan -f.- hp "to 

### kw-hr/yr ts (V)/(0.00134lhp)*(KW/1DOOW)* (842• hr/yr) 

### ************************************************************************************************* J7) 

### n- arrestors
- Cotta 'lven by Penny Lassiter fraa a telecon by A. &ttel•n (R 1). Each arrestor ta eattmted at $100. Coat ts tn Septllllber 198& dollars. COST INDEX • 319 Frc. on RTJ ""P.trt frail Paul Peterson to Susan ThDmloe, EPA/CPI. dated Januaey 18, 1988: It ts 11..-d that 

### vent ltftll fi'CIIII tN storage tanks, COftdenaera, and decanters each had fl

.. arrestors tn place. The current approach asStllleS that these vent ltnes are routed beck to the feed storage tank for tt. ste111 strtpper and a that there ts a stngle fl.,. arrestor on the vent ltne fraa the storage tank to the control clevtce. Cost of 1
. arrester. $ • 100

........................ _.**************************************-************************* B. AIIJIUAL COSTS

- Uttltty costs BASIS: 8424 hr/yr operatton uttltty cosh constat of
. electrtc1ty. Iteam, and weter costa 1) Electrtctty

- Electricity tl needed for pumps and for refrigeration. a .**P~** - electrtctty use ts calculated under the capital costs

,._. Electl'tclty use • (Total PIIIIP use tn hp)*0.7457KW(mech. )/hp*(84Z4 hr/yrJ Tot ,._. Use, HP • 11.85 PlJUI ELECT USE, KW-H/yr • 74, 435 TOTAL ELECT USE, KW-H/YR • 74,4352) 

### st
.. - st
... ta needed for stripping the 0!'91nlcl
. st
.. c:ott I• •tt111ted at $9.21/MI ($4.20/111111)

. Thtl cott t1**~** In July1989 

## •nan. There Is no coat Index
. The at.. tt .., palg aat•d ate. wtth a heat cont•t of 

## zaoz KJ/kg (1201 BTUIH•)• A factor of 1.25 Ia u....t to account for radlatton losses
.

St.- uae, Mg/yr • 15.172 3) Vater

- Cooling
... ter Is used In the primary .condenaer
. Vater use • (Prl cond HZO flow,p)*(60 mln/hr)*(3
. 7851tters/ga1)* (8424hr/yr)*(frac:tlon loat to caollng ta.er evaporation and blCMdown • 0.04) WATER USE, LIYR • 21 , 999.767

## ATTACBMEBT 2 STAINLESS STEEL COST FACTOR

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### ATTACHMENT 3 PEED TANK COSTS

## SUMMARY OF FEED TANK.COSTS

Vendor cost1 Adjusted ·Vendor Flow rate Tank size HON cost cost1 July Percent

(gpm) (gal) July 1989$ April 1993S 1989S difference 10.6 33,920 31,666 40,000 39,866 20.6 39.6 126,720 53,340 55,000 54,815 2.7 79.3 253,760 74,800 80,000 79,731 6.18 120 "384,000 93,443 105,000 104,647 10.7 201 643,200 125,990 135,000 134,546 6.4 1 Uses the February 1993 Chemical Engineering final cost index value of 357.2 and the July, 1989 final cost index of 356. Costs are from April 1993 but this index was not published at the time of this analysis.



## From Richardson•s Cost Manual: Cone Roof. Storage Tank cost includes fabrication, delivery, and erection on provided foundations. cost.includes two manways, draw-off, ladder, vent, qauqe hatch, and level indicator.

-**255,245~qallon** 

## tank (6,099 barrel) = 

## $75,200.

- 380,800-qallon tank (9,064 barrel) = 

## $89,800.FISHER TFN< 

### ca f'A4fY 

# PI&HER 

# TANK COMPANY 2330 TWO NOTCH

## R~D • 

### LEXINGTON. &WTH cAAouNA

# 290r2-



# ----- ----· ··-


# FAX COVER SHEET

DATE: 

