Development of Fly Ash Handling Conveyance Methodologies - 

Conveyance Equations and Factors

This Excel file contains the following worksheets:

Conveyance Equipment

Conveyance Installation

Conveyance Engineering

Conveyance Operating Labor

Conveyance Maintenance Labor

Conv Op and Maint Labor Rate

Conveyance Maint Mats

Combination of the operating and labor rates from "Conveyance Operating 

"Conveyance Maintenance Labor" tabs, to calculate the overall median. Th

is highlighted orange.

Evaluates the data from the Steam Electric Survey for dry vacuum systems 

Question C2-36) and corresponding cost data for maintenance materials. E

the ratio between the cost for maintenance materials and the total O&M co

a factor. The value used (the calculated median percentage) is highlighted 

tab.

This Excel workbook documents EPA's analyses to calculate equations and factors used in the fly ash conveyance cost method

Contains data from Clyde Bergemann Power Group (CBPG) used to devel

curve to estimate equipment capital costs associated with the conveyance p

fly ash handling systems, based on fly ash conveyance rates in tons per day

Contains data from United Conveyor Corporation and capital cost data fro

Electric Survey (Question C2-34) to estimate an installation factor for conv

Contains data from the Steam Electric Survey (Question C2-34) to evaluat

percentage of total capital costs represented by engineering overhead costs

used (the calculated median percentage) is highlighted orange.

Evaluates the data from the Steam Electric Survey for dry vacuum systems 

Question C2-36) and corresponding data for the operating labor rate. Ultim

combined operation labor rate and maintenance data for conveyance to cal

estimate operating and maintenance labor rate for the conveyance portion o

See the "Conv Op and Maint Labor Rate" tab for the calculation of the com

Additionally, EPA used this data to determine the operating hours per day 

operation for the conveyance system. The value used (the calculated media

highlighted orange. Evaluates the data from the Steam Electric Survey for dry vacuum systems 

Question C2-36) and corresponding data for the maintenance labor rate. U

combined operation labor rate and maintenance data for conveyance to cal

estimate operating and maintenance labor rate for the conveyance portion o

See the "Conv Op and Maint Labor Rate" tab for the calculation of the com

Additionally, EPA used this data to determine the maintenance hours per y

for maintenance for the conveyance system. The value used (the calculated 

value) is highlighted orange.
 from "Conveyance Operating Labor" and 

lculate the overall median. The value used 

urvey for dry vacuum systems (from 

a for maintenance materials. EPA calculated 

aterials and the total O&M cost to estimate 

an percentage) is highlighted orange on the 

fly ash conveyance cost methodology.

 Group (CBPG) used to develop a cost 

ociated with the conveyance portion of the 

nveyance rates in tons per day.

ation and capital cost data from the Steam 

 an installation factor for conveyance data.

y (Question C2-34) to evaluate the 

by engineering overhead costs. The value 

ghlighted orange.

urvey for dry vacuum systems (from 

the operating labor rate. Ultimately, EPA 

nce data for conveyance to calculate the 

e for the conveyance portion of the system. 

 for the calculation of the combined rate. 

e the operating hours per day estimate for 

ue used (the calculated median value) is 

urvey for dry vacuum systems (from 

the maintenance labor rate. Ultimately, EPA 

nce data for conveyance to calculate the 

e for the conveyance portion of the system. 

 for the calculation of the combined rate. 

e the maintenance hours per year estimate 

The value used (the calculated median 
EPA's Methodology for Developing the Conveyance Equipment Capital Cost Curve (per unit conversion)

From Clyde Bergemann Power Group's (CBPG) fly ash handling conversion costs, EPA used the following non CBI 

For the Dry Vacuum System (with Dry Vacuum Pumps), EPA used the following costs (assuming that all hopper & b

Table Format:

Fly Ash Generation Rate TPH 5.5 11.5 16

Fly Ash Conveyance Rate (Generation Rate x 2)TPH 11 21 32

Primary Line Size Inches 6 8 10

New Header, Filter-Receiver, Dry Pumps 359,750.00 419,100.00 540,000.00

Using the values above, EPA generated the following plot:

