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Introduction to Aspen Cost Estimation Products Sunil Patil Principal Business Consultant ©© 2010 Aspen Technology, Inc.
Introduction to Aspen Cost Estimation Products
Sunil Patil
Principal Business Consultant
©© 2010 Aspen Technology, Inc. All rights reserved
2010 Aspen Technology, Inc. All rights reserved
Agenda Introduction and Overview Cost Basis Process Equipment and Bulk Modeling Workflow Overview – Configuring Templates
Agenda
Introduction and Overview
Cost Basis
Process Equipment and Bulk Modeling
Workflow Overview
– Configuring Templates
– Loading and Mapping Simulation Data
– Evaluating the Project and Generating Reports
Detailed hands on information
Decision Analyzer (Project Scaling and Relocation)
Integrated Costing and Sizing
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Asset Engineering Workflow Safety & Controllability Analysis Process Performance Modeling & Analysis Analyze Economic Performance Conceptual
Asset Engineering Workflow
Safety &
Controllability
Analysis
Process
Performance
Modeling & Analysis
Analyze
Economic
Performance
Conceptual
Design / R&D
Detailed
Develop Basic
Design Package
Basic
Equipment
Analyze
Engineering
Design
Detailed
Costs
Develop Detailed
Plant Design
Detailed
Engineering
Reuse Process
Model for
Operations Decisions
Reuse Process
Models for
Planning Decisions
Operations/
Maintenance
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What is Icarus technology? Computer aided, design, estimating, and scheduling system for the process industries System
What is Icarus technology?
Computer aided, design, estimating, and scheduling system
for the process industries
System generates “scope” quantities
“Engineering department” embodied in software
Incorporates current construction practices and costs
Used to evaluate ca ital costs for:
p
– Major process plants / mills
– Process alternatives
– Scope changes
– Work orders
Used by owner/operators and engineering/constructors
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Logically Connected Asset Optimization De- Process Plant Constr- Concept Startup Bottle- Retrofit Production Design Design uction
Logically Connected
Asset Optimization
De-
Process
Plant
Constr-
Concept
Startup
Bottle-
Retrofit
Production
Design
Design
uction
neck
Process
Economic Analyzer
Capital Cost Estimator
In-Plant Cost Estimator
Process Simulators
Aspen Plus
Primavera Scheduling
User Data
Aspen
HYSYS
Reporter
Excel & Crystal
Reports
Icarus
Excel Custom Models
CAE/CAD
Client
Intergraph
Aspen Basic Engineering
Data Sheets, Plot Plan
Technology
(via API)
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Aspen Economic Evaluation Products Process Economic Analyzer Capital Cost Estimator In-Plant Cost Estimator •Economics for Process
Aspen Economic Evaluation Products
Process Economic
Analyzer
Capital Cost Estimator
In-Plant Cost Estimator
•Economics for Process
•Multi-contractor project
•All Design Basis,
Engineers
execution
Equipment & Plant Bulks
•Interface to Aspen Plus
•Power/Process Control
as ACCE
and HYSYS
systems
•No volumetric models
•Expand Unit Operations
•Optimized equipment
•Foundation design
to Equipment (Map)
rental
•Primavera CPM schedule
•Equipment sizing
•Primavera detailed CPM
incl. costs (P3 or P6)
•PFD’s
schedule (P6)
•Equipment Rental
•Stream list incl. utilities
•Project Relocation &
•User data sources
Scaling
•Project Relocation &
Scaling
•Modular Construction
•Cooling Water analysis
•Pipelines
•Financial Analysis
(CAPEX and OPEX)
(CAPEX and OPEX)
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Built-In Knowledge Modules Detailed Design International and Cost Design Methods Models CPM-based Fabrication and Expert Systems
Built-In Knowledge Modules
Detailed Design
International
and Cost
Design Methods
Models
CPM-based
Fabrication and
Expert Systems
Scheduling
Construction
Knowledge Bases
Methods
Methods
Materials
Contractor’s
of
Engineering
Construction
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AspenTech Integration Example Aspen Process Economic Analyzer 2) Economic screening performed for multiple cases 1) Process
AspenTech Integration Example
Aspen Process
Economic Analyzer
2) Economic
screening performed
for multiple cases
1) Process
simulation cases
developed
Aspen Capital
Cost Estimator
3) Preliminary
sized equipment
used to develop
conceptual cost
estimate
Aspen Basic
Engineering
4) Data loaded for
“best” case
5) Additional design
and sizing
6) Preliminary
conceptual
estimate revised
with latest project
data from Aspen
Basic
Engineering
Equipment Design and
Rating Tools and MS
Excel
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New Product Nomenclature Old Name New Name Aspen Icarus Process Evaluator (IPE) Aspen Process Economic Analyzer
New Product Nomenclature
Old Name
New Name
Aspen Icarus Process
Evaluator (IPE)
Aspen Process
Economic Analyzer
Aspen Kbase
Aspen Capital Cost
Estimator
Aspen Icarus Project
Manager (IPM)
Aspen In-Plant Cost
Estimator
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What is Aspen Process Economic Analyzer? Tools for preliminary/relative economic analysis Generates equipment sizes and designs
What is Aspen Process Economic Analyzer?
