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July 2009 1 Coastal Water Project Capital and O&M Cost Description North Marina Alternative - Desalination Plant Site
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2 Introduction Present cost estimates for North Marina Project Alternative 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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North Marina Project First Proposed in PEA, 2005 Basic Components, per DEIR: 11 mgd Desalination Plant in North Marina Sourced from Slant Wells Return up to 800 afy to water users in Salinas Valley Brine Disposal to MRWPCA 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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North Marina Project (cont’d) Cost Estimate History Capital Costs Annual O&M Costs PEA: $214M$7.8M (gross) (2005 $) (for 11,730 afy) Current: $250M$9.6 -10.1M (gross) (2009 $) $7.6M-8.1M (net) (for 10,100-10,900 afy)
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North Marina Cost Estimates Changes, Compared to PEA Estimate: Updated to 2009 dollars (from 2005 dollars), checked previous estimates, and added more detail Slant well intakes instead of HDD well intakes 11mgd desalination plant capacity, instead of 10 mgd Added facilities for delivery of up to 2 mgd to CSIP system Brine disposal to MRWPCA Outfall instead of MLPP Outfall
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North Marina Cost Estimates (Cont’d) Changes, Compared to PEA Estimate: Added pressure dual media filters Added 20% RO standby capacity Incorporated same system changes as Moss Landing Project, south of Reservation Road O&M costs estimated at meeting 15,200 afy total CAW system demand plus 800 afy to CSIP Assumed power from grid instead of self-generation
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7 Capital Cost Estimate Capital Cost Description Pipeline Pump StationWell Process Equipment Building/ Structure Civil WorksTank Elec. I&CProperty Allowance (% of total) 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 Cathodic Protection $5/ LF for metallic pipelines Contractor Overhead & Profit (OH&P) 18.5% of all above costs
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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 Slant Wells Test Slant Well & 5 Additional Production Slant Wells $13.8 million, Including contractor OH&P Slant Well Drilling costs detailed by Doheny State Beach Slant Well Driller Stainless Steel Material Includes: Well Pumps & Installation Well Development & Testing Testing / Development Water Disposal facility Civil works and well head vaults Electrical, I&C Electrical Costs Include additional $250,000 for upgraded service to site
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13 Process Equipment Cost Components: Vendor Supplied Equipment RO System, Pressure Filters, 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 The North Marina RO Process Facility cost was developed by multiplying the Moss Landing RO Process cost by a factor of 1.10
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14 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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15 Civil Works Line Items in the Estimate: 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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16 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 Above Costs Include 18.5% Contractor OH&P
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17 Tanks (Reservoirs) Circumferentially Pre-stressed, Post-Tensioned Concrete Tanks w/ Concrete Covers Partially Buried Clearwell: $1.75/ gallon Clearwell at Moss Landing:$1.50/gallon Buried Terminal Reservoir:$1.75/ 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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18 Electrical, Instrumentation &Control (I&C) 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 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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19 Property Site Acquisition Desalination Plant and other above ground facilities 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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20 Allowances Electrical / I&C Contractor OH&P 18.5% except for RO Equipment at 10% Contractor Mobilization/Demobilization Included in OH&P. Added 1% for Desalination Plant only
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21 Allowances (cont’d) Implementation Project Administration and Management, Engineering, Legal Design/Bid/Build Facilities: Used 30% of base construction costs, based on experience, excluding costs through December 31, 2008. Design/Build Facility: Used 20% of base construction costs 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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22 North Marina Capital Cost Estimate Summary ( 2009 $) Off-site Feedwater/Brine$ 20M Desalination Plant$ 81M Desalinated Water Conveyance$ 38M Terminal Reservoir/ ASRPS$ 15M ASR System$ 10M Subtotal for Construction$ 164M Implementation Costs$ 42M Present Worth of Land/ROW Costs $ 5M Contingency Allowance$ 42M Total Capital Costs$ 253M Rounded to$ 250M
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23 Accuracy of Estimate Cost estimating accuracy is typically keyed to project development stage North Marina Alternative 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 % Final North Marina Project capital costs could be in range of $210M to $310M in 2009 Dollars.
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24 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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25 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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26 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 North Marina Desal Plant Unit Costs Winter $0.093 / kwh Summer $0.136 / kwh Highest Unit Cost is at remote pump stations
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27 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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28 Labor Fixed, does not vary with annual production Operations labor categories and rates from CAW- Monterey Desalination plant staffing levels estimated on basis of two other desalination plants and consultation with industry experts
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29 Repair and Replacement Assumed replacement of 15% of membranes every year starting in 2017 for North Marina Project Assumed R&R for structures, buildings, and civil works at 1% of original cost, per year. Assumed R&R for mechanical and electrical systems at 3% of original cost, per year.
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30 O&M Costs Avoided Project will reduce production and operations costs at: Begonia WTP (BIRP) by 6,900 afy, $1.36M annual reduction Segunda PS, by 6,900 afy, $0.37M annual reduction Seaside Wells, by 2,200 afy, $0.28M annual reduction Datum used is current conditions: Begonia WTP (BIRP) at 11,500 afy Seaside Wells at 3,700 afy Avoided costs were developed on basis of existing operational data, calculation of avoided power, and consistent (calculated) energy unit cost
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31 North Marina Project O&M Cost Estimate For 2021, in 2009 Dollars, at 10,900 AFY: Desalination Plant:$ 9.2M Desalinated Water Conveyance:$ 0.5M ASR System:$ 0.5M Total (gross) $10.2M Costs avoided: ($ 2.0M) Total (net)$ 8.2M
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