Preliminary Capital Cost Estimate for 

Environmental Protection Agency

July 20, 2010

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Navajo Generating Station

Preliminary Capital Cost Estimate

Environmental Protection Agency – July 20, 2010

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Navajo Generating Station

Preliminary Capital Cost Estimate

Environmental Protection Agency – July 20, 2010

AGENDA

• Introductions

• Background

• Experience

• Study Overview

• Emissions Criteria

• Functional Description 

• Site General Arrangements & 3D Model

• Conceptual Design Overview

• Constructability 

• Schedule

• Cost Estimate

• NPS Input

• General Discussion & Q&A

• Closure, EPA Input, &Action Item Review

Barry Drost - SRP
Preliminary Capital Cost Estimate for 

Environmental Protection Agency

July 20, 2010

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Navajo Generating Station

Preliminary Capital Cost Estimate

Environmental Protection Agency – July 20, 2010

TABLE OF CONTENTS

ITEM SLIDE NO.

• Background 4

• Experience Listing 5

• Study Overview 26

• Emissions Criteria 33

• Functional Description 38

• Site General Arrangements 43

• Conceptual Design Overview 57

• Constructability 63

• Schedule 79

• Cost Estimate 84

• NPS Input 99

• Supplemental Information

- Conceptual Design Description – Mechanical Systems 106

- Conceptual Design Description – Electrical Systems 115

- Schedule Requirements 127

- Cost Estimate Details & Expected Cash Flows 131

- Expected Operating & Maintenance Costs 135

- 3D Model Views 137

Barry Drost - SRP

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Navajo Generating Station

Preliminary Capital Cost Estimate

Environmental Protection Agency – July 20, 2010

Cost Estimate Background

• 2008: Developed high level cost estimate for SCRs only

• 2009: Developed supplemental cost estimates for Baghouses

• 2009: ANPRM included cost information suggesting estimates were too high - ANPR approximately one-third of SRP’s estimates

• 2010: SRP contracts S&L to develop a conceptual design & detailed cost estimate

- Invited EPA and NPS to participate in the development of the cost study

- Study based on best management practices for developing accurate pre-construction estimates

• EPA agreed to consider results of the cost estimate study in developing the draft NGS 

BART determination

• Cost Estimate Presented to NPS on May 19, 2010

- NPS acknowledged the appropriateness of the methodology and thoroughness of the engineering / 

construction evaluations and cost estimates 

Barry Drost - SRP
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Environmental Protection Agency

July 20, 2010

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EXPERIENCE LISTING EXPERIENCE LISTING

•• S&L SCR & BAGHOUSE EXPERIENCE S&L SCR & BAGHOUSE EXPERIENCE S&L SCR & BAGHOUSE EXPERIENCE 

•• FOSTER WHEELER CONS FOSTER WHEELER CONSTRUCTION EXPERIENCE TRUCTION EXPERIENCE

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Sargent & LundyLLC

NOx SCR Control

Experience and Qualifications
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Recent SCR Projects (Page 1)

Utility Station/Unit MW (Total) Status

Ameren (CIPS) Coffeen 1, 2 1,006 Operating

Associated Electric New Madrid 1, 2 600 Operating

Basin Electric Dry Fork 1 400 Design

Cinergy Services 8 units 5,400 Operating

CPS Energy Deely 2 450 Design

Dynegy Baldwin 1, 2 1,200 Operating

Havana 6 450 Operating

Exelon Power Mountain Creek 8 550 Operating

Handley 3 400 Operating

Handley 4-5 916 Operating

Gainesville 

Regional Utilities

Deerhaven 2 200 Operating

Lakeland Electric McIntosh 3 364 Operating

MidAmerican 

Energy

Walter Scott Jr. 4 870 Operating

Includes Gibson 

S&L Design

Gibson – FWC 

Construction

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Utility Station/Unit MW (Total) Status

Mirant Morgantown 1,2 1,252 Operating

Owensboro 

Municipal

Elmer Smith 1 150 Operating

Nebraska Public 

Power Dist.