Tools for preliminary/relative economic analysis
Generates equipment sizes and designs using process
simulator data
Calculates estimated capital and operating costs for a
process
Allows rapid evaluation of processes alternatives to compare
relative profitability
Projects created in Aspen Process Economic Analyzer can be
refined in Aspen Capital Cost Estimator
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Aspen Economic Evaluation Family and the Project Lifecycle De- Process Plant Constr- Concept Startup Bottle- Retrofit
Aspen Economic Evaluation
Family and the Project Lifecycle
De-
Process
Plant
Constr-
Concept
Startup
Bottle-
Retrofit
Production
Design
Design
uction
neck
Aspen
Aspen
P rocess
Capital
Economic
Cost
Analyzer
Estimator
Aspen In-Plant
Cost Estimator
Two interfaces to the
same underlying model
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Aspen Process Economic Analyzer Project Basis Establish cost basis Rules for generation of preliminary sized equipment
Aspen Process Economic Analyzer
Project Basis
Establish cost basis
Rules for generation of
preliminary sized
equipment list from
simulation data
Define investment
parameters, costs, and
product value(s)
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Aspen Capital Cost Estimator Project Basis Establish Customize cost models Fine tune CPM schedule basis ©
Aspen Capital Cost Estimator
Project Basis
Establish
Customize
cost
models
Fine tune CPM
schedule
basis
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Capital Costs Costs for initial and working capital Direct costs – Equipment – Piping Civil –
Capital Costs
Costs for initial and working capital
Direct costs
– Equipment
– Piping
Civil
– Steel, etc.
Indirect costs
– Construction rental equipment
– Construction management
– Engineering, etc.
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Operating Costs Operator and supervisor costs Feedstock costs estimated using stream data and user entered information
Operating Costs
Operator and supervisor costs
Feedstock costs estimated using stream data and user
entered information
Utility costs
– Steam
– Heating oil
– Cooling water
– Refrigerants
– Electricity, etc.
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Cost Basis Cost basis updated with each annual release Five base locations – US Gulf Coast
Cost Basis
Cost basis updated with each annual release
Five base locations
– US Gulf Coast
EU
– Japan
– Middle East
UK
Material and labor specifications can be adjusted to
represent site-specific conditions
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Investment Analysis Product sales estimated using stream data and user entered information Profit = Sales -
Investment Analysis
Product sales estimated using stream data and user entered
information
Profit = Sales - (Capital Costs + Operating Costs)
Investment analysis module generates typical economic
metrics
NPV
IRR
PO, etc.
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Process Equipment Primary equipment items derived from simulation – Simulator blocks mapped to one or more
Process Equipment
Primary equipment items derived from simulation
– Simulator blocks mapped to one or more Icarus equipment
models
– User-defined parameters govern designs
Additional process equipment items added by user
– Pumps
– Storage tanks
– Spares
Equipment models have attached P&ID
– Used to estimate piping and instrumentation costs
– Sizing equations used to estimate pipe quantities (length
and diameter)
Volumetric modeling used to estimate other bulk
quantities and costs (civil, paint, insulation, etc.)