419,100.00 

540,000.00 

732,312.00 

y = 9791.9x + 233721 400,000.00

 500,000.00

 600,000.00

 700,000.00

 800,000.00

Dry Vacuum Cap Cost
EPA generated the equation of the line using a linear trend line (which had the best r-squared value). Therefore, the fo

Cost (2010$) = (9,791 × Recalculated Unit Fly Ash Conveyance Rate, tph + 23,372) × Number of Un

359,750.00 

419,100.00 

y = 9791.9x + 233721

R2 = 0.9892

 -

 100,000.00

 200,000.00

 300,000.00

 400,000.00

0 10 20 30 40 50
unit conversion)

used the following non CBI data to generate a cost curve to estimate capital costs for conveyance equipment based on fly ash con

assuming that all hopper & branch line equipment will be re-used).

25

50

12

 732,312.00

732,312.00 
ared value). Therefore, the following equation was used to estimate unit-level conveyance capital costs for equipment.

 23,372) × Number of Unit Vacuum Systems

60
nt based on fly ash conveyance rate.
equipment.
EPA's Methodology for Determining Conveyance Equipment Installation Factor - Determined Using Data from UCC 

From UCC Data (nonCBI):

Type of Conversion Approx Equip Cost Min Approx Equip Cost Max

Dry Vacuum 4,000,000 4,000,000

Vac/Pressure 10,000,000 15,000,000

From Questionnaire: Summary Statistics

Original Ratio Min Original Ratio Max Original Ratio Median

[Redacted] 6.917719635 0.676295495

Raw Data from Survey (Question C2-34) - Installation costs for Dry Vacuum Systems if available.

Plant ID SE Unit ID CBI Cap Table 

2079 SE Unit-A TRUE

2601 SE Unit-2 FALSE

2601 SE Unit-3 FALSE

2601 SE Unit-4 FALSE

9861 SE Unit-3 TRUE

4993 SE Unit-1, SE Unit-2 FALSE

4993 SE Unit-3 FALSE

4237 SE Unit-1 TRUE

4237 SE Unit-2 TRUE

8462 SE Unit-4 TRUE

6672 SE Unit-1 TRUE

7175 SE Unit-1 TRUE

7651 SE Unit-5 TRUE

4599 SE Unit-5 TRUE

4011 SE Unit-1 TRUE

2601 SE Unit-1 FALSE

4702 SE Unit-4 TRUE

8179 SE Unit-1 TRUE

8179 SE Unit-2 TRUE

7761 SE Unit-3 TRUE

7761 SE Unit-4 TRUE

2402 SE Unit-1 FALSE

Notes: UCC stated that it is difficult to estimate installation capital cost from equipment capital cost. Cost data from 

support the findings from the analysis of the UCC cost data.EPA suggests an installation factor of 2 based on the UC
7300 SE Unit-1 FALSE