Gerald Gentleman 

1,2

1400 Hold

PSEG Mercer 1,2 640 Operating

Reliant Energy Parish 5-8 2,500 Operating

8 Gas Units 5,150 Operating/Lay-up

Santee Cooper Cross 1, 2 1,200 Operating

Winyah 1-4 1,260 Operating

Southern Illinois 

Power

Marion 4 174 Operating

Tampa Electric Big Bend 1-4 1,200 Operating

TXU Lake Hubbard 2 528 Operating

Northlake 2 175 Operating

TOTALS 56 units 29,150

Recent SCR Projects (Page 2)
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SCR Project Summary

• 56 Utility SCR Units

9 42 coal-fired units

9 14 gas-fired units

• 40 Full S&L Design

9 32 coal-fired units

9 8 gas-fired units

• 16 Designed for PRB Coal

9 Most in industry

• 40 Used Multiple Lump Sum (MLS) Contracting Approach

9 ~15% lower capital cost

• 30% Market Share (56 S&L units of 189 industry units)

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Recent S&L SCR Projects - 2002 to Date
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S&L Experience with 

Every Qualified Catalyst Supplier/OEM

• Argillon

• Ceram

• Cormetech

• Haldor Topsoe

• Hitachi

• IHI

• KWH

Catalyst Suppliers OEMs

• Alstom

• Babcock Power

• Babcock & Wilcox

• Foster Wheeler

• Sargent & Lundy LLC

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Santee Cooper Winyah - View from Unit 4 Chimney (Aug 2005)

New 

SCRs
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Santee Cooper - Winyah Unit 1 & 2 SCRs

Unit 2

Unit 1

New 

SCRs

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Gibson 

Units 1-5
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Gibson 

Units 4 & 5

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Sargent & LundyLLC

Particulate Control

Fabric Filters

Experience and Qualifications
Preliminary Capital Cost Estimate for 

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Baghouse Design Projects (Page 1)

* Designed for mercury control

Client Station Unit MW 

(total)

Baghouse 

Type Status

Basin Electric *Dry Fork 1 420 Pulse Jet 2011

Cinergy *Gallagher 1-4 600 Pulse jet 2008-2009

*Genoa 3 350 Pulse jet 2007

*Madgett 1 370 Pulse jet 2007

*Baldwin 1,2,3 1,905 Pulse jet 2010–2012

*Havana 6 450 Pulse jet 2009

*Vermilion 1,2 183 Pulse jet 2007

*Hennepin 1,2 306 Pulse jet 2008

MidAmerican *Walter Scott, 

Jr. 4

870 Pulse jet 2007

Mirant Dickerson 1-3 300 Pulse jet 2003

Nova Scotia Power 

Corp.

Point Aconi 1 165 Reverse Air 1994

NPPD Gerald 

Gentleman 1-2

1,200 Reverse air 2001

Dairyland

Dynegy

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* Designed for mercury control

Baghouse Design Projects (Page 2)

Client Station Unit MW 

(total)

Baghouse 

Type Status

Public Service New 

Mexico

* San Juan 1-4 1,760 Pulse jet 2007

Reliant Energy *Shawville Unit 

3-4

572 Pulse jet 2012

Reserve Mining 

Company

Lakeside 1-2 125 Reverse Air 1993

Southern Illinois 

PowerCoop

Marion 1-3 174 Pulse Jet 2002

Texas-Genco Parish 5-7 2,083 Reverse air 1989

TU Electric Big Brown 140 COHPAC – 

Demo

1993

Big Brown 2 593 COHPAC 1995

Big Brown 1 593 COHPAC 1995

Wisconsin Electric Valley 1-2 280 Pulse jet 1996

Wisconsin Public 

Service

Weston 3 320 Pulse jet 2002

Totals 41 Units 9,283
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Recent S&L 

Baghouse Projects 

- 2001 to Date -

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Foster Wheeler Constructors, Inc.

NOx SCR Control

Experience and Qualifications

-- 2000 to Present --
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FWCI Recent SCR Construction Projects

Client Plant Unit # Unit Capacity 

MWe

Start-Up 

Date

AES Deepwater 1 210 2007

Cinergy Gibson 1 660 2005

AEP Muskingum River 5 600 2005

Cinergy Gibson 5 660 2004

IPL Petersburg 2 460 2004

IPL Petersburg 3 560 2004

Cinergy Gibson 4 660 2003

Cinergy Miami Fort 7 530 2003

Cinergy Gibson 3 660 2002

Cinergy East Bend 2 670 2002

Cinergy Miami Fort 8 530 2002

Cinergy Gibson 2 668 2001

S&L Design

S&L Design

S&L Design

S&L Design

S&L Design

S&L Design

S&L Design

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\

Muskingum 

River Unit 5
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\

Muskingum 

River Unit 5

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IPL Petersburg 

Unit 2 
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IPL Petersburg Unit 2 

