DACE Labour Norms Equipment Installation V2
DACE Labour Norms Equipment Installation V2
DACE Labour Norms Equipment Installation V2
1 Introduction ............................................................................................................................... 2
2 Installation of Static Equipment ................................................................................................. 2
2.1 General ................................................................................................................................. 2
2.2 Installation of Vessels / Columns and Towers ...................................................................... 2
2.2.1 Pressure vessel horizontal (drum) .................................................................................... 2
2.2.2 Pressure vessel vertical.................................................................................................... 3
2.2.3 Column (tower) ................................................................................................................. 3
2.3 Installation of Trays and Demisters....................................................................................... 6
2.3.1 Demister Pads .................................................................................................................. 6
2.3.2 Sieve Trays ...................................................................................................................... 6
2.3.3 Valve trays........................................................................................................................ 6
2.4 Installation of Exchangers / Condensers / Reboilers ............................................................ 8
2.4.1 Fixed tube, sheet or U-tube heat exchanger .................................................................... 8
2.4.2 Floating Head Heat exchanger ......................................................................................... 8
2.5 Installation of Airfin Coolers ................................................................................................ 11
3 Rotating Equipment ................................................................................................................ 12
3.1 General ............................................................................................................................... 12
3.2 Installation of Pumps .......................................................................................................... 13
3.3 Installation of Fans and Motors ........................................................................................... 14
3.4 Installation of Compressors ................................................................................................ 15
3.4.1 Centrifugal compressor .................................................................................................. 15
3.4.2 Reciprocating compressor .............................................................................................. 17
3.5 Turbines.............................................................................................................................. 19
4 Miscellaneous Equipment ....................................................................................................... 20
4.1 Belt conveyors .................................................................................................................... 20
4.1.1 Open type without walkway ............................................................................................ 21
4.1.2 Enclosed type with side walkway ................................................................................... 22
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DACE Labour Norms V2 / Equipment Installation
1 Introduction
This section includes labour norms for Equipment installation work.
The labour norms listed are for direct labour only and have no bearing on equipment or material
cost, constructions, equipment rental, small tools or overhead (other than listed in the man-hour all
in rate). For the general description of labour norms we refer to the “DACE Labour Norms – general
description”.
All labour for unloading from railroad cars or trucks, storing in storage yard or warehouse, hauling to
installation site and installing are included in the man-hours listed.
2.1 General
All labour norms shown in the following tables include:
Unloading near foundation
Assembling (if applicable)
Rigging
Alignment
Bolting
Not included are:
Check and adjustment of foundations
Grouting
Cranes and lifting devices
Scaffolding
Hydro testing
Internals
Platforms, ladders etc
Cleaning
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DACE Labour Norms V2 / Equipment Installation
2.2.2 Pressure vessel vertical
A vertical pressure vessel is a vertical oriented and designed to hold gases or liquids at a pressure
substantially different from the ambient pressure.
The pressure vessels are widely used in the process industries (oil & gas, chemical,
pharmaceutical, plastics and rubber and the food and beverage industry) and high temperature
process industry (glass, paper and board).
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DACE Labour Norms V2 / Equipment Installation
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DACE Labour Norms V2 / Equipment Installation
The labour norms include:
Loading and onsite transport from on-site storage yard or warehouse location to plant
location.
Complete installation, adjustment and alignment of equipment, including fastening with
shim plates and anchor bolts.
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DACE Labour Norms V2 / Equipment Installation
2.3 Installation of Trays and Demisters
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DACE Labour Norms V2 / Equipment Installation
The labour norms exclude:
Unpacking crates
Install winch
Close tray manholes
Note:
Close tray manhole Bolted : 3 hours each
Close tray manhole Clips : 2 hours each
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DACE Labour Norms V2 / Equipment Installation
2.4 Installation of Exchangers / Condensers / Reboilers
A floating head exchanger is excellent for applications where the difference in temperature between
the hot and cold fluid causes unacceptable stresses in the axial direction of the shell and tubes. The
floating head can move, i.e. provides the possibility to expand in the axial direction.
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DACE Labour Norms V2 / Equipment Installation
“Tema types”
Front End Shell Rear End
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DACE Labour Norms V2 / Equipment Installation
The labour norms include:
Loading and Onsite transport from on-site storage yard or warehouse location to plant
location.
Unloading from truck
Check foundations
Unloading assistance, Rigging assistance, and Crane assistance
Hauling to installation site
Complete installation, adjustment and alignment of equipment, including fastening with
shim plates and anchor bolts.