# HIN TOTAL. NO. OFPAGES :.!.,(NOTINCLUDING 

## THIS COVM lei!T) 

## SENT TO: ·•
. :· ..·. : .i --:**~** ..



### Tlii.&FAX' 

### Nutllla: 17Hf7•197.t 

## FROII::IIJN' 111!NIQC


## SU8JECT: YOUR FACSM£.2 DATS**412111~** 

## IIJDGB

# DmMrE WAilJilllliB

## ITDMGIT4NA INACCORDANCE WITH WWR·REQUDT

## Mil WISH 

## 70 MOVIDii THE 

## FOLLCMfNG 

## !NI?OIUIATIONPER .'lOUR**~ACSIIII.I.** 

## · · 

# tmMfiP,,
.

.. TMIAL RM catarRUCTION

## IHOUI.D liE

## Me 

# CAitaotlsm&wmt ne o 

## AI'I'LiaPAINTON lll7liRIOR • BXTifRIOII 

## SURFACD.
.

.**Q~** 

## 011.,_

## I'll 

# ,,..Till!WA'IM**IOL~** 

## THe FOLLOWING



## I'Mir8Y8711ilfl IHOIJI.D 8SADEQCMnL 

# ""'198CCMT

# m7EE' l'h GREATER THNI4: lJVIiiii!C Ult/0 YN

## (IIIIIH 

# SOUDaPOXYJ·
.

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# IllCOATIYBJBI

## NW IBiAre 7D I 

## •Lilla

## COAT IMIDILAST: 

## SII'C NO. 

## fO (NMR 

### WMJ'E &ASJ)

### Ph 

### LESS THAN 4: TNEMEC SERIES 

### 120 VINESTI!R 

### 7WO (2} 

### COAT 

### SYSTEMAPPLIED AT

### I TO 12 AfiLLS PER COAT 

### SAND8LAST: 

### SSI'C. NO. 

### 5 

### (WHITE METAL 

### BLAST} 

### t!XTERIOR CQATSQT€M PER YOUR STANDARD EXTERIOR PAINTSPeC/PICA 'nON> 

### l'[FMNO. 2 

### COST ESTIMATE 

### 31S,OOO 

### OAUON TANK
...................................................

## $ 4(1,000.00 1.28,700 GAL.LON TANI<

........................................................

### $ 

### 11,000.00**2~0,000** GALLON 

### TANK
....................,••••••••••••••.•••••••••••••$ 

### 80,000.00 

### 3114,000 GALLON TANK

...............................................$101,000.00 

## 843,000 GALLON TANK

..............................................$131,000.00
IP 

### YOU SHOULD HAVI! ANY QUeS170NS Ott 

### NEI!D ANYI'URTHeR 

### ASSISTANCE PLEASE FEEL FREE TO CONTACT THIS OFFICB.


### FISHI!It TANK CO. FAX NUMBER: (BOI} tf7•331f IF YOU DO NOT

### RECEIVE COMPI.ETE TRANSMISSION PLEASe CAU. 

### THE FQLLOWING NUIIBSR: (103} 

### 359-4113 ORIGINAL 

### WILL. OR X WILL NOT

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## ATTACHMENT 4 FEED PREHEATER COSTS

## HEAT .EXCHANGER COSTS
Adjusted Flow rate Area of**hea~** Vendor cast May vendor cost 1

(gpm) exchanger 

### c ft ) 1993$ July 1989S 10.6 345 10,800 10,764 39.6 1,289 23,000 22,923 79.3 2,600 35,009 34,882 '120 3,906 45,000 44,849 201 6,542 56,000 55,812 Uses the February 1993 Chemical Engineering final cost index value o1 357.2 and the July, 1989 final cost 'index of 356. Costs are frOm May 1993 but this index was not published at the time of this analysis. The cost of the heat exchanger was first. plotted versus the flow rate (gpm) to obtain ah equation. The graph of the cost of the heat exchanger versu$ the square root of the flow rate (gpm) produced a better linear regression and equation. Therefore, the equation for the cost of the heat exchanger versus the square root of the flow rate is:
1 

### Y 

### = (4213. 357) (x) 2 - 

### 2882. 3i

## Flow Rate (qpm)

10.6 39.6 79.3



### 120 201**'Jendo~** 

### Cost 

## (July 89 $) 

### 10764 22923 34882 

## 44849 55812 

## /":"\.**C..o~** 

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### 1'-.n_;- 

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## \!) Regression 

## output: constant
. 12964.28 

### Std Err of Y Est 4668.126 

## R Squared
. 0 •.947980 

## No. of ObserVations 5 

## Deqrees of Freedom 3 

## X 

## Coefficient(&)**~ S~d**  

### Err 

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# eq,'-"l.t.~n<D .231.7615 31.34456 10.6 15421 39.6 