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STUDY OVERVIEW STUDY OVERVIEW
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Obtain Equipment, 

Material, &

Labor Costs

Develop

Commodities

& Summary 

Specifications

Establish Design

Criteria & Plant 

Performance

Parameters

Develop 

Plant General 

Arrangements &

System Designs

6 Main Phases of Cost Estimate Development

Develop

Schedule & 

Cash Flow

Issue 

Conceptual

Design & Cost 

Estimate

Report

Study Overview Barry Drost - SRP

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Navajo Generating Station

Preliminary Capital Cost Estimate

Environmental Protection Agency – July 20, 2010

• Scope

9 Develop Capital Cost Estimates

• Unit 1, 2, and 3 & Common for Selective Catalyst Reduction (SCR) Option 

• Unit 1, 2, and 3 & Common for SCR Plus Pulse Jet Fabric Filter (Baghouse) Option

(Final EPA, BART, and PSD requirements will determine need for baghouse implementation) 

• Established Design Basis and Performance Parameters

9 Defined emission control requirements

9 Defined key parameters for major equipment

• Developed Plant General Arrangements

9 Performed Initial Site Walkdown (FWC, S&L, & SRP)

9 Identified Site Constraints

9 Constructability Issues

9 Developed Preliminary General Arrangement

Study Overview Arvind Patel – S&L
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• Developed conceptual system designs

9 Reviewed existing electrical aux power system

9 Performed equipment sizing

9 Performed constructability site walkdown (S&L / FWC)

9 Developed conceptual General Arrangement

• Major Equipment

9 Letter specifications solicited to obtain budgetary pricing & sizing

• Ammonia Storage and Transfer System

• Low Oxidation Catalyst

• Dry Sorbent Injection (DSI)

• ID Booster Fans / ID Fan Rotor Replacement

• Baghouse

• Air Compressors

• Unit Auxiliary Transformers (UAT)

Study Overview Arvind Patel – S&L

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Environmental Protection Agency – July 20, 2010

• Developed material/commodity quantities based on GAs

9 Piping

9 Cable

9 Cable Tray

9 Ductwork

9 Structural steel

9 Foundation work

9 Relocation work

• B.O.P. Equipment and Material/ Commodity Cost

9 S&L in-house database

9 Recent awards on related projects

9 Industry publications and vendor catalogs

• Owners Cost

9 Construction Management

9 Operations and Maintenance Support During Commissioning

9 Legal Support & Owner’s Insurance

9 Lost Generation During Relocation Outages (7 days / unit)

9 Ammonia unloading facility at rail head

9 Spare Parts

• Operation & Maintenance Costs

Study Overview Arvind Patel – S&L
Preliminary Capital Cost Estimate for 

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• Labor and Erection Costs (by Foster Wheeler)

9 Manhours per unit quantity

9 Labor Wage Rates

9 Productivity factors

• Regional productivity

• Difficulty for item of work

9 Construction equipment

9 Heavy lift equipment

• Order of Magnitude Comparison of FWC Estimate by S&L

Study Overview Arvind Patel – S&L

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• Prepared Project Schedule

9 Engineering & procurement developed by S&L

9 Construction schedule developed by FWC

9 Ordinal schedule reflecting overall durations as shown below:

(Authorization of Detailed Engineering to Systems In Service / Testing)

- SCR Only: 42 Months

- SCR Plus Baghouse: 48 Months

Study Overview Arvind Patel – S&L
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EMISSIONS CRITERIA EMISSIONS CRITERIA

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Emissions Criteria – Basis William DePriest – S&L
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Emissions Criteria – Basis William DePriest – S&L

Constituent Weight %(1)

Carbon 59.16 

Hydrogen 4.38 

Nitrogen 1.03 

Sulfur 0.63 

Oxygen 11.11 

Ash 10.36 

Moisture 13.33 

(1) As-Received 

Ash Analysis 

Silicon Dioxide 56.67 

Aluminum Dioxide 21.53 

Titanium Dioxide 1.02 

Iron Oxide 5.17 

Calcium Oxide 5.47 

Magnesium Oxide 1.33 

Potassium Oxide 1.23 

Sodium Oxide 1.73 

Sulfur Trioxide 5.83 

Phosphorus Pentoxide 0.22 

Strontium Oxide 0.18 

Barium Oxide 0.38 

Manganese Oxide 0.01 

Coal Composition

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Emissions Criteria – Basis William DePriest – S&L