942 SE Unit-1 FALSE

6634 SE Unit-1 TRUE

6634 SE Unit-2 FALSE

6634 SE Unit-3 FALSE

6634 SE Unit-4 FALSE

2766 SE unit-1 FALSE

8233 SE Unit-1 FALSE

7416 SE Unit-4 FALSE

2623 SE Unit-2 FALSE

9534 SE Unit-7 FALSE

263 SE Unit-6 TRUE

1476 SE Unit-1 FALSE

1476 SE Unit-2 FALSE

9886 SE Unit-4 FALSE

5015

SE Unit-1, SE Unit-2, SE 

Unit-3 FALSE

2244 SE Unit-3 TRUE

2244 SE Unit-4 TRUE

1957 SE Unit-1 and 2 FALSE

2550

SE Unit-1, SE Unit-2, SE 

Unit-3, SE Unit-4, SE Unit-5 TRUE

14

SE Unit-1, SE Unit-2, SE 

Unit-3 TRUE

9213 SE Unit-2 TRUE

654 SE Unit-4 TRUE

70 SE Unit-3 TRUE

9373 SE Unit-1 TRUE

9213 SE Unit-1 TRUE

5043 SE Unit-1 TRUE

5043 SE Unit-2 TRUE

4242 SE Unit-1, SE Unit-2 TRUE

4242 SE Unit-3, SE Unit-4 TRUE

4391 SE Unit-1 FALSE

4676 SE Unit-1 FALSE

4676 SE Unit-2 FALSE

928 SE Unit-5 TRUE

4021 SE Unit-1 FALSE

2612 SE Unit-1, SE Unit-2 TRUE

9161 SE Unit-3 TRUE
7411 SE Unit-1 FALSE

7411 SE Unit-2 FALSE

4781 SE Unit-2 FALSE

6596 SE Unit-1 TRUE

9692 SE Unit-1, SE Unit-2 TRUE

9370 SE Unit-1 TRUE

3624 SE Unit-1 TRUE

3624 SE Unit-2 TRUE

3831 SE Unit-1 TRUE

3235 SE Unit-3 FALSE

3235 SE Unit-4 FALSE

70 SE Unit-4 TRUE

556 SE Unit-1 TRUE

3831 SE Unit-2 TRUE

249 SE Unit-1 FALSE

265 SE Unit-1 FALSE

265 SE Unit-2 FALSE

265 SE Unit-3 FALSE

265 SE Unit-4 FALSE

265 SE Unit-5 FALSE

265 SE Unit-6 FALSE

265 SE Unit-7 FALSE

265 SE Unit-8 FALSE

265 SE Unit-9 FALSE

7624 SE Unit-1 FALSE

6005 SE Unit-2 TRUE

6005 SE Unit-3 TRUE

6005 SE Unit-4 TRUE

3672 SE Unit-3 FALSE

3672 SE Unit-2 FALSE

3672 SE Unit-1 FALSE

8013 SE Unit-1 TRUE

8013 SE Unit-2 TRUE

1761 SE Unit-3 TRUE

5887 SE Unit-1 FALSE
5887 SE Unit-2 FALSE

5887 SE Unit-3 FALSE

1402 SE Unit-6 TRUE

1402 SE Unit-5 TRUE

3997 SE Unit-1 FALSE

6005 SE Unit-1 TRUE

3997 SE Unit-2 FALSE

548

SE Unit-1, SE Unit-2, SE 

Unit-3, SE Unit-4, SE Unit-5 FALSE

1402 SE Unit-4 TRUE

562 SE Unit-1, SE Unit-2 FALSE

3018 SE Unit-1, SE Unit-2 FALSE

4679 SE Unit-4 TRUE

3649 SE Unit-1 FALSE

8654 SE Unit-1 FALSE

8654 SE Unit-2 FALSE

8654 SE Unit-4 FALSE

3097 SE Unit-3 FALSE

3097 SE Unit-4 FALSE

8750 SE Unit-1 FALSE

9526 SE Unit-4 FALSE

4690 SE Unit-2 TRUE

3146 SE Unit-2 FALSE

444 SE Unit-1, SE Unit-2 TRUE

493 SE Unit-2 FALSE

1435

SE Unit-1, SE Unit-2, SE 

Unit-3, SE Unit-4 FALSE

2326 SE Unit-A TRUE

3625 SE Unit-1 FALSE

5743 SE Unit-6 TRUE

8471 SE Unit-2 FALSE

8471 SE Unit-3 FALSE

8471 SE Unit-4 FALSE

8471 SE Unit-5 FALSE

8471 SE Unit-6 FALSE

8704 SE Unit-1 FALSE

9168 SE Unit-1 FALSE

1577 SE Unit-1, SE Unit-2 FALSE

2673 SE Unit-1 FALSE

2673 SE Unit-2 FALSE
2673 SE Unit-5 FALSE

3146 SE Unit-1 FALSE

6377 SE Unit-1 FALSE

6377 SE Unit-2 FALSE

6377 SE Unit-3 FALSE

6377 SE Unit-4 FALSE

369 SE Unit-1 FALSE

654 SE Unit-5 FALSE

508 Insert Unit ID FALSE

904 SE Unit-2 FALSE

2548 SE Unit-1 FALSE

2548 SE Unit-2 FALSE

2548 SE Unit-3 FALSE

3309 SE Unit-1 FALSE

3649 SE Unit-2 FALSE

3649 SE Unit-3 FALSE

3649 SE Unit-4 FALSE

4495 SE Unit-1, SE Unit-2 TRUE

8502 SE Unit-1 FALSE

9093 SE Unit-1 FALSE

9481 SE Unit-1 FALSE