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Equipment Design and Cost Procedure PROJECT SPECS: • Mechanical design specs • Project components specs MECHANICAL
Equipment Design and Cost Procedure
PROJECT SPECS:
• Mechanical design specs
• Project components specs
MECHANICAL DESIGN:
Equipment
design generated
Develop physical dimensions using:
• design code procedures
• industry standard methods
FABRICATION LABOR:
• Shop [+ Field]
• Labor
• Man-hours
Equipment cost
estimated
VESSEL COST:
1. Mat’l cost of parts
2.Shop [+ field] fab labor
3.Labor overheads
4.G and A
5.Profit
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Equipment Design Data and Estimated FOB Cost from Vendor © 2010 Aspen Technology, Inc. All rights
Equipment Design Data and Estimated FOB
Cost from Vendor
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x x x Volumetric Models: Calculation of Installation Bulks – Total installed cost estimated – Quantities
x
x
x
Volumetric Models:
Calculation of Installation Bulks
– Total installed cost estimated
– Quantities and costs for bulk
materials based upon equipment
specifications
– Volumetric models for process
equipment:
x
Conceptual P&IDs
Civil
Steel
x
Electrical
Insulation
Paint
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P&ID Library: Double Diameter Tower © 2010 Aspen Technology, Inc. All rights reserved | 22
P&ID Library:
Double Diameter Tower
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Non-Equipment Costs System estimates costs for additional bulk quantities – Project bulks Process control Power distribution
Non-Equipment Costs
System estimates costs for additional bulk quantities
– Project bulks
Process control
Power distribution
– Area bulks
Grounding
Lighting
Steel structures
Users can account for additional costs using system
models
– Plant bulks
Pipe rack
Rack piping
– Buildings
– Site development
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Typical Workflow Prepare library files Load simulator data Map simulator blocks to Icarus components Evaluate ©
Typical Workflow
Prepare library files
Load simulator data
Map simulator blocks to Icarus components
Evaluate
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Library Files Basis for capital costs – Project type and location – Construction workforce specifications –
Library Files
Basis for capital costs
– Project type and location
– Construction workforce specifications
– Material and man-hour indices
Design criteria for equipment
Investment parameters
– Analysis period
– Tax and interest rates
– Escalation
Operating unit costs
Product and raw material specifications
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Mapping Simulator Data Creates Process Economic Analyzer equipment components from computational block data Map 1-to-1 or
Mapping Simulator Data
Creates Process Economic Analyzer equipment
components from computational block data
Map 1-to-1 or 1-to-many
Components are sized using simulator data and
Process Economic Analyzer design criteria
Resulting process flow diagram can be viewed in
Aspen Process Economic Analyzer
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Project Evaluation Project evaluation generates design quantities and estimates costs Available reports – Investment analysis reports
Project Evaluation
Project evaluation generates design quantities and
estimates costs
Available reports
– Investment analysis reports
Equipment
Project summary
Cashflow
Executive summary
– Capital cost reports
Standard reports (using Crystal Reports components)
Excel reports
HTML reports
Management reports (can be exported to Excel)
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Hands On Information © 2010 Aspen Technology, Inc. All rights reserved | 28
Hands On Information
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Loading Data from Aspen HYSYS Tools | Aspen Economic Evaluation | Export to Process Economic Analyzer
Loading Data from Aspen HYSYS
Tools | Aspen Economic Evaluation | Export to Process
Economic Analyzer
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Loading Data from Aspen HYSYS After being prompted to load simulation data, the following interface window
Loading Data from Aspen HYSYS
After being prompted to load simulation data, the following
interface window appears
•Confirms that HYSYS is running
•Establishes link
•Extracts simulation data
•Changes to “Export Again”
when export is complete
•Disconnects interface
•Closes interface
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Loading Data from Aspen Plus File | Send To | Aspen Process Economic Analyzer © 2010
Loading Data from Aspen Plus
File | Send To | Aspen Process Economic Analyzer
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Creating a New Project in Aspen Plus Create using “Aspen IPE Stream Properties” template to ensure
Creating a New Project in Aspen Plus
Create using “Aspen IPE Stream Properties” template to ensure
all necessary stream properties transferred to Aspen Process
Economic Analyzer
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Adding Properties to Existing Aspen Plus Project Import IPE-1, IPE-2, and IPE-3 Prop-Sets from “Aspen IPE
Adding Properties to Existing Aspen
Plus Project
Import IPE-1, IPE-2, and IPE-3 Prop-Sets from “Aspen IPE
Stream Properties” template
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Interface – No Open Project Palette View Properties Window © 2010 Aspen Technology, Inc. All rights
Interface – No Open Project
Palette
View
Properties
Window
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Interface – Open Project Palette View Project List Explorer View Properties Window © 2010 Aspen Technology,
Interface – Open Project
