Document pmQ8w16mK2K9BY1eD1K8aL6w

BIG RED, YELLOW (W-A) AKE-003254 ENGINEERING REPORT PROJECT 7104 STEAM DISTRIBUTION SYSTEM MIDDLETOWN WORKS MARCH 31, 1966 KAISER ENGINEERS, INC. REPORT NO. 7104-2 PREPARED V'/s'-e. <> DATE APPROVED BY --- V. X. KAST KAISER ENGINEERING MANAGER APPROVED BY T. R. FOLEY T ARMCO PROJECT MANA< DATE BIG RED, YELLOW (W-A) AKE-003255 TABIE OF CONTENTS 1. INTRODUCTION AND SUMMARY 2. GENERAL DESCRIPTION 2.1 Main Steam Line 2.2 Branch Lines and Connections for Future Needs 2.3 Design Criteria 2.4 Materials 2.5 Structures 3. SCHEDULE 4. CHART OF ACCOUNTS 5. ESTIMATE 6. SCOPING DRAWING i BIG RED, YELLOW (W-A) AKE-003256 1. INTRODUCTION AND SUMMARY 3his report covers the extension, of the Steam Distribution System to the South Area Finishing Facilities for Project >'600" at the Middletown Works. Steam distribution within each facility will be covered in the Engineering Report for that facility. All steam lines have been sized to satieiy Phase I and Phase II steam requirements. Generally, the lines will be laid under ground utilizing Rlc-Wil conduit systems. BIG RED, YELLOW (W-A) Page 1 AKE-003257 2. GENERAL' DESCRIPTION 2.1 Main Steam Line A 16' k2$ psig-, 750F steam line is routed from a connection in the Hot Strip Kill at Column C to the Hot Strip Mill Pump House and is covered in the Hot Strip Mill Engineering Report. A 12" line will be routed from a connection off this 16" line to the Pickle Line Building where it will terminate at a pressure reducing and desuperheating station within the building. This pressure reducing and desuper heating station will be furnished under the Pickle Line Facility. A 12" 16$ psig? 500F steam line will be routed from a connection in the north end of the Hot Strip Mill to the Pickle Lino Building where it will connect to the loop serving that facility* Ihe routing of the steam lines is shown on Drawing No. PR~329?~lb53P BIG RED, YELLOW (W-A) Page 2 AKE-003258 2.2 Branch Lines and Connections for Future Needs At the Hot Strip Mill Pump House, a 12" valve will be provided for future maintenance requirements. Also, a blanked tee will be provided for future extension to additional finishing facilities. A 10" valved connection will be provided at the finishing area for furnishing steam to the finishing facilities. 2.3 Design Criteria Bie Steam Distribution System will conform to the A.S.M.E. Code for Unfired Pressure Vessels and Bulletin No. 2lli of the Ohio State Code. The k25> psig line will be designed for ?50F superheated steam and the 163 psig line will be designed for 5>00F superheated steam* 2.U Materials Pipe for the h,2$ psig, 750F line will be seamless A.S.T.M. A-106, Grade B, and pipe for the 163 psig, 500P line will be A.S.T.M. A-33> Grade B. Wall and insulation thickness will be as follows: Nominal Pipe Wall Line Pressure Size_____ Thickness Insulation thickness h2$ psig 12" 0.U06 h*$n 165 psig 12" 0.U06" 3.0 BIG RED, YELLOW (W-A) Page 3 AKE-003259 /i Ric-Wil corrugated conduit systems vdll be used for all under ground installation. Insulation -will be double layer calcium silicate with staggered joints. Conduit will be 14 gage galva nized Helcor, asphalt coated and wrapped with fiberglass rein forced asphalt impregnated felt. The underground conduit will be cathodically protected. Valves in the 425 psig, ?50F line will conform to Arnco Standard Specification ACS-400-04 and vdll be suitable for 600 psig and 750F service-. Valves in the 165 psig, 500F line will conform to Armco Standard Specification ACS-400-03 and will be suitable for 300 psig and 500F service. Expansion joints will be bellows type with Inconel 600 corru gations internally guided full inlet pipe area throughout, welded ends, and cast iron reinforcing rings* 2.5 Structures All underground valves, expansion joints and anchor ells will be located in reinforced concrete pits with removable steel cover plates for access. Expansion joint pits will be located approximately 240 feet on centers. BIG RED, YELLOW (W-A) Page 4 AKE-003260 3. SCHEDULE Work covered by this report will be performed in accordance with the schedule on the following page. BIG RED, YELLOW (W-A) Page 5 AKE-003261 -........... ........................................... -.... S V 33N IO N 3 3 3 S IV X _ ' *I0Xl 'ON 103COUd BIG RED, YELLOW (W-A) AKE-003262 4. CHART OF ACCOUNTS PROJ. CONS3R* SECT. DETAIL 710 ----- STSAM DISTRIBUTION Ibis project section will include all costs for labor, material, and equipment usage to install the tmderground steam line in the South Area as follows: 1. A 12 inch 1*25# steam line from the Hot Strip Mill Pump House to the Pickle Line Structure. This line connects to the 16 inch line from the Hot Strip Mill to the Pump House* 2* A 12 inch 165// steam line from the north end of the Hot Strip Mill Structure to the Pickle Line Structure. 