3597 SE Unit-1 TRUE

3597 SE Unit-2 TRUE

3597 SE Unit-3 TRUE

3597 SE Unit-4 TRUE

5038 SE Unit-1 FALSE

5038 SE Unit-2 FALSE

8471 SE Unit-1 FALSE

8969

SE Unit-1, SE Unit-2, SE 

Unit-3 TRUE
r - Determined Using Data from UCC and the Steam Electric Survey (Question C2-34)

Approx Installation Cost Min

Approx Installation Cost 

Max

Ratio Using Min of Cost 

Range

8,000,000 12,000,000 2

15,000,000 30,000,000 1.5

Retrofit Ratio Min Retrofit Ratio Max Retrofit Ratio Median

0.088110692 7.479215573 0.854894225

ystems if available.

Purchase Equip (Original) Installation (Original) Compare Original

[Redacted] [Redacted] [Redacted]

3425000 322459 0.094148613

3425000 322459 0.094148613

3425000 322459 0.094148613

[Redacted] [Redacted] [Redacted]

1116641.96 165345.75 0.148074097

3408323.09 504684.37 0.148074099

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

51253881 13399829 0.26144028

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

800000 300000 0.375

quipment capital cost. Cost data from UCC show that it can range from a factor of 1 to 3. The comparison of the cost data from th

stallation factor of 2 based on the UCC data.
391122 147635 0.377465343

660513 285153 0.43171444

[Redacted] [Redacted] [Redacted]

2083246.25 907088 0.435420441

2083246.25 907088 0.435420441

2083246.25 907088 0.435420441

208000 91000 0.4375

330000 145000 0.439393939

1395979 697509 0.499655797

148273.74 74136.87 0.5

156000 80334 0.514961538

[Redacted] [Redacted] [Redacted]

5000000 3000000 0.6

5000000 3000000 0.6

1188167 764000 0.643007254

1033000 733000 0.709583737

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

2394976 1822116 0.760807624

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

625000 700000 1.12

625000 700000 1.12

625000 700000 1.12

[Redacted] [Redacted] [Redacted]

1182690 1458934 1.233572618

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]
165363 211376 1.278254507

182353 233094 1.278257007

2069448 2702503 1.305905246

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

1847414 3399582 1.840184171

1934506 3800921 1.964801867

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

56811.61 393006.79 6.917719635

-999 -999 Blank Answers

-999 -999 Blank Answers

-999 -999 Blank Answers

-999 -999 Blank Answers

-999 -999 Blank Answers

-999 -999 Blank Answers

-999 -999 Blank Answers

-999 -999 Blank Answers

-999 -999 Blank Answers

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

-999 -999 Blank Costs

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs
-999 -999 Blank Costs

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

-999 -999 Blank Costs

-999 -999 Blank Costs

-999 -999 Blank Costs

273614.46 -555 Installation is $0

2199980 -555 Installation is $0

1250947.39 -555 Installation is $0

100000 -555 Installation is $0

[Redacted] [Redacted] [Redacted]

98000 -555 Installation is $0

[Redacted] [Redacted] [Redacted]

-111 -111 Missing Costs

-111 -111 Missing Costs

[Redacted] [Redacted] [Redacted]

-111 -111 Missing Costs

[Redacted] [Redacted] [Redacted]