Palette
View
Project
List
Explorer
View
Properties
Window
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Palette View Three tabs – Projects – Libraries (Template files) – Components (Equipment, bulk items, buildings,
Palette View
Three tabs
– Projects
– Libraries (Template files)
– Components (Equipment, bulk items, buildings, and site
development models)
Locations of projects / libraries
– Specified using the Locations tab of Preferences menu (Tools |
Options | Preferences)
– Locations can be on a local or network drive
Use drag-and-drop from Components tab (to Project View or
List View) to select components into project
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Properties Window Contains location information for items in the Projects and Libraries tabs of the Palette
Properties Window
Contains location information for items in the Projects and
Libraries tabs of the Palette View
Provides details for fields within a component specification form
– Allowable data type
– Default value(s)
– Minimum / maximum allowable values
– Description
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Project Explorer Three tabs – Project Basis View – Process View – Project View Project Basis
Project Explorer
Three tabs
– Project Basis View
– Process View
– Project View
Project Basis View tab allows input of project level specifications
Process View tab displays unit operations loaded from process
simulator data
– Yellow unit operations are unmapped
– Green unit operations have been mapped to equipment
Project View tab allows addition of components
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Project Basis Specifications © 2010 Aspen Technology, Inc. All rights reserved | 39
Project Basis Specifications
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Project Basis Specifications Capital cost basis – General specifications – Construction workforce – Indexing Process design
Project Basis Specifications
Capital cost basis
– General specifications
– Construction workforce
– Indexing
Process design
– Simulator file
– Mapping specifications
– Design criteria
Investment analysis
– Operating unit costs
– Raw material and product specifications
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Loading Simulator Data Not necessary if data is sent from HYSYS or Aspen Plus Load data
Loading Simulator Data
Not necessary if data is sent from HYSYS or Aspen Plus
Load data
Specify simulator type
and file name
Aspen Plus - .apw or .xml
HYSYS - .hsc
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Loading Simulator Data Loads block and stream data from simulator Populates Process View tab with unit
Loading Simulator Data
Loads block and stream data from simulator
Populates Process View tab with unit operations
View streams list and block flow diagram
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Loading Simulator Data Simulator type and simulator file name specified in project basis Block and stream
Loading Simulator Data
Simulator type and simulator file name specified in
project basis
Block and stream data loaded from simulator
Block flow diagram and streams list can be viewed in
Aspen Process Economic Analyzer
Simulator link allows Aspen Plus and HYSYS simulation
data to be exported directly to Aspen Process Economic
Analyzer
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Mapping Simulator Items Map simulator items © 2010 Aspen Technology, Inc. All rights reserved | 44
Mapping Simulator Items
Map simulator items
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Mapping Simulator Items Maps unit operations to equipment models – Simple (1-to-1 mapping) – Complex (1-to-many
Mapping Simulator Items
Maps unit operations to equipment models
– Simple (1-to-1 mapping)
– Complex (1-to-many mapping)
Defaults are based upon “Project Component Map
Specifications” in the Project Basis
– A default file is available out of the box for each supported
simulator type
– Customers can create their own files and store as a template
(found in the Libraries tab of the Palette View)
Performs preliminary sizing using design criteria specified in
project basis, unit operation, and stream data
Populates Project View tab
After mapping, user can view a process flow diagram
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Tower Configurations Tower configuration selected during mapping Configuration drives equipment generated by unit operation Single -
Tower Configurations
Tower configuration selected
during mapping
Configuration drives equipment
generated by unit operation
Single - Tower has one condenser
Split - Tower has multiple condensers
Total - Reflux pump handles the total outlet liquid flow from the
accumulator. In such configurations, the splitting into a reflux and
overhead liquid product occurs after the reflux pump
Circ. – There is a pump between the bottoms splitter and reboiler giving a
forced circulation configuration around the reboiler
Full configurations include the following equipment (not found in Standard
configurations)
overhead pump
overhead product heat exchanger
bottoms product pump
bottoms product heat exchanger
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Process Flow Diagram: Radfrac Block PFD is interactive Additional equipment (pumps, storage tanks, etc.) can be
Process Flow Diagram: Radfrac Block
PFD is interactive
Additional equipment
(pumps, storage tanks,
etc.) can be added to a
project manually
Manually added equipment
can be placed on the
appropriate stream and
sized using design
parameters
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Evaluating the scenario Generates designs, quantities, and estimated costs Evaluate project © 2010 Aspen Technology, Inc.
