SECTION 4.0

Engineering Costs

Detailed engineering manhour estimates across all disciplines at the composite billing rate of INR 2,125 per manhour, covering FEED through commissioning support.

Billing Rate Basis

The composite engineering billing rate of ₹ 2,125 per manhour is an all-inclusive rate covering salaries, overheads, software licenses (PDMS/E3D, Caesar II, STAAD Pro, SmartPlant), office infrastructure, and management costs. This rate is applied uniformly across all engineering disciplines.

Total Manhours

64,735

Rate per Manhour

₹ 2,125

Total Engineering Cost

₹ 13.76 Cr

4.1 Discipline-wise Manhour Estimate

Discipline	Manhours	Cost (₹ Cr)	% Share	Scope
Process Engineering	9,500	2.02	14.7%	Process design, PFDs, P&IDs, heat & mass balance, process datasheets, HAZOP
Mechanical / Equipment	10,500	2.23	16.2%	Equipment sizing, datasheets, vendor drawings review, GA drawings
Piping Engineering	14,000	2.98	21.6%	Piping layout, isometrics, stress analysis, material take-off, pipe supports
Civil & Structural	6,500	1.38	10.0%	Foundation design, structural steel, building design, soil investigation review
Electrical Engineering	5,500	1.17	8.5%	SLD, cable sizing, motor control, lighting, earthing, substation design
Instrumentation & Control	6,000	1.27	9.3%	DCS/PLC configuration, instrument datasheets, control narratives, SIS
Project Management	5,500	1.17	8.5%	Project planning, scheduling, cost control, progress monitoring, reporting
Procurement Support	3,500	0.74	5.4%	Vendor evaluation, TBE, purchase orders, expediting, inspection coordination
Construction Management	2,500	0.53	3.9%	Site supervision, quality assurance, safety management, commissioning support
HSE & Regulatory	1,235	0.26	1.9%	EIA, consent applications, safety studies, PESO approvals, fire protection
TOTAL	64,735	13.76	100.0%

4.2 Manhour Distribution

Process Engineering

9,500

15%

Mechanical / Equipment

10,500

16%

Piping Engineering

14,000

22%

Civil & Structural

6,500

10%

Electrical Engineering

5,500

Instrumentation & Control

6,000

Project Management

5,500

Procurement Support

Construction Management

HSE & Regulatory

4.3 Engineering Deliverables by Phase

FEED (Front End Engineering Design)

3 months

Process Design Basis
PFDs & Heat/Mass Balance
Equipment Sizing & Selection
Plot Plan & General Arrangement
Preliminary P&IDs
HAZOP Study
Capital Cost Estimate (±15%)

Detailed Engineering

8 months

Detailed P&IDs
Equipment Datasheets & Drawings
Piping Isometrics & Stress Analysis
Civil & Structural Drawings
Electrical SLDs & Cable Schedules
Instrument Hook-up & Loop Diagrams
3D Model Review

Procurement Engineering

10 months

Technical Bid Evaluation
Vendor Drawing Review
Material Requisitions
Inspection & Test Plans
Expediting Reports

Construction Support

10 months

Site Engineering Support
As-Built Drawing Updates
Pre-commissioning Procedures
Commissioning & Start-up Support
Performance Test Run

3.0Materials of Construction

Procurement Costs5.0