-111 -111 Missing Costs

-111 -111 Missing Costs

-111 -111 Missing Costs

-111 -111 Missing Costs

-111 -111 Missing Costs

-111 -111 Missing Costs

-111 -111 Missing Costs

-111 -111 Missing Costs

-111 -111 Missing Costs

-111 -111 Missing Costs
-111 -111 Missing Costs

-111 -111 Missing Costs

-111 -111 Missing Costs

-111 -111 Missing Costs

-111 -111 Missing Costs

-111 -111 Missing Costs

-111 -111 Missing Costs

-111 -111 Missing Costs

-999 No Installation Costs

-999 No Installation Costs

200000 No Installation Costs

200000 No Installation Costs

200000 No Installation Costs

1433372 No Installation Costs

-999 No Installation Costs

-999 No Installation Costs

-999 No Installation Costs

[Redacted] [Redacted] [Redacted]

-999 No Installation Costs

-555 -555 Zero 

-555 -555 Zero 

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

-555 -555 Zero 

-555 -555 Zero 

-555 -555 Zero 

[Redacted] [Redacted] [Redacted]
Ratio Using Max of Cost 

Range

Combination of Min Equip 

and Max Installation

Combination of Max Equip 

and Min Installation

3 3 2

2 3 1

Purchased Equip 

(Modification) Installation (Modification) Compare Modification

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

-999 -999 Blank Costs

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

94000 30300 0.322340426

he comparison of the cost data from the survey does not seem to 
-999 -999 Blank Costs

-555 -555 Zero

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

-999 -999 Blank Costs

-999 -999 Blank Costs

-555 -555 Zero

-555 -555 Zero

-555 -555 Zero

-999 -999 Blank Costs

20000 6116 0.3058

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

-999 -999 Blank Costs

-999 -999 Blank Costs

-555 -555 Zero

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

-111 -111 Missing

-555 -555 Zero

-555 -555 Zero

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]
164422.47 147027.72 0.894206978

308195.28 164422.47 0.533500935

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

28832115 19819781 0.687420295

28832115 19819781 0.687420295

28832115 19819781 0.687420295

28832115 19819781 0.687420295

28832115 19819781 0.687420295

28832115 19819781 0.687420295

28832115 19819781 0.687420295

28832115 19819781 0.687420295

28832115 19819781 0.687420295

209373 18448 0.088110692

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

2045600 1748771 0.854893919

871895 745378 0.854894225

435947 372689 0.854895205

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

368026 408000 1.108617326
368026 408000 1.108617326

368026 408000 1.108617326

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

393120 567720 1.444139194

[Redacted] [Redacted] [Redacted]

698880 1920080 2.747367216

106817 390210 3.653070204

[Redacted] [Redacted] [Redacted]

103515 774211 7.479215573

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]

1527885 -111 Missing Installation Costs

-555 -555 Zero

-555 -555 Zero

-555 -555 Zero

-999 -999 Blank Costs

-999 -999 Blank Costs

-999 -999 Blank Costs

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]

-555 -555 Zero

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

-999 -999 Blank Costs

-999 -999 Blank Costs

-999 -999 Blank Costs

-999 -999 Blank Costs

-999 -999 Blank Costs

-999 -999 Blank Costs

-999 35000 Blank Equipment Cost

-111 -111 Missing

-111 -111 Missing
-111 -111 Missing

-111 -111 Missing

-111 -111 Missing

-111 -111 Missing

-111 -111 Missing

-111 -111 Missing

-555 -555 Zero

-555 -555 Zero

-999 No Installation Costs

-999 No Installation Costs

-999 No Installation Costs

-999 No Installation Costs

-999 No Installation Costs

-999 No Installation Costs

1618534 No Installation Costs

2494345 No Installation Costs

2354450 No Installation Costs

[Redacted] [Redacted] [Redacted]

-999 No Installation Costs

8000 2000 0.25

7209000 3541905 0.491317104

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted]

-999 -999 Blank Costs

-999 -999 Blank Costs

-999 -999 Blank Costs

[Redacted] [Redacted] [Redacted]
EPA's Methodology for Estimating the Engineering Overhead Factor (based on responses from the survey; C2-34).