3* One 12 inch and one 10 inch valved connection for future connections. U. Concrete anchor and guide blocks for the steam lines. 5* Excavation and backfill for the steam lines. 6. Cathodic protection. Tiis project section does not include any sleeves for crossing under roads and railroads. 03h Ditching and Backfill 052 Pumping 170 Concrete Anchors and Guides J46I Purchase - Pipe and Fittings 1(62 Purchase - Valves U6U Pipe Installation U65 Pipe Insulation ij68 Purchase ~ Expansion Joints 1*6? Expansion Joint Covers 51? Cathodic Protection BIG RED, YELLOW (W-A) Page 7 AKE-003263 PRCXJ. CONSTR. SECT. DETAIL 711 ----- VALVE PI IS This project section will include all costs for labor, material, and equipment usage to construct the concrete pits for valves, anchor ells and expansion joints. Excavation and backfj.ll is included in Project Section 710. 120 Formwork 130 Re-Steel 11*0 Embedded Metals 15>0 Concrete 220 Miscellaneous Steel BIG RED, YELLOW (W-A) Page 8 AKE-003264 PRQJ. CONSTR. SECT* DETAIL 690 6U3 SPARE PARTS 691 oh3 MECHANICAL REPLACEMENT PARTS 693 6UL MIDDLETOWN WORKS, START-UP - MECHANICAL The above project sections have been established . to provide accounts for future use. These accounts will be available for property accounting or other uses that may be necessary at some subsequent time. The accounts are not, at the present time, part of this project. 69k 6hl VENDOR'S ASSISTANCE - MECHANICAL This project section will include all the costs for Personnel assistance rendered by the Mechan ical vendor. 69 6bh CONSTRUCTION FORCES - START-UP This project section will include the costs Tor labor, material, and equipment for oil, grease, final tests, tune-up, etc. BIG RED, YELLOW (W-A) Page 9 AKE-003265 PRQJ. CONSTR. SECT. DETAIL 880 ----- 500 ELECTRICAL SUBCONTRACTOR OVERHEAD AND FEE This project section shall include the estimated allowance for the electrical subcontractor's overhead and fee. Die overhead allowance is based on a percentage of the total direct labor and includes such Items as follows: 1. Supervisory and clerical expense including superintendent, assistant superintendent, field engineers, secretarial and clerical personnel 2. Electrical construction small tools (under $500). 3. Consumable supplies U. Office supplies Such items as the following are furnished by Kaiser Engineers and are not included in the subcontractor's overhead allowance: 1. Construction Plant and facilities 2. Construction equipment and equipment usage 3. Services such as reproduction, accounting, cost control, scheduling, purchasing, etc# U. Telegraph, telephone and utilities consumption The fee for this estimate is based on a percentage of the total direct labor and material. Electrical subcontractor's overhead and fee BIG RED, YELLOW (W-A) Page 10 AKE-003266 PHOJ. CONSTR SECT. DETAIL 910 911 90B 962 96h CONSTHJCTEON OVERHEAD Surveying This account shall include the wages, employee benefits, and equipment usage of field survey crews. Chief of survey, his assistants and clerical help are provided for in Project Section No. 7100. Small Tools and Consumables This account shall include the cost of pro-rate distribution of total small tool and consumables accumulated for the program. Acquisition of these tools and consumables will be charged to clearing account 99$-99$c The relief on this clearing account will be charged to 910-958. Winter Protection This account shall include all wages, materials, employee benefits, and equipment usage for pro tection from the cold whenever necessary during construct!on of the Hot Strip Mill. Clean Up This account shall include wages, employee benefits and equipment usage for general site dean up for the specific project. BIG RED, YELLOW (W-A) Page 11 AKE-003267 PRDJ. CONSTR. SECT* DETAIL 5>IjO ----- ENGINEERING AMP STAFF 906 Design Engineering This account shall include wages, and employee benefits for all project engineering efforts, excluding those individuals assigned to Project No. 7100, after the date of preparation of the engineering report. Direct labor charges for engineering effort by home office personnel after the completion of the engineering report are also included. (The overhead portion of home office personnel will be included in its proper project under account 91)0-95?.) 