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DACE Labour Norms V2 / Equipment Installation
2.5 Installation of Airfin Coolers
An air cooler is a device for ejecting heat from a fluid directly to ambient air. This is in contrast to
ejecting heat to water and then ejecting it to air, as with a shell and tube heat exchanger and a wet
cooling tower system. The obvious advantage of an air cooler is that it does not require water,
which means that plants requiring large cooling capacities need not be located near a supply of
cooling water.
Weight TF
From To Hours/ton
- 5.00 15.00
5.00 10.00 12.00
10.00 20.00 10.00
20.00 30.00 9.00
> 30 8.00
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DACE Labour Norms V2 / Equipment Installation
3 Rotating Equipment
3.1 General
All man-hours shown in the following tables include:
Unloading near foundation
Assembling (if applicable)
Rigging
First Alignment
Bolting
Standard cleaning
Final cold alignment
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DACE Labour Norms V2 / Equipment Installation
3.2 Installation of Pumps
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DACE Labour Norms V2 / Equipment Installation
3.3 Installation of Fans and Motors
Note:
For flexible Coupling reduce hours with 20%
For install coupling increase hours with 40%
If “assembly” required increase hours with 100%
Power
Weight Ton kW Hours
Fan &
Motor
Ton Install
0.20 0.75 30.00 6.00
0.25 1.1 30.00 7.50
0.30 1.5 30.00 9.00
0.35 2.2 30.00 10.50
0.65 4.0 24.00 15.60
0.90 5.5 24.00 21.60
1.25 7.5 24.00 30.00
2.00 11 21.00 42.00
2.50 15 21.00 52.50
3.00 18.5 21.00 63.00
> 3.00 18.5 20.00 80.00
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DACE Labour Norms V2 / Equipment Installation
3.4 Installation of Compressors
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DACE Labour Norms V2 / Equipment Installation
Total weight Hours set & align Hours installation Hours Hours Total Total
in parts on
in tons foundation Pre-assembled Cold Install Hours Hours
per
ton total unit alignment accessories
1 2 3 4 1+3+4 2+3+4
Compressors
10 40.0 400 200 20 100 520 320
15 30.0 450 220 30 110 590 360
20 25.0 500 240 40 120 660 400
25 22.0 550 260 50 130 730 440
30 20.0 600 280 60 140 800 480
35 18.6 650 300 70 150 870 520
40 17.5 700 320 80 160 940 560
45 16.7 750 340 90 170 1,010 600
50 16.0 800 360 100 180 1,080 640
60 14.2 850 380 110 190 1,150 680
70 12.9 900 400 120 200 1,220 720
80 11.9 950 420 130 210 1,290 760
90 11.1 1,000 440 140 220 1,360 800
100 10.5 1,050 460 150 230 1,430 840
125 9.6 1,200 500 160 250 1,610 910
150 9.0 1,350 540 170 270 1,790 980
175 8.6 1,500 580 180 290 1,970 1,050
200 8.3 1,650 620 190 310 2,150 1,120
225 8.0 1,800 660 200 330 2,330 1,190
250 7.8 1,950 700 210 350 2,510 1,260
7.5 hrs / ton 2.5 hrs / ton 1.0 hrs / ton 1.5 hrs / ton 10.0 hrs / ton 5.0 hrs / ton
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DACE Labour Norms V2 / Equipment Installation
3.4.2 Reciprocating compressor
A reciprocating compressor or piston compressor is a positive-displacement compressor that uses
pistons driven by a crankshaft to deliver gases at high pressure. We can categorize reciprocating
compressors into many types and for many applications. Primarily, it is used in a great many
industries, including oil refineries, gas pipelines, chemical plants, natural gas processing plants and
refrigeration plants.
