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July 2009 1 Coastal Water Project Capital and O&M Cost Description Moss Landing Power Plant - Desalination Plant Site
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2 Introduction Present updated cost estimates for Proposed Project at Moss Landing including key assumptions and approach Workshop Presenters: Mark Schubert, PE, CAW Paul Findley, PE, RBF Consulting Dave Stephenson, CAW Data and assumptions derived from cost estimates contained in Attachments K and L of the Schubert Testimony, dated May 22, 2009
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Moss Landing Project First Proposed in Plan B Report, 2002 Proposed Project in PEA, 2005 Basic Components, Per DEIR: 10 mgd Desalination Plant near Moss Landing Sourced from MLPP Cooling Water System Brine Disposal to MLPP Outfall Pipelines to CAW Service Area Terminal Reservoir Pump Station and Pipeline to ASR Wells 2 New ASR Wells + 2 Existing ASR Wells
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Moss Landing Project (cont’d) Cost Estimate History Capital Costs Annual O&M Costs Plan B $176M$6.4M (2001 $) (for 10,730 afy) PEA/CDR: $191-197M$7.9-9.1M (gross) (2005 $) $6.4M (net) (for 11,730 afy) Current: $270M$9.3-10.3M (gross) (2009 $) $7.4M-8.3M (net) (for 9,300-10,100 afy)
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Updating the Moss Landing Cost Estimates Changes, Compared to PEA/CDR Estimate: Updated to 2009 dollars (from 2005 dollars), checked previous estimates, and added more detail Changed implementation and contingency factors Pressure membrane filters instead of submerged Added 20% RO standby capacity 36-inch diameter product water pipeline
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Updating the Moss Landing Cost Estimates (Cont’d) Changes, Compared to PEA/CDR Estimate: Monterey Pipeline with Valley Greens PS 2 new ASR wells (instead of 3), shorter ASR Pipelines Assumed 700 afy of desal water delivered via ASR Increased ASR PS capacity, buried Terminal Reservoir O&M costs estimated at 15,200 afy total system demand Changed energy unit costs
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7 Capital Cost Estimate Capital Cost Description Pipeline Pump StationWell Process Equipment Building/ Structure Civil WorksTank Elec. I&CPropertyAllowance Construction Costs Off-Site Feedwater & Brine FacilitiesXXNMML NM X Desalination Plant X XXXXX X Desalinated Water ConveyanceXX XX X X Terminal Reservoir & ASR PSXX XXX X X ASR SystemX X XX X X Implementation Costs X ROW Easement & Land Acquisition X Contingency Allowance X ML = Moss Landing NM = North Marina X = Both Sites
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8 Pipelines Cost Components: Material Adjusted Vendor Quotes for Pipes Type II Asphalt Concrete Erosion Control (BMP) Labor & Equipment ROW Preparation, Pipeline Installation, Erosion Control, Surface Restoration, & Bore Pit Construction Prevailing Wages per Department of Labor Variable Production Rates for Standard Crews Off-site Transport and Storage of Excavated Material Required Equipment per Construction Expert
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9 Pipelines (cont’d) Special Construction $1,500/ LF for Jack and Bore Dewatering Wells = $32,000 per Jack and Bore Crossing Bridge Crossings: Tembladero Slough ($670/LF) and Salinas River ($1,890/ LF) Cathodic Protection $5/ LF for metallic pipelines Contractor Overhead & Profit (OH&P) 18.5% of all above costs Average Total Cost: $400/ LF
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10 Pump Stations Desalinated Water PS & ASR PS: Quantity estimates and unit prices per recent similar project estimate All Other Pump Stations: Equipment estimated on $/ Installed HP, plus 25% for taxes, installation, & material, plus 18.5% for contractor OH&P Building based on $110/ SF, includes contractor OH&P Wet wells based on $700/ CY of concrete
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11 ASR Wells Monitoring Well, Core, & Test well at ASR Well 3 Test Well at ASR Well 4 Stainless Steel Material for Test Wells Wellhead facilities at ASR Wells 3 & 4 Conversion of Test Wells to Production wells Well Pumps Electrical & Pump Building Well Field Piping & Civil Work Electrical, I&C Back flush Water Reclamation Facility Estimates from ASR Systems Contractor OH&P included in above
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12 Process Equipment Cost Components: Vendor Supplied Equipment RO System, UF System, Pumps, Screens, & Chemical Systems Includes Delivery, Taxes, Manuals, Testing, & Training Installation Includes Labor, Equipment, & Contractor Supplied Appurtenances Estimate based on expert consultation and experience Building, Electrical, I&C, and Site Work Estimated Separately Contractor OH&P 10% for RO Equipment 18.5% for other installed equipment
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13 Buildings & Structures Floor Slabs, Foundations, and Hydraulic Structures were estimated at $1100/ CY Superstructures were estimated at: $120/ SF for large process buildings $110/ SF for pump stations $350/ SF (first floor area) for two story admin building Detailed estimates for buildings were estimated using commercially available cost estimating software
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14 Civil Works Line Items in the Estimate: Desalination Plant Equalization Basin Desalination Plant Earthwork, Sitework, & Piping Terminal Reservoir Earthwork, Sitework, & Piping ASR Backflush Reclamation Basin Dried Solids Storage RO Clean in Place (CIP) Waste Storage
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15 Civil Works (cont’d) Unit Costs: General Site work $5/ SF Site Preparation Rough Grading Fine Grading Paving Landscape & Irrigation Site Lighting & Security Fencing Excavation / Backfill $7/ CY Yard Piping $400/ LF Equalization Basin Liner$7/ SF Above Costs Include 18.5% Contractor OH&P