910 Feasibility Engineering This account shall include wages, and employee j benefits for all project engineering efforts, excluding those individuals assigned to Project No. 7100, before the date of preparation of the engineering report. Direct labor charges for engineering effort by home office personnel before the completion of the engineering report are also" included. (The overhead portion of home office personnel will be included in the proper project under account 91)0-957.) 927 Reproduction This account shall include the reproduction expenses for the Chicago office only with respect to the Hot Strip Mill. The Middletown reproduction expenses are included in Project No. 7100. 953 Permits This account includes the cost of all permits required by local statute for constructing the facilities included in the sepcific project. 957 Home Office Overhead This account shall include the home office over head related to reimbursable home office labor chargeable to the specific project. The direct labor charges for home office personnel are included in, and are to be charged to their respective accounts. Page 12 BIG RED, YELLOW (W-A) ! AKE-003268 BIG RED, YELLOW (W-A) AKE-003269 BIG RED, YELLOW (W-A) AKE-003270 PROJECT 710U APPROPRIATION ESTIMATE NO. Oh-2 This estimate covers the cost of the Steam Distribution System for the Middletown Works as described in this report, together with the following additional estimate criteria: Engineering, manufacturing, and construction personnel will work the standard forty (i;0) hour week and no allowance has been made in the estimate for scheduled overtime work. If it becomes necessary to work the con struction forces an extended work week to man the pro ject, the premium pay exposure could amount to $23,000. This amount is based on eight (8) hours of overtime per week for the duration of the project for KE Craft Labor, KB Equipment Usage Labor and Subcontract Craft Labor, and includes ten percent (10) labor Burden applicable to premium pay. Construction is scheduled to start January 1, 1967, and the scheduled completion date is June 1, 1967. Since current labor contracts cor the major crafts cover the scheduled major work periods, future wage increases specified in these contracts have been included in the labor estimate. Estimated wage increases for the minor crafts have also been included based on precedent estab lished for the major crafts. Material, Subcontract and Equipment prices are as of the date of the Estimate. Increases due to escalation are not included in the estimate and this exposure is esti mated to be approximately as follows: Total Direct Item Cost Material 236,^00 Subcontract . 1>,5>00 Engineered Equipment ---------- Estm. Amt. Subject To Escalation 13,200 Estm. % Escala. 7.1i IuO Estm. Total Escalation 16,800 00 Total Estimated Escalation Exposure $17,300 Material and equipment prices include freight costs to the job site. Ohio State Use, Sales, and similar taxes are not included in the estimate. page If? BIG RED, YELLOW (W-A) AKE-003271 PROJECT 71QU APPROPRIATION ESTIMATE NO. Olj-2 e o e e Continued Indirect costs, which are a pro-rata share of Project 7100, are not included in the estimate total, litis pro-rata amount of $21,300 is included as a part of the fee base. Hie estimated fee shown is based upon an average fee for the Middletown and Butler Programs and a total estimated fee base for such programs in excess of $k00,000*000. Spare Equipment, Spare Parts and Middletown Works Startup costs are not included in the estimate. Si!i i i BIG RED, YELLOW (W-A) Page 16 AKE-003272 BIG RED, YELLOW (W-A) AKE-003273