Evaluating the scenario
Generates designs, quantities, and estimated costs
Evaluate project
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Additional Modules Decision Analyzer – Analyzer Scale-Up Module (ASM) – Analyzer Relocation Module (ARM) – Analyzer
Additional Modules
Decision Analyzer
– Analyzer Scale-Up Module (ASM)
– Analyzer Relocation Module (ARM)
– Analyzer Economic Module (AEM)
Utility Models
– Air (instrument and plant)
– Cooling water
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Decision Analyzer module © 2010 Aspen Technology, Inc. All rights reserved | 50
Decision Analyzer module
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Decision Analyzer module Conceptual scale-up and relocation of a base case Allows a user to generate
Decision Analyzer module
Conceptual scale-up and relocation of a base case
Allows a user to generate relative costs for changed
capacity or construction/engineering in a new location
Scale-up module resizes equipment and associated
bulk quantities (piping, instrumentation, foundations,
etc.)
Scale-up module will not automatically model multiple
trains of equipment
Relocation module primarily indexes material costs
and modifies workforce specifications (wages and
productivities) – These changes will override
specifications that the customer may have made
Relocation module does not modify design codes and
construction/fabrication models
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Integrated Simulation & Cost Analysis View Show Activate Evaluate Unit Op Current Costing Equipment Grid State
Integrated Simulation & Cost Analysis
View
Show
Activate
Evaluate
Unit Op
Current
Costing
Equipment
Grid
State
Engine
Map
Models to
Equipment
Costs
Load
Size
View
Simulation
Equipment
Equipment
Data
Object
Grid
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Integrated Simulation & Cost Analysis Unit Operation Summary Grid View Unit Op Summary Grid View Results
Integrated Simulation & Cost Analysis
Unit Operation Summary Grid
View Unit Op
Summary Grid
View Results and
Change Inputs
One tab for each type of unit operation
model in the simulation case
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Integrated Simulation & Cost Analysis Mapping Unit Operation Models to Equipment Map Unit Operation Models to
Integrated Simulation & Cost Analysis
Mapping Unit Operation Models to Equipment
Map Unit Operation
Models to Equipment
E1210
Condenser
C1200
Packed
T1220
Column
Reciever
Packin g
Section 1
P1230A/B
Reflux Pumps
E1250
Packing
Exchanger
Section 2
C1200
P1240
Pump
E1260
Reboiler
Conceptual Unit
Equipment Models
Operation Models
for Cost Analysis
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Integrated Simulation & Cost Analysis Mapping Unit Operation Models to Equipment Map Unit Operation Models to
Integrated Simulation & Cost Analysis
Mapping Unit Operation Models to Equipment
Map Unit Operation
Models to Equipment
Equipment objects are
created during the
mapping process
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Integrated Simulation & Cost Analysis Viewing / Changing Equipment Specifications View/Change Equipment Specifications Summary of Equipment
Integrated Simulation & Cost Analysis
Viewing / Changing Equipment Specifications
View/Change Equipment
Specifications
Summary of
Equipment Costs and
Net Process Costs
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Integrated Workflow Advantages • One environment = faster learning curve • Interactive sizing from inside the
Integrated Workflow Advantages
• One environment = faster learning curve
• Interactive sizing from inside the simulator
• Enables concurrent design & costing
• Rigorous cost modeling allows rapid evaluation
of
p
rocess scenarios
• Resulting project file can be opened directly in
Aspen Capital Cost Estimator
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