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16 Tanks (Reservoirs) Circumferentially Pre-stressed, Post-Tensioned Concrete Tanks w/ Concrete Covers Buried Terminal Reservoir: $1.75/ gallon Above Ground Clearwell: $1.50/ gallon Costs Include 18.5% Contractor OH&P Earthwork, Site work, and Piping estimated separately Based on analysis of two similar recently constructed projects
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17 Electrical, Instrumentation & Controls Desalination Plant Electrical /I&C Power intensive facility Allowance of 25% of other plant non-electrical costs, based on recommendation from electrical engineering expert Includes plant control systems, and SCADA system for remote communications and control Additional $1M for substation to step down from 230 KV to 12 KV, per recent estimate on similar project Other Facilities Electrical /I&C Allowance of 5 to 15% of facility non-electrical costs, depending on power intensity of facility Includes connection to SCADA system
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18 Property Site Acquisition Based on 2009 communication with licensed real estate appraiser: Residential:$400,000-$1,000,000/Acre Light Industrial:$600,000-$800,000/Acre Agricultural:$3,000-40,000/Acre ROW Acquisition for Pipelines (Present Worth) Transportation Agency of Monterey County and private agricultural lands evaluated by licensed real estate appraiser
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19 Allowances Electrical/ I&C Contractor OH&P Used 18.5%, except for RO Equipment at 10% Contractor Mobilization/Demobilization Typically included in OH&P. Added 1% for Desalination Plant only
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20 Allowances (cont’d) Implementation Project Administration and Management, Engineering, Legal Used 30% of base construction costs, based on experience, excluding costs through December 31, 2008. Approximately half (15% of base construction costs) included with construction for design-build facilities Contingency Covers unanticipated changes in project scope or schedule due to unforeseen changed site conditions; regulatory or institutional requirements, including mitigation implementation and permit compliance; and acts of nature. 20%, based on AACEI, for “conceptual design” stage of project development.
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21 Moss Landing Capital Cost Estimate Summary ( 2009 $) Off-site Feedwater/Brine$ 3M Desalination Plant$ 96M Desalinated Water Conveyance$ 54M Terminal Reservoir/ ASRPS$ 15M ASR System$ 10M Subtotal for Construction$ 178M Implementation Costs$ 39M Present Worth of Land/ROW Costs $ 7M Contingency Allowance$ 45M Total- Capital Costs$ 270M
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22 Accuracy Cost estimating accuracy is typically keyed to project development stage Proposed Project between Class 3 and Class 4 AACEI Class 3-Budget, 10-40%: -10/20% to +10/30% AACEI Class 4-Study, 1-15%: -15/30% to +20/50% Used -15%/+25 % So final Moss Landing Project capital costs could be in range of $230M to $340M in 2009 Dollars
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23 Operation & Maintenance Costs O&M Cost Description EnergyChemicalsLabor Membrane Replacement General R&R O&M Costs Avoided Facilities Off-Site Feedwater & Brine FacilitiesX NM Desalination PlantXXXXX Desalinated Water PumpingX X Terminal Reservoir & ASR PSX X ASR WellsXXX X Valley Greens PSX X Begonia Iron Removal PlantXXX X Segunda PSX X X Seaside Wells X General System X ML = Moss Landing NM = North Marina X = Both Sites O&M Costs Avoided Include: Energy, Chemicals, & Labor
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24 Energy Energy Rate Schedules were selected considering: Based on PG&E Tariffs Load E-19 (< 1000 kw) E-20 (> 1000 kw) Grid Voltage Transmission Voltage Primary Voltage Secondary Voltage
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25 Energy (cont’d) Unit Costs for Energy for each facility were developed considering: Time of day (Peak, Partial Peak, Off-Peak) Season (Summer / Winter) Service Voltage Maximum Demand per Month Average Use per month Diurnal Load Profiles Energy Unit Costs: $0.079 - $0.142 /kWh Desalination Plant at Moss Landing Winter $0.079/ kwh Summer $0.0112/ kwh Highest Unit Cost is at remote pump stations
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26 Chemicals Variable according to annual production Chemicals and dosages per DEIR Project Description Chemical costs obtained by 2009 quotation from national vendor Bulk delivery and storage
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27 Labor Fixed, does not vary with annual production Operations labor categories and rates from CAW- Monterey Desalination plant staffing levels estimated on the basis of two other desalination plants and consultation with industry experts
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28 Repair and Replacement Assumed replacement of 20 % of membranes every year starting in 2021 for Moss Landing Project Assumed R&R for structures, buildings, and civil works at 1% of original cost, per year. Assumed R&R for mechanical systems at 3% of original cost, per year.
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29 O&M Costs Avoided Project will reduce production and operations costs at: Begonia WTP (BIRP) by 6900 afy, $1.36M annual reduction Segunda PS, by 6900 afy, $0.37M annual reduction Seaside Wells, by 2200 afy, $0.28M annual reduction Datum used is current conditions: Begonia WTP (BIRP) at 11,500 afy Seaside Wells at 3,700 afy Avoided costs were developed on basis of existing operational data, calculation of avoided power, and consistent (calculated) energy unit cost
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30 ML Project O&M Cost Estimate For 2021, in 2009 Dollars, at 10,100 AFY: Desalination Plant:$ 9.3M Desalinated Water Conveyance:$ 0.5M ASR System:$ 0.5M Total (gross) $10.3M Costs avoided: ($ 2.0M) Total (net)$ 8.3M
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31 End of Formal Presentation
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