From Steam Electric Survey - Question C2-34

Plant ID SE Unit ID CBI Flag Project Cost

14 SE Unit-1, SE Unit-2, SE Unit-3TRUE [Redacted] [Redacted]

249 SE Unit-1 FALSE Engineering Overhead 15063.55

263 SE Unit-6 TRUE [Redacted] [Redacted]

654 SE Unit-4 TRUE [Redacted] [Redacted]

928 SE Unit-5 TRUE [Redacted] [Redacted]

942 SE Unit-1 FALSE Engineering Overhead 376193

1957 SE Unit-1 and 2 FALSE Engineering Overhead 0

2244 SE Unit-3 TRUE [Redacted] [Redacted]

2244 SE Unit-4 TRUE [Redacted] [Redacted]

2550 SE Unit-1, SE Unit-2, SE Unit-3, SE Unit-4, SE Unit-5 TRUE [Redacted] [Redacted]

2612 SE Unit-1, SE Unit-2 TRUE [Redacted] [Redacted]

2766 SE unit-1 FALSE Engineering Overhead 10000

3097 SE Unit-4 FALSE Engineering Overhead 0

3146 SE Unit-2 FALSE Engineering Overhead 0

3235 SE Unit-3 FALSE Engineering Overhead 0

3235 SE Unit-4 FALSE Engineering Overhead 0

3597 SE Unit-1 TRUE [Redacted] [Redacted]

3597 SE Unit-2 TRUE [Redacted] [Redacted]

3597 SE Unit-3 TRUE [Redacted] [Redacted]

3597 SE Unit-4 TRUE [Redacted] [Redacted]

3624 SE Unit-1 TRUE [Redacted] [Redacted]

3624 SE Unit-2 TRUE [Redacted] [Redacted]

3831 SE Unit-1 TRUE [Redacted] [Redacted]

3831 SE Unit-2 TRUE [Redacted] [Redacted]

4011 SE Unit-1 TRUE [Redacted] [Redacted]

4021 SE Unit-1 FALSE Engineering Overhead 65000

4237 SE Unit-1 TRUE [Redacted] [Redacted]

4237 SE Unit-2 TRUE [Redacted] [Redacted]

4242 SE Unit-1, SE Unit-2 TRUE [Redacted] [Redacted]

4242 SE Unit-3, SE Unit-4 TRUE [Redacted] [Redacted]

4391 SE Unit-1 FALSE Engineering Overhead 10000

4599 SE Unit-5 TRUE [Redacted] [Redacted]

4676 SE Unit-1 FALSE Engineering Overhead 10000

4676 SE Unit-2 FALSE Engineering Overhead 10000

EPA used data from C2-34 to compare the engineering costs to total capital costs to develop a factor for estimating e

overhead costs. EPA excluded any responses that were marked as blank or missing, and total capital costs listed as ze
4690 SE Unit-2 TRUE [Redacted] [Redacted]

4702 SE Unit-4 TRUE [Redacted] [Redacted]

4781 SE Unit-2 FALSE Engineering Overhead 94458

4993 SE Unit-1, SE Unit-2 FALSE Engineering Overhead 9700.55

4993 SE Unit-3 FALSE Engineering Overhead 29608.95

5015 SE Unit-1, SE Unit-2, SE Unit-3FALSE Engineering Overhead 0

5043 SE Unit-1 TRUE [Redacted] [Redacted]

5043 SE Unit-2 TRUE [Redacted] [Redacted]

6672 SE Unit-1 TRUE [Redacted] [Redacted]

7300 SE Unit-1 FALSE Engineering Overhead 125000

7416 SE Unit-4 FALSE Engineering Overhead 68771

7651 SE Unit-5 TRUE [Redacted] [Redacted]

8179 SE Unit-1 TRUE [Redacted] [Redacted]

8179 SE Unit-2 TRUE [Redacted] [Redacted]

8233 SE Unit-1 FALSE Engineering Overhead 16000

8471 SE Unit-1 FALSE Engineering Overhead 0

8750 SE Unit-1 FALSE Engineering Overhead 0

8969 SE Unit-1, SE Unit-2, SE Unit-3TRUE [Redacted] [Redacted]

9161 SE Unit-3 TRUE [Redacted] [Redacted]

9370 SE Unit-1 TRUE [Redacted] [Redacted]

9526 SE Unit-4 FALSE Engineering Overhead 0

9534 SE Unit-7 FALSE Engineering Overhead 50000

9861 SE Unit-3 TRUE [Redacted] [Redacted]
nses from the survey; C2-34).

Year Basis Plant ID SE Unit ID CBI Flag Project

[Redacted] 14 SE Unit-1, SE Unit-2, SE Unit-3TRUE [Redacted]