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DACE Labour Norms V2 / Equipment Installation
Weight, Hours set & align of gear
tons box Hours Hours Hours Total Total
and cylinders on
compressor foundation Install Install Cold Hours Hours
assembled
and driver per ton total unit accessories alignment
1 2 3 4 1-4 2-4
< 30 hrs / ton 20 hrs / ton 20 12
5 24.0 120 80 24 16 240 120
10 16.0 160 100 32 24 316 156
15 13.3 200 120 40 32 392 192
20 12.0 240 140 48 40 468 228
25 11.2 280 160 56 48 544 264
30 10.7 320 180 64 56 620 300
35 10.3 360 200 72 64 696 336
40 10.0 400 220 80 72 772 372
45 9.8 440 240 88 80 848 408
50 9.6 480 260 96 88 924 444
55 9.5 520 280 104 96 1,000 480
60 9.3 560 300 112 104 1,076 516
65 9.2 600 320 120 112 1,152 552
70 9.1 640 340 128 120 1,228 588
75 9.1 680 360 136 128 1,304 624
80 9.0 720 380 144 136 1,380 660
85 8.9 760 400 152 144 1,456 696
90 8.9 800 420 160 152 1,532 732
95 8.8 840 440 168 160 1,608 768
100 8.8 880 460 176 168 1,684 804
105 8.8 920 480 184 176 1,760 840
110 8.7 960 500 192 184 1,836 876
115 8.7 1,000 520 200 192 1,912 912
120 8.7 1,040 540 208 200 1,988 948
125 8.6 1,080 560 216 208 2,064 984
130 8.6 1,120 580 224 216 2,140 1,020
135 8.6 1,160 600 232 224 2,216 1,056
140 8.6 1,200 620 240 232 2,292 1,092
145 8.6 1,240 640 248 240 2,368 1,128
150 8.5 1,280 660 256 248 2,444 1,164
> 8 hrs / ton 4 hrs / ton 2 hrs / ton 2 hrs / ton 16 hrs / ton 8 hrs / ton
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DACE Labour Norms V2 / Equipment Installation
3.5 Turbines
Hours
Total weight Hours set & align installation Hours Hours Total Total
pre-
of the unit in parts on foundation assembled Cold Install Hours Hours
per
in tons ton total unit alignment accessories
1 2 3 4 1+3+4 2+3+4
Steam Turbines
10 50.0 500 200 20 100 620 320
15 43.3 650 280 30 140 820 450
20 40.0 800 360 40 180 1,020 580
25 38.0 950 440 50 220 1,220 710
30 36.7 1,100 520 60 260 1,420 840
35 35.7 1,250 600 70 300 1,620 970
40 35.0 1,400 680 80 340 1,820 1,100
45 34.4 1,550 760 90 380 2,020 1,230
50 34.0 1,700 840 100 420 2,220 1,360
60 30.8 1,850 920 110 460 2,420 1,490
70 28.6 2,000 1,000 120 500 2,620 1,620
80 26.9 2,150 1,080 130 540 2,820 1,750
90 25.6 2,300 1,160 140 580 3,020 1,880
100 24.5 2,450 1,240 150 620 3,220 2,010
125 24.0 3,000 1,320 160 660 3,820 2,140
150 23.3 3,500 1,400 170 700 4,370 2,270
175 22.9 4,000 1,480 180 740 4,920 2,400
200 22.5 4,500 1,560 190 780 5,470 2,530
225 22.2 5,000 1,640 200 820 6,020 2,660
250 22.0 5,500 1,720 210 860 6,570 2,790
25 hrs /
20 hrs / ton 6 hrs / ton 1 hrs / ton 4 hrs / ton ton 11 hrs / ton
Gas
Turbines
25 32.0 800 400 40 240 1,080 680
50 24.0 1,200 550 60 280 1,540 890
75 21.3 1,600 700 80 320 2,000 1,100
100 20.0 2,000 850 100 360 2,460 1,310
125 19.2 2,400 1,000 120 400 2,920 1,520
150 18.7 2,800 1,150 140 440 3,380 1,730
175 18.3 3,200 1,300 160 480 3,840 1,940
200 18.0 3,600 1,450 180 520 4,300 2,150
225 17.8 4,000 1,600 200 560 4,760 2,360
250 17.6 4,400 1,750 220 600 5,220 2,570
21 hrs / 10.5 hrs /
17.5 hrs / ton 7 hrs / ton 1 hrs / ton 2.5 hrs / ton ton ton
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DACE Labour Norms V2 / Equipment Installation
4 Miscellaneous Equipment
A belt conveyor consists of two or more pulleys, with a continuous loop of material - the conveyor
belt - that rotates about them. One or both of the pulleys are powered, moving the belt and the
material on the belt forward. Belt conveyors are commonly used to convey items with irregular
bottom surfaces or small items that would fall in between rollers.
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DACE Labour Norms V2 / Equipment Installation
4.1.1 Open type without walkway
Hours per meter
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DACE Labour Norms V2 / Equipment Installation
4.1.2 Enclosed type with side walkway
Hours per meter
The labour norms include:
Head and tail end equipment
Enclosure structure and sheeting
Support structures
(truss
bridges)Length Width in mm
in meters 450 600 750 900 1500 1900 2500
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DACE Labour Norms V2 / Equipment Installation