### 22142 79.3 31343

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## -t- (r•cw

## R.ctte(~p,.....J;**V~ndor** CoSL 

### 3.25576411 10764 6.29285308 22923 8.90505474 34882 10.9544511 44849 14.1774468 55812

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## Constant std Err of Y Est R 

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## No. of Observations 

## Degrees of Freedom X 

## coafficient(s) 4213.357 

## Std Err 

## of coef. 139-.7482 -2882.31 1173.882 0.996710 5 3

# Cost vs. Square Root Of· Flo.w Rate
60
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### 14 15 SquQre Root of Flow Rate (gpm}P.Gil



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## ATTACHMENT 6 COOLING WATER .LOSSES

### CALCULATION SHEET 

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# --~------------------~------ 

# '

New York St.Louil Son Franclsco Auckland



# ...

. . tobrJburg Johalalelburg 'london Madrid

. Mexico Momrlal New Ollti Panama Paris 

# sao Paulo Si..,.**Sv~** Tokyo Toronto 

# RADIAN 

# LIBRARY RESEARt):t TRIANGLE PARI<fNC Prepared by 

## a staff of 

### specialists under the 

## eclltoriaJ direction of
late Editor

### 1-...H.P~ Editor 

### DonW. Green Conger.Gabel Professc;w of 

### Chemical and Petroleum Engineering, University 

### of Kansas



### . ASsistant Editor 

### James 

## 0. Maloney Professor of 

### Chemical Engineering, University 

### of KansasLibrary of Congress Cataloging in Publication Data Main entry under title: Perry's Chemical engineen' handook. (McGraw-Hill chemical engineering series) Rev. ed. of: Chemical engineers' handbook. 5th ed. 1973. Includes bibliographical references and index. 1. Chemical engineering-Handbooks. manuals. etc. I. Perry, Robert H., 1924-1978. IL Green. Don W. III. Maloney, 

### James 0. IV. Chemical engineers' handbook. 

### v. Series. TP151.P4S 1984 660.2'8 84-837

Copyright@ 1984, 1973, 1963 by McGraw-Hill. Inc. AU rights reserved. Copyright renewed 1962, 1969 by Robert H. Perry. Copyright 1950, 1941, 1934 by McGraw·Hill. Inc. All rights reserved. Printed in the United States of America. Except as pemiitted under the United States Copyright Act of 1976, no part of this pubUcation may be reproduced or distributed in any form or by any means, or stored in a data baae or retrieval system, without the prior w,!itten permission of the publisher. 234567890 DOW/DOW 8987654 

### ISBN**0-0~-049479-7** The editors for this book were Harold B. Crawford and Beatrice E. Eckes, the designer was Mark E. Safran. and the productiim supervisor was Teresa M. Leaden. lt was set in Caledonia by University Graphics. Inc.
. Printed and bound by It R. Donnelley 6 Sons Company.



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- J • ' 1 ' H I 0 o ,l ·.1 I •12-16 PSYCHROMETRY, EVAPORATIVE COOUNG, REFRIGERATION, AND CRYOGENIC PROCESSES

Turntng**p~nt** g**0.025~ ~**  0.030**~** 

## ... 00350 0.040-:: 0.045cK 

### o.o5oi 0.055 

## i o.osof**~** ::t FIG. 12·15 Horsepower chart for a counterflow induced-draft cooling tower. [Fluor Corp. (now £codynt Corp.))

. ·
obtain the desired results. Once the necessarv water concentration has been established, tower area can be calculated by dividing the gallons per minute circulated by the water concentration in gallons per minute-square foot. The required tower size then is a function of the following:

1. Cooling range . {hot·water temperature minus cold-water temperature) ·

2. Approach 'to wet-bulb temperature (cold-water temperature minus wet-bulb temperature)

3. Quahtity of water to be cooled 4. Wet-bulb temperature 5. Air velocity through the cell 6. Tower height Example 11 To Illustrate the we of the charts. wume the following conditions: Hot-water**temperatu~r.** rl. °F**~** 102 Cold-water temperature Ta. °F • 78

Wet-bulb temperature r.,. °F • 70 Water rate. gal/min • 2000 A straight line on Fig. 12·14. connecting the points representing the**desl~P!** water and wet·bulb temperatures, shows that a water concentration of 2 gal/ (min·ftl) Is required. The area of the tower is calculated as 1000 ftl (quantity of water circulated divided by water concentration).