-999 249 SE Unit-1 FALSE Total Capital

[Redacted] 263 SE Unit-6 TRUE [Redacted]

[Redacted] 654 SE Unit-4 TRUE [Redacted]

[Redacted] 928 SE Unit-5 TRUE [Redacted]

2002 942 SE Unit-1 FALSE Total Capital

-999 1957 SE Unit-1 and 2 FALSE Total Capital

[Redacted] 2244 SE Unit-3 TRUE [Redacted]

[Redacted] 2244 SE Unit-4 TRUE [Redacted]

[Redacted] 2550 SE Unit-1, SE Unit-2, SE Unit-3, SE Unit-4, SE Unit-5 TRUE [Redacted]

[Redacted] 2612 SE Unit-1, SE Unit-2 TRUE [Redacted]

2003 2766 SE unit-1 FALSE Total Capital

-999 3097 SE Unit-4 FALSE Total Capital

2008 3146 SE Unit-2 FALSE Total Capital

-999 3235 SE Unit-3 FALSE Total Capital

-999 3235 SE Unit-4 FALSE Total Capital

[Redacted] 3597 SE Unit-1 TRUE [Redacted]

[Redacted] 3597 SE Unit-2 TRUE [Redacted]

[Redacted] 3597 SE Unit-3 TRUE [Redacted]

[Redacted] 3597 SE Unit-4 TRUE [Redacted]

[Redacted] 3624 SE Unit-1 TRUE [Redacted]

[Redacted] 3624 SE Unit-2 TRUE [Redacted]

[Redacted] 3831 SE Unit-1 TRUE [Redacted]

[Redacted] 3831 SE Unit-2 TRUE [Redacted]

[Redacted] 4011 SE Unit-1 TRUE [Redacted]

2008 4021 SE Unit-1 FALSE Total Capital

[Redacted] 4237 SE Unit-1 TRUE [Redacted]

[Redacted] 4237 SE Unit-2 TRUE [Redacted]

[Redacted] 4242 SE Unit-1, SE Unit-2 TRUE [Redacted]

[Redacted] 4242 SE Unit-3, SE Unit-4 TRUE [Redacted]

2006 4391 SE Unit-1 FALSE Total Capital

[Redacted] 4599 SE Unit-5 TRUE [Redacted]

2006 4676 SE Unit-1 FALSE Total Capital

2006 4676 SE Unit-2 FALSE Total Capital

evelop a factor for estimating engineering 

nd total capital costs listed as zero.
[Redacted] 4690 SE Unit-2 TRUE [Redacted]

[Redacted] 4702 SE Unit-4 TRUE [Redacted]

2008 4781 SE Unit-2 FALSE Total Capital

2009 4993 SE Unit-1, SE Unit-2 FALSE Total Capital

2009 4993 SE Unit-3 FALSE Total Capital

2002 5015 SE Unit-1, SE Unit-2, SE Unit-3FALSE Total Capital

[Redacted] 5043 SE Unit-1 TRUE [Redacted]

[Redacted] 5043 SE Unit-2 TRUE [Redacted]

[Redacted] 6672 SE Unit-1 TRUE [Redacted]

-999 7300 SE Unit-1 FALSE Total Capital

2006 7416 SE Unit-4 FALSE Total Capital

[Redacted] 7651 SE Unit-5 TRUE [Redacted]

[Redacted] 8179 SE Unit-1 TRUE [Redacted]

[Redacted] 8179 SE Unit-2 TRUE [Redacted]

