Introduction on Consumable Cost Estimation for Offshore Oil & Gas Hook-Up Works

Hook-up and Commissioning (HUC) team should have a precise understanding of offshore HUC scope of works and technology , to ensure HUC works will be better prepared and success to function as HUC engineers, CSR, construction superintendents, workpack engineers, planning engineers, and QAQC coordinator/engineers/inspectors.

Why do a HUC Engineer/Planner/QAQC Coordinator need to carry out consumable cost estimation by carefully?

In order to ensure that the hook-up project work will be completed ahead or according to schedule (on-time delivery), while meeting the budget or price specified in the workpack (profitable), comply with Customer Requirements/Statutory, safety, quality, and environmental.

  • do not run out of consumable material, because material shortage will stop the crucial offshore work which will cost up the project and cause delay in delivery.
  • do not too much surplus of consumable material because too much surplus material will cost up the project


  1. Total cost – weld electrode
  2. Total cost – paint consumables
  3. Total cost – gas consumables
  4. Total cost – welder consumables
  5. Total cost – fitter consumables
  6. Total cost – rigger consumables
  7. Total cost – e & i consumables
  8. Total cost – fire & safety consumables
  9. Total cost – personal safety and protection consumables
  10. Total cost – general supplies consumables


In the welding technology and application , many methods may be used to calculate the cost of welding for a given job or contract. The cost in itself is obviously dependent on the process chosen, the complexity or simplicity of the assembly, the joint preparation and configuration, the price tag on the filler metal and otherconsumables, labor, overhead, operator skill and many other factors.

One factor in particular will remain stable; that is the actual amount of weld deposit required to fill a joint of given dimension and geometry.

The consumption of welding consumables can be estimated as a function of plate thickness, welding process, groove angle, and root opening for butt joints.

C = [(A1 + A2) × L × G/E ] × 1/10

where C: Consumption of welding consumables (kg); A1: Area of Section A1 weld metal (mm2) (See Fig.3); A2: Area of Section A2 reinforcement (mm2); L: Weld length (m); G: Specific gravity ofweld metal (7.85 g/cm3); E: Deposition Efficiency (%) — SMAW covered electrodes: 55%; GMAWsolid/metal-cored wires: 95%; FCAW flux-cored wires: 90%; SAW solid wires: 100%

Electrode / Weld consumable cost estimation report for Piping, Pipe Support and Riser:

  • S/No
  • Diameter (mm)
  • Qty (kg)
  • Unit Price (US$)
  • Total Price (US$)


Whether you’re bidding on a paint job or underpreparation for construction / Hook-up project works, it’s important to understand what goes into estimating the price. A quote is generally based on the cost of materials plus time billed at various wage scales, but there are a host of other factors that affect both. Here are things to take into consideration when estimating a painting job.

  1. Assess the job.
  2. Calculate the square footage.
  3. Calculate your paint needs.
  4. Factor in the cost of consumables.
  5. Add in your labor.
  6. Factor in the cost of your overhead.
  7. Figure out market rates for the area and client base.
  8. Remember that experience counts.

Read more : How to Estimate Painting Jobs,

Example: “To be painted a Tank using Epoxy mastic , painted area of 500 m2, 40 % loss”

Epoxy mastic , DFT: 200 microns , % VS: 85 %

40 % loss implies that only 60 % will remain on the surface.
The correction factor, Loss factor, will be 0.6

Consumption (in Litre) = (Area, m2 x DFT ) / ( 10 x % VS x Efficiency )

.: Epoxy mastic = (500 x 200) / (10 x 85 x 0.6) = 196 litre.

A certain roughness will give a certain dead volume.
For Roughness 60 microns -> Dead volume, 0.04 l/m2

Total Dead volume, litre = ( Area (m2) x DV x 100 ) / ( % VS x Eff )
.: Litre dead volume = ( 500 x 0,04 x 100 ) / ( 85 x 0,6 ) = 39 litre

Paint Consumable Cost Estimation Report:

  • S/No.
  • Description
  • Qty.
  • Unit of measurement
  • Unit Cost in US$
  • Cost in US$
  • Remarks

Related Training / Course :

  • Offshore Hook-up, Construction and Commissioning (HuCC) and Workpack Planning (OE576), [This course aims to provide the skills and knowledge of planning and preparing a work package (workpack) and executing an Offshore Hook-up, Construction and Commissioning (HuCC) project. It is designed for offshore operations engineers, workpack engineers and HuCC project planners.]

References / Read more :


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