Fan horsepower is obtained from Fig. 12-1&. Connecting the point representing 100**~t** of standard tower performance with the turning point**~d** eJCtendlng this straight llne to the horsepower scale show that it will**r~uire** 0.041 hp/ftl of actual effective tower area. For a tower area of 1000 ftl41.0 · fan hp is required to perform the necessary cooling.

Suppose that the actual commercial tower size has an area of only 910 ftl. Within reasonable limits, the shortage of actual area can be compensated for by an increase in air velocity through the tower. However, this requires boost· ing fan horsepower to achieve 110**percet~t** of standard tower performance. From Fig. 12·15, the fan horsepower is found to be 0,057 hp/ftl of actuaJ tower area, or 0.057 X 910 • 51.9 hp.

On the other hand, if the actual comiUfCial tower area is 1110 ftl, the cooling equivalent to 1000 rtl of standard tower area can be accomplished with less air**an~** less fan horsepower. From Fig. 11&-15, the fan horsepower for a tower operating at 90 percent of standard performance Is 0.031 hp/ftl of actual tower area, or 34.5 hp.

This example illustrates !,!le sensitivity of fan horsepower to small changes in tower area. The importanCe of designing a tower that is slightly oversize in ground area and of providing plenty of fan capacity becomes immediately apparent

Example 12 As1ume the same cooling range and approach as used in Eumple 11 e1cept that the wet-bulb temperature Is lower. Design condltlom would then be Water rate, gal/min • 2000 Temperature range (T 1 - T1), °F • 24 Temperature approach ( T 2 - tur), °F
.. 8 Hot-water temperature T,, °F • 92 Cold-water temperature T2. °F a 68

Wet-bulb temperature t.,, °F • 60 From Fig. 12-14, the water concentration required to perform the COo. is l.i5 gal/(min· ft2), giving a tower area of ll45 ftl venus LOOO ftl for 1**-~"~** wet-bulb temperature. This shows that the lower the wet-bulb temper11

## u; 

# ;r the same cooling range and approach, the larger ts the area of the 1 t or required and therefore the more difficult is the cooling job.**0\\'~**

Figure 12-16 illustrates the type of performance curve furnish by the cooling-tower manufacturer. This shows the variation in**~** formance with changes in wet-bulb and hot-water**temperat~·** while the water quantity is maintained constant. res**90~----------~----------r---------------~------------ ~85~------------~-------------+------------~~~~~** 

### ~ 

## e

.

### ~80.----+­

.s!

7060 65 8000 gal./min

70 75 Wet-bulb temperature, 0 F. fiG, 12·16 Typical cooling-tower performance curve. COOLING-TOWER OPERAOON BO

Water Makeup Makeup requirements for a cooling tower consist of the summation of evaporation loss. drift loss, and blowdown. Therefore, 

### w,- w, + 

### wd + 

### w, (12·91 where W, .• makeup water, Wd • drift loss, and W, = blowdown (consistent units. m3/(h·gal·mtnn

Evaporation loss can be estimated by the following equation: W, • 0.00085 Wc(T1 - Ts) 02·101 where We • circulating-water Bow, gal/min at tower inlet

T 1 - T11 • inlet-water temperature minus outlet·water tempera·

. ture. OF Drift is entrained water in the tower discharge vapon. Drift loss is a function of the drift-eliminator design. which typically varies between 0.1 and 0.2 percent of the water supplied to the tower: New developments in eliminator design make it possible to reduce drift loss well below 0.1 percent

Slowdown discards a portion of the concentrated circulating water due to the evaporation process in order to lower the system soUcb concentratton. The amount of blowdown can be calculated according to the number of cycles of concentration required to limit scale formation. Cycles of concentration are the ratio of dissolved solids iD the recirculating water to dissolved solids in the makeup water. Since chlorides remain soluble on concentration. cycles of concentration are best expressed as the ratio of the chloride content of the circu

# r

!·**l)t)lin~ ~**  :-oor ••rt' f,.,r**l<>"'~'r** lishl'd n J>er. atures

conI own. 12-9J
own
:-10)

.erat loss .uies**~ew** drift \ater .olids ·ord- ;cale dsin ;jnce ltion ircu· 

# 1

. and makeup waters. Thus. the blowdown quantities required laung · --' from .lfe deternuneu Cycles of concentration e**(W~** 

### + W&)IW&) t12-ll)

or W& 

### = W,/(cycles

- ll (12-12) les of concentration involved with cooling-tower operation norC\Jiv range from three to five cycles. Below three cycles of concenrn_iltion.**e:~~cessh·e** blowdown quantities· are required and the addition**~:**ac 1d to limit scale formation should be considered.