2007 8233 SE Unit-1 FALSE Total Capital

-999 8471 SE Unit-1 FALSE Total Capital

-999 8750 SE Unit-1 FALSE Total Capital

[Redacted] 8969 SE Unit-1, SE Unit-2, SE Unit-3TRUE [Redacted]

[Redacted] 9161 SE Unit-3 TRUE [Redacted]

[Redacted] 9370 SE Unit-1 TRUE [Redacted]

2006 9526 SE Unit-4 FALSE Total Capital

2002 9534 SE Unit-7 FALSE Total Capital

[Redacted] 9861 SE Unit-3 TRUE [Redacted]
Cost Year Basis

Total Capital 

minus Overhead

Overhead % of 

Capital 

(excluding 

overhead)

[Redacted] [Redacted] [Redacted] [Redacted]

505596.87 NA 490533.32 3%

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

2283473 NA 1907280 20%

4217092 NA 4217092 0%

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

330000 NA 320000 3%

2289444.96 NA 2289444.96 0%

95780 NA 95780 0%

5246996 NA 5246996 0%

5735427 NA 5735427 0%

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

3067656 NA 3002656 2%

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

325000 NA 315000 3%

[Redacted] [Redacted] [Redacted] [Redacted]

1895000 NA 1885000 1%

1895000 NA 1885000 1%
[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

5446649 NA 5352191 2%

1406801.11 NA 1397100.56 1%

13985861.63 NA 13956252.68 0%

2342000 NA 2342000 0%

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

765157 NA 640157 20%

2871037 NA 2802266 2%

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

529000 NA 513000 3%

143450 NA 143450 0%

1629258.67 NA 1629258.67 0%

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

[Redacted] [Redacted] [Redacted] [Redacted]

122000 NA 122000 0%

388391 NA 338391 15%

[Redacted] [Redacted] [Redacted] [Redacted]

Min 0%

Max 29%

Average 4.419%

Median [Redacted]
EPA's Methodology for Estimating Operating Labor Rates for Dry Vacuum Systems

Assumptions

Operating Days = 2009 Calendar days of operation from Table A-8.

Summary Statistics: 

U.S. Labor Stats (http://www.bls.gov/oes/current/oes_nat.htm)

Mean Hourly 

Wage

Factor to 

Load Wages

Loaded 

Wages

Operating Engineer 21.24 0.3 27.61

Engineering Technician 27.66 0.3 35.96

All plant-level data has been removed from this tab as a result of CBI sanitization. All data used to calculate c

factors is considered CBI or CBI deducible.
All data used to calculate conveyance operating labor 
EPA's Methodology for Estimating Maintenance Labor Rates and ours per Year for Dry Vacuum Systems

Notes: This is similar to the operating O&M, just includes DPY in the analysis. 

Summary Statistics: 

U.S. Labor Stats (http://www.bls.gov/oes/current/oes_nat.htm)

Mean Hourly Wage

Factor to 

Load 

Wages

Loaded 

Wages

Operating Engineer 21.24 0.3 27.61

Engineering 

Technician 27.66 0.3 35.96

All plant-level data has been removed from this tab as a result of CBI sanitization. All 

data used to calculate conveyance maintenance labor factors is considered CBI or CBI 
Dry Vacuum Systems
EPA's Methodology for Calculating the Operating and Maintenance Labor Rate for Conveyance Costs

EPA took the median of all costs for operating labor and maintenance labor (calculation shown below). 

All plant-level data has been removed from this tab as a result of CBI sanitization. All data used to 

calculate conveyance operating and maintenance labor factors is considered CBI or CBI deducible.
for Conveyance Costs

culation shown below). 

zation. All data used to 

d CBI or CBI deducible.
EPA's Methodology for Calculating the Conveyance Maintenance Materials Factor

Summary Stats

Methodology: ($ Maintenance Mats + $ Other)/(Opr Labor $ + Maintenance Labor $ + Energy $)

All plant-level data has been removed from this tab as a result of CBI 

sanitization. All data used to calculate conveyance maintenance materials 

factors is considered CBI or CBI deducible.
+ Energy $)