Emission lb/mmBtu 

NOX Current Permit 

Current Operation 

30-Day Rolling Average with SCR 

SCR Design 

0.24 (1)

0.20 to 0.22 (1)

0.07 to 0.08 

0.05 

SO3/ H2SO3 Ultra-Low Oxidation Catalyst @ < 0.5% 

SCR Option Design Emissions

Notes: (1) Based on LNB in operation
Preliminary Capital Cost Estimate for 

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• Collateral sulfuric acid mist and PM10 emissions may trigger 

Prevention of Significant Deterioration (PSD) Permitting

• PSD permitting requires BACT determination

• Potential BACT outcomes for sulfuric acid mist:

9 Low oxidation SCR catalyst

9 Low oxidation SCR catalyst + sorbent injection with existing scrubber 

for particulate removal

9 Low oxidation SCR catalyst + sorbent injection with new polishing 

baghouse for particulate removal 

• A sulfuric acid mist BACT determination of Low Oxidation SCR 

catalyst could still result in significant increase in PM10

• PM10 BACT could be a polishing baghouse

Regulatory Basis For Baghouse Option

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FUNCTIONAL DESCRIPTION FUNCTIONAL DESCRIPTION
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Navajo Generating Station

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SCR Option

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Navajo Generating Station

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SCR & Baghouse Option
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9 Pulse-jet baghouse downstream of SCR with filter bags and pulse-jet cleaning 

system to remove particulates.

9 Material removed by the pulse-jet cleaning system is collected in hoppers located 

below the bags.

Clean

Gas Outlet

Dirty

Gas Inlet

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Functional Description

Questions?
Preliminary Capital Cost Estimate for 

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SITE GENERAL ARRANGEMENTS SITE GENERAL ARRANGEMENTS

& &

3D MODEL REVIEW 3D MODEL REVIEW

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Environmental Protection Agency – July 20, 2010

• SCR Option

9 Mechanical

• Common Anhydrous Ammonia Storage & Transfer Facility

• Anhydrous Ammonia Vaporization and Delivery System (per Unit)

• Low Oxidation Catalyst

• ID Fans: Rotating Element Replacement (rotor/bearings)

9 Electrical

• 480V transformers located in FGD area; switchgear / MCCs in existing FGD building

• SCR and Baghouse Option

9 Same as SCR Option, with following additional items:

9 Mechanical

• Polishing Pulse Jet Fabric Filter (PJFF) with Blowers (gas inlet & outlet on same side)

• Axial Flow ID Booster Fans

• Dry Sorbent Injection System (per Unit)

• Waste Collection System (Storage Silo & Blowers)

• Compressed Air System

9 Electrical

• New Unit Auxiliary Transformer (per Unit)

• New Power Distribution Center (PDC) (per Unit)

Site GA – Major Equipment Arvind Patel – S&L
Preliminary Capital Cost Estimate for 

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• SCR Option msk-1001 Site Plan SCR and BH.pdf

9 Unit 3 & Common msk-1003 Unit 3.pdf

• Requires demolition & relocation of existing maintenance/ fabrication shop

Site GA - Restrictions/Constraints Arvind Patel – S&L

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• SCR Option msk-1001 Site Plan SCR and BH.pdf

9 Unit 2 msk-1003 Unit 2.pdf

• Numerous space restrictions (existing coal conveyor, racks, U/G duct banks, etc.)

• Flue gas ducts and SCR reactors separated due to space constraints (precip access)

• New ducts on both sides of Unit

Site GA - Restrictions/Constraints Arvind Patel – S&L
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• SCR Option msk-1001 Site Plan SCR and BH.pdf

9 Unit 1 msk-1003 Unit 1.pdf

• Need to relocate existing fly ash blowers

Site GA - Restrictions/Constraints Arvind Patel – S&L

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• SCR and Baghouse Option msk-1000 Site Plan SCR.pdf

9 Unit 3 & Common msk-1002 Unit 3.pdf

• Maintains site access roads 

• Baghouses/ID fans located in open area adjacent to reagent preparation facility

Site GA - Restrictions/Constraints Arvind Patel – S&L
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• SCR and Baghouse Option msk-1000 Site Plan SCR.pdf

9 Unit 2 msk-1002 Unit 2.pdf

• Numerous space restrictions (existing coal conveyor, racks, U/G duct banks, etc.)