Etomple 13 Determine the amount of·makeup required for a cooling tower with following conditions:**~r** Bow. m3/h (gal/min) Inlet water temperature, °C (OF) Outlet water temperature, °C (OF) Drift loss. percent Concentration. cycles

Evapora'um lou 2270 37.77 29.44 0.2 5

W., m3/h • 0.00085 X 2270 X (37.77

- 29.44) X 1.8

- 28.9 W•· gal/min • 127.5 Drift lou
B/ou1doum

Makeup W4, m 3/h • 2270 X 0.002 • 4.54 WIf, gal/min • 20

3 w. 28.9 w., m /h • -- • - • 7.24 (S- 1) 4 

### w._ gal/min • 31.9 W,., m 3/h • 28.9 + 4.54 + 7.24 • 40.7 

### w"
.. gal/min

- 179.4 (10.000) (100) (85)

Fan Honepower In evaluating cooling-tower owning and operating costs, fan-horsepower requirements can be a significant factor. Large air quantities are circulated through cooling towen at exit velocities of about 10.2 m/s (2000 ft/min) maximum for induceddraft towers. Fan air-Bow quantities depend upon tower-design (acton, including suG:h items as type of 8.11, tower con&guration. and thermal-performance conditions.

The effective output of the fan is static air horsepower (SAHP). which is obtained by the following equation: SAHP • Q(h,)(d) 33.000(12) (12-13) where Q :a air volume. fr/min; h. • static head. in of water; and d • density of water at ambient temperature. lb/fr.

CooUng-tower fan horsepower can be reduced substantiaUy as the ambient wet-bulb temperature decreases tf two-speed fan motors are used. Theoretically, operating at half speed will reduce air ftow by 50 percent while decreasing horsepower to one-eighth of full-speed operation. However, actual half-speed operation will require about
. 17 percent of the**horsepowe~at** full speed as a result of the inherent motor losses at lighter loads.

- ·

Figure 12-17 shows a typ1Cal plot of outlet-water temperatures when a cooling tower is operated (1) in the fan-off position. (2) with the fan at half speed, and (31 with the fan at full speed. Note that at decreasing wet-bulb temperatures the water leaving the tower during half-speed operation could meet destgn water-temperature requirements of, say, 85°F. For example, for a 60°F wet-bulb, 20°F range, a leaving-water temperature slightly below 85°F is obtained with design water tlow over the tower. If the fan had a 100-hp motor, COOUNG-TOWER OPERATION

120

... 110 I I I I I :::;a;:.....,..-- d."" I



### ... = 

## = <l z•• 20' 18' 2

.. :: F
. 

### i 100**~** d""'"f I :::a> ,.........-- 

## = I I = 

### :c It 90 9 8

80

70 10 15 70 n 10 8!1 WIT BULB TEM,EAATUAl·' F 12-17

FIG. 12·17 Typical plot of cooling-tower performance at varying fan speeds. 83 hp would be saved when operating it at half speed. In calculating savings, one should not overlook the advantage of having colder tower water available for the overall water-circulating system.

Recent developments in cooling-tower fan energy management also include automatic variable-pitch propeller-type fans and inverter-type devices to permit variable fan speeds. These schemes involve tracking the load at a constant leaving-water temperature.

The variable'-pitch arrangement at constant motor speed changes the pitch of the blades through a pneumatic signal from the leavingwater temperature. As the thermal load and/or the ambient wetbulb temperature decreases, the blade pitch reduces air Oow and less fan energy is required.

Inverters make it possible to control a variable-speed fan by changing the frequency modulation. Standard alternating-current fan motors may be speed-regulated between 0 and 60 Hz. In using inverters for this application. it is important to avoid frequencies that would result in fan critical speeds.

Even though tower-fan energy savings can result from these arrangement!, they may not constitute the best system approach. Power-plant steam condensen and refrigeration units, for example, can take advantage of colder tower water to reduce power consumption. Invariably, these system savings are much larger than coolingtower fan savings with constant leaving-water temperatures. A refrigeration-unit condenser can utilize inlet·water temperatures down to 12.8°C (55°F} to reduce compressor energy consumption by 25 to 30·percent.

Pumping Honepower Another important factor in analyzing cooling-tower selections, especially in medium to large sizes, is the portion of pump horsepower directly attributed to the cooling tower. A counterflow type of tower with spray nozzles will have a pumping head equal to static lift plus nozzle pressure loss. A cross-Bow type of tower with gravity Bow enables a pumping head to equal static lift. A reduction in tower height therefore reduces static Uft, thus reducing pump horsepower: Pum bh • gal/min(ht)
. p p 3960 (pump efficiency) (12-14) where h, • total head.. ft

Fogging ancl Plume Abatement A phenomenon that occurs in cooling-tower operation is fogging, which produceS a highly visible plume and possible icing hazards. Fogging resulu from mixing warm, highly saturated tower discharge air with cooler ambient air that lacb the capacity to absorb all the moisture as vapor. While in the past visible plumes have not been considered undesirable, properly locating towers to minimize possible sources of complaints has 

# '

### ATmACBMEN'l' 7 

## LflBOR COSTS

# BUILDING CONSTRUCTION COST DATA



# 1989 47th Annual Edition 

# £Means·**~,.**

# ,,

' .•**~** ..a.

### ea.,ttnl4=toi"'S 

### Overhead & 

## PrOfit installing contractor's percentage mark-ups -::=-rateS to arrive at

### typi~ billing rates. Column**~** 

## n E: Pet:centages in Columns 0 and 

## eare based on the presumptron that the rnstalling contractor has annual billing of $500 000 and up. Overhead percentages may increase with smaller annual bilii The overhead percentages for any given contractor may vary greatly

### ~d**d~d ~n**  a**numbe~ ~f**  factors, such as the contractor's annual volume.**~ngrneenng** and log1strcal support costs. and staff requirements. The ftgures**f~r overh~ad**  and profit will also vary depending on the type of JOb, the JOb locatton. and the prevailing economic conditions. All factors should be examined very carefully tor each job. •

### ~bor rates are baSed on union wages averaged for 30 major

. A:

# e'ase rates includj.ng fringe benefits are listed hourfy and daily.**Cl~~:res** are the sum of the wage rate**~nd** employer-paid fringe 

## -rnes:ts such as vacation pay, employer-patd health and welfare costs.**~on** cOsts. plus approPf'!_Ste training and industry advancement funds costs. Cofumn 8: Workers' Compensation rates are the national average of state rates established for each trade. Cofumn C: Column C lists average fixed overhead figures for all trades. Included are Federal and State Unemployment costs set at 6.2%; Soctal**secur~ty** Taxes (FICA) set at 7.65%: Builder's Risk Insurance costs set at 0.34%: and Public L1ab11ity costs set at 1.55%. All the percentages except those tor Soc1al**Secur~ty** Taxes vary from state to state as well as from company to company. 

# A Base Rate Abbr. Trade Incl. Frin1es Hourly Daily Skwk Sk1lled Workers Average (35 trades) $21.90 $175.20 Helpers Average (5 trades) 16.60 132.80 Foremen Average, Inside (SOC over trade) 22.40 179.20 Foremen Average, Outside ($2.00 over trade) 23.90 191.20 Clab Common Buildmg Laborers 16.85 134.80 :.sbe Asbestos Workers 23.85 190.80 Bo1l Borlermakers 23.90 191.20 Bnc Bricklayers 22.10 176.80 Brhe Brrcklayer Helpers 17.10 136.80 Carp Carpenters
.. 21.40 171.20 Cefi Cement Finishers 20.80 166.40 Elec Electricrans 24.25 194.00 Elev Elevator Constructors 24.15 193.20 Eqhv Equ1pment Operators, Crane or Shovel 22.40 179.20 Eqmd Equipment Operators, Medium Equipment 21.65 173.20 Eqlt Equipment Operators, light Equipment Eqol Equrpment Operators, Oilers Eqmm Equ1pment Operators, Master Mechanics Glaz Glazrers Lath Lathers Marb Marble Setters Mill Millwrrghts Mstz Mosaic and Terrazzo Workers Pard Parnters. Ordinary Psst Parnters, Structural Steel Pape Paper Hangers Pile Pile Drivers Plas Plasterers Plah Plasterer Helpers Plum Plumbers Rodm Rodmen (Rernforc.ng) Rotc Roofers. Composition Rots Roofers, Tile & Slate Rohe Roofer Helpers (Composition) Shee Sheet Metal Workers Spn Sprinkler Installers Stpi Steamfitters or Pipefitters Ston Stone Masons Sswk Structural Steel Workers Tilf Tile Layers !floor) Tilh Tile Layer Helpers Trlt Truck Drivers, Ught Trhv Truck Drivers. Heavy Sswl Welders. Structural Steel Wrck •wrecking •Not included in Averages.

,;:.. &L.
.**·.~illf~.-r··** ....**~~r.-.~·"''** 

### ... 20.60 164.80 18.45 147.60 23.10 184.80 22.05 176.40 21.60 172.80 21.95 175.60 22.15 177.20 21.45 171.60 20.10 160.80 20.85 166.80 20.25 162.00 21.50 172.00 21.10 168.80 17.35 138.80 24.45 195.60 23.15 185.20 19.75 158.00 19.85 158.80 14.65 117.20 24.05 192.40 25.25·' 202.00 24.55 196.40 22.00 176.00 23.25 186.00 21.50 172.00 17.05 136.40 17.45 139.60 

### .l1.&l 140.80**~** }3.20 186.00 

### -rr.so 134.40 

# BColumn F: Column F lists the total of columns B. C. D. and E. Column G: Column G is.Cotumn A (hourly base labor rate) multiplied by the percentage in Column F (O&P percentage). Column H: Column H is the total of Column A (hourly base labor rate) plus Column G (Total O&P). Column 1: Column I •s Column H multiplied by eight hours. 

# c D 

# E F 

# G H I Work· Avera1t Total Rate with ers' Fixed Over· Profit Overhead & Profit O&P Comp. Over- held

Ins. head % Amount Hourly Daily 12.59(. 15.796 12.896 10\ 51.09& $11.15 $33.05 S264.40 13.8 13.0 52.5 8.70 25 30 202.40 12.5 12.8 51.0 11.40 33.80 27040 12.5 12.8 51.0 12.20 36 10 288.80 13.9 11.0 50.6 8,55 25.40 2(]9.20 11.6 16.0 53.3 12.70 36.55 292.40 7.9 16.0 49.6 11.85 35.75 286.00 11.3 11.0 48.0 10.60 32.70 261.60 11.3 11.0 48.0 8.20 25.30 202.40 13.9 11.0 50.6 10.85 32.25 25800 7.9 11.0 44.6 9.30 30.10 240.80 5.2 16.0 46.9 11.35 35.60 284.80 6.8 16.0 48.5 11.70 35.85 286.80 8.8 14.0 48.5 10.85 33.25 266.00 8.8 14.0 48.5 10.50 32.15 257.20 8.8 14.0 48.5 10.00 30.60 244.80 8.8 14.0 48.5 8.95 27.40 219.20 8.8 14.0 48.5 11.20 34.30 274.40 10.4 11.0 47.1 10.40 32.45 259.60 8.4 ,' 11.0. 45.1 9.75 31.3$ 250.80 11.3 11.0 48.0 10.55 32.50 260.00 8.4 11.0 45.1 10.00 32.15 257.20 7.0 11.0 43.7 9.35 30.80 246.40 10.4 11.0 47.1 9.45 29.55 236.40 34.9 11.0 71.6 14.95 35.80 286.40 10.4 11.0 47.1 9.55 29.80 238.40 21.9 16.0 63.6 13.65 35.15 281'20 11.0 11.0 47.7 10.05 31.15 249.20 11.0 11.0 47.7 8.30 25.65 205.20 6.2 16.0 47.9 11.70 36.15 289.20 22.0 14.0 61.7 14.30 37.45 299.60 25.7 11.0 62.4 12.30 '32.05 256.40 25.7 11.0 62.4 12.40 32.25 258.00 25.7 11.0 62.4 9.15 23.80 190.40

8.8 16.0 50.5 12.15. 36.20 289.60 6.7 16.0 48.4 12.20 37.45 299.60 6.2 16.0 47.9 11.75 36.30 290.40 11.3 .11.0 48.0 10.55 32.55 260.40 26.8 14.0 66.5 • 15.45 38.70 309.60

7.0 11.0 43.7 9.40 30.90 247.20 7.0 11.0 43.7 7.45 24.50 196.00 11.8 11.0 48.5 8.45 25.90 207.20 11.8 11.0



### - 4l5 8.55 26.15 209.20 26.8 14.0 66.5 15.45 38.70 309.60 28.1 

### ', 11.0'' 

# , 64.8 10.90 27.70 221.60 

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