Modularized Oil Refinery EPC Benchmarks
We Are Seeing a New Trend of Constructing Smaller “Modularized / Fast Track” 10,000 to 30,000 Barrel a Day Oil Refinery Projects Around the World.
Recently, we have been involved in a Capital Project (CAPEX) benchmark cost study for a Major Consulting firm. The following are some general benchmarks from that study & earlier studies.
#
ISBL Scope - Class 3 Estimate
$ Cost
% Split
1
Major Equipment - Towers / Columns, Reactors, Fired Heaters, Heat Exchangers, Compressors, Drums & Pumps (165 Items)
93,435,000
31.5%
2
Modules / Pre-Assemblies - Skids
32,550,000
11.0%
3
Freight
3,842,000
1.3%
4
Equipment Setting
3,713,000
1.3%
5
Site Work
10,743,500
3.6%
6
Concrete Foundations
12,943,700
4.4%
7
Structural Steel
14,654,000
4.9%
8
Piping
45,885,000
15.5%
9
Electrical & Instrumentation
19,453,000
6.6%
10
Insulation / Painting
3,743,700
1.3%
11
Construction In Directs / General Conditions
23,665,000
8.0%
12
Engineering / Design & PM - HO Support
25,055,000
8.5%
13
Construction Management
4,253,000
1.4%
14
Start - Up & Spare Parts
1,587,000
0.5%
15
Other Minor Items
960,700
0.3%
16
Total ISBL Scope - Class 3 Estimate
296,483,600
100%
17
Cost per Barrel
11,859
Production Rate 25,000 Barrels a Day / Modularized Oil Refinery - Located in North Africa:
- Producing Product Slate of Gasoline, Kerosene, Naphtha, Jet Fuel & Diesel Products
- Project Was 50% Stick Built & Included 135 Modules / Pre-Assemblies / Skids
- Modules Built in Turkey, Egypt & UAE
- EPC Project Duration 32 months – Cost Basis 2024
#
OSBL Offsite Scope - Class 3 Estimate
$ Cost
% Split
1
Tank Farm 6 # Field Erected Oil Product Storage Tanks c/w Containment /
Bund Walls & Loading Stations
4,830,000
32.3%
2
Boilers / Stream - Power Plant Addition
2,850,000
19.0%
3
(2) Pipeline 18 / 24" Oil / Water
1,430,000
9.6%
4
Pipe Tracks
600,450
4.0%
5
Other Utilities / Tie Ins
1,342,770
9.0%
6
WWT / Reservoir / MU Water
753,000
5.0%
7
Roads / Buildings - Warehouse
537,000
3.6%
8
Ship Loading Jetty Modifications
1,034,000
6.9%
9
Minor items
85,640
0.6%
10
Construction In-Directs / General Conditions
632,860
4.2%
11
Detailed Design / Construction Management
870,000
5.8%
12
Total OSBL
$14,965,720
100%
13
Cost per Barrel
$599
A
Total ISBL & OSBL
$311,449,320
B
Cost per Barrel
$12,458
C
Cost Range Low - 20%
$9,966
D
Cost Range High +20%
$14,950