• Requires stacked baghouse arrangement (non-conventional) 

• ID booster fans installed in separate locations (limited maintenance access)

• Requires warehouse/tool room demolition & relocation 

Site GA - Restrictions/Constraints Arvind Patel – S&L

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• SCR and Baghouse Option msk-1000 Site Plan SCR.pdf

9 Unit 1 msk-1002 Unit 1.pdf

• Baghouses located in close proximity to operating water treatment facilities

• One baghouse casing elevated 25 ft to allow road access

• Relocate existing east – west pipe rack to allow equipment installation

• Major underground utility corridor under booster fan foundations

• Water treatment sump relocation

Site GA - Restrictions/Constraints Arvind Patel – S&L
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• SCR Option

9 A common ammonia truck unloading area located southeast of the units 

9 SCR reactors arranged to minimize capital costs and maximize accessibility

9 Minimum clearance of 25 feet maintained above roads

9 New 480V transformers and electrical equipment located in space available in the 

FGD area

Site GA – Other Development Considerations Arvind Patel – S&L

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• SCR and Baghouse Option

9 The SCR reactor locations remain as optimized for the SCR Option. 

9 Within the remaining available space on each unit after positioning of the SCRs, the 

baghouses and ID Booster Fans have been arranged to minimize capital costs while 

maximizing accessibility for maintenance activities.

9 Sorbent injection silo for each unit located adjacent existing plant roads

9 The waste silo for each unit’s baghouse has been located near both casings and an 

existing plant road for ease of truck loading.

9 As a cost-saving measure the abandoned chimney shells have been used for support of 

the ductwork associated with the baghouses.

9 The Unit 2 ID Booster Fans have been separated due to space restrictions. A side-byside arrangement is desirable for maintenance access; however, access is possible from 

an adjacent existing plant road for each of the fans.

9 The Unit 2 baghouse ductwork passes over both the existing coal conveyor and the SCR 

inlet / outlet ductwork.

9 The Unit 2 Power Distribution Center has been located north of Unit 1 because of 

insufficient space closer to the new baghouses.

9 New UATs have been located adjacent to existing transformers outside the turbine 

building.

Site GA – Other Development Considerations Arvind Patel – S&L
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Site GA – Other Development Considerations Arvind Patel – S&L

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• SCR Option

9 No major piping relocation anticipated

9 Cathodic protection to be modified as required

9 Precipitator transformers – relocate under precipitator due to platform demo 

between U1 and U2 precips

• SCR and Baghouse Option

9 Unit 1 ID fans location – U/G piping would be relocated onto new piperack

9 New pipe rack from U1 Baghouse to PDC building

• U/G piping in corridor to be relocated onto rack

• Cables on existing rack to be relocated to new rack

• Distribution panels under existing rack to be relocated

Site GA – Utility Relocation Arvind Patel – S&L

msk-1001 Site Plan SCR and BH_UG.pdf msk-1001_UGO_Markup.pdf
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• Other General Items

9 Ash conveying piping near U2 baghouse to be relocated onto existing pipe rack 

9 Fire protection piping near Unit 3 baghouse to be relocated

9 All piping relocated from U/G to A/G to be heat traced and insulated

9 NGS has implemented a phased underground to aboveground utility relocation 

plan

9 Precipitator transformers – relocate under precipitator due to platform demo 

between U1 and U2 precips

9 Cable tray in/along side tool room between U1 and U2 precips to be relocated

Site GA – Utility Relocation Arvind Patel – S&L

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Site GA / 3D Model 

Questions?
Preliminary Capital Cost Estimate for 

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CONCEPTUAL DESIGN OVERVIEW CONCEPTUAL DESIGN OVERVIEW

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• General 

9 Based on previous experience with retrofit projects and site walkdowns, BOP systems 

(air, water, fire protection) have adequate pressure/flow margins to support new users

9 Installed equipment spares

9 Maximize turndown capability & operator flexibility

• SCR Option

9 2 x 50% Selective Catalytic Reduction Reactors w/4-layer design (2 + 2)

9 Existing ID Fans & Motors with replacement rotor assembly (impeller, rotor, bearings) 

9 Anhydrous Ammonia utilized as reagent; 14-day storage and transfer facility

• SCR and Baghouse Option

9 New Polishing Pulse Jet Fabric Filter (PJFF - Baghouse); air to cloth ratio 6:1

9 Existing ID Fans & Motors w/o modifications

9 New 2 x 50% Axial ID Booster Fans downstream of new PJFF

9 Utilize sodium-based sorbent; i.e. Trona

9 Waste Collection & Disposