Introduction to Aspen Cost Estimation Products

Sunil Patil
Principal Business Consultant

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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

Analyze
Economic
Performance

Process
Performance
Modeling & Analysis

Conceptual
Design / R&D

Basic
Engineering

Detailed
Engineering

Operations/
Maintenance

Detailed
Equipment
Design

Develop Basic
Design Package

Analyze
Detailed
Costs

Develop Detailed
Plant Design

Reuse Process
Model for
Operations Decisions

Reuse Process
Models for
Planning Decisions

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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 capital costs for:

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
Concept

Process
Design

Process
Economic Analyzer

Plant
Design

Construction

Startup

DeBottleneck

Capital Cost Estimator

Process Simulators

Retrofit

Production

In-Plant Cost Estimator

Primavera Scheduling

Aspen Plus
HYSYS
Reporter
Excel & Crystal
Reports
Aspen Basic Engineering
Data Sheets, Plot Plan

User Data

Aspen
Icarus

Excel Custom Models

CAE/CAD
Intergraph

Client
Technology
(via API)

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Aspen Economic Evaluation Products

Process Economic
Analyzer

Economics for Process

Engineers
Interface to Aspen Plus
and HYSYS
Expand Unit Operations
to Equipment (Map)
Equipment sizing
PFDs
Stream list incl. utilities
Project Relocation &
Scaling
Cooling Water analysis
Financial Analysis
(CAPEX and OPEX)

Capital Cost Estimator

In-Plant Cost Estimator

Multi-contractor project
execution
Power/Process Control
systems
Optimized equipment
rental
Primavera detailed CPM
schedule (P6)
Project Relocation &
Scaling
Modular Construction
Pipelines

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All Design Basis,

Equipment & Plant Bulks
as ACCE
No volumetric models
Foundation design
Primavera CPM schedule
incl. costs (P3 or P6)
Equipment Rental
User data sources

Built-In Knowledge Modules

International
Design Methods

CPM-based
Scheduling
Methods

Detailed Design
and Cost
Models

Fabrication and
Construction
Methods

Expert Systems
Knowledge Bases

Contractors
Engineering

Materials
of
Construction

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AspenTech Integration Example

1) Process
simulation cases
developed

Aspen Capital
Cost Estimator
3) Preliminary
sized equipment
used to develop
conceptual cost
estimate

Aspen Process
Economic Analyzer
2) Economic
screening performed
for multiple cases

Aspen Basic
Engineering
4) Data loaded for
best case

6) Preliminary
conceptual
estimate revised
with latest project
data from Aspen
Basic
Engineering

5) Additional design
and sizing
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

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 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

Concept

Process
Design

Aspen
Process
Economic
Analyzer

Plant
Design

Construction

Startup

DeBottleneck

Aspen
Capital
Cost
Estimator

Retrofit

Aspen In-Plant
Cost Estimator

Two interfaces to the

same underlying model

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Production

11

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
cost
basis

Customize
models

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Fine tune CPM

schedule

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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

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
EU
UK
Japan
Middle East

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 - (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 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 DESIGN:
Develop physical dimensions using:
design code procedures
industry standard methods

Equipment
design generated

FABRICATION LABOR:
Shop [+ Field]
Labor
Man-hours

Equipment cost
estimated

VESSEL COST:
1. Matl 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

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Volumetric Models:
Calculation of Installation Bulks

x
x

Conceptual P&IDs
Civil
Steel
Electrical
Insulation
Paint

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x
x

Total installed cost estimated

Quantities and costs for bulk
materials based upon equipment
specifications
Volumetric models for process
equipment:

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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

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

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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 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

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

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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 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

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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
Stream Properties template

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Interface No Open Project

Palette
View

Properties
Window

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Interface Open Project

Palette
View
Project
Explorer

List
View
Properties
Window

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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 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 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

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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
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 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 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

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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 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 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

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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

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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
Unit Op
Grid

Show
Current
State

Activate
Costing
Engine

Map
Models to
Equipment

Load
Simulation
Data

Size
Equipment
Object

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Evaluate
Equipment
Costs

View
Equipment
Grid

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 Equipment

E1210
Condenser
C1200
Packed
Column

T1220
Reciever

Packing
Section 1

P1230A/B
Reflux Pumps
E1250
Exchanger

Packing
Section 2

P1240
Pump

C1200

E1260
Reboiler

Conceptual Unit
Operation Models

Equipment Models
for Cost Analysis

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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 Costs and
Net Process Costs

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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 process scenarios
Resulting project file can be opened directly in
Aspen Capital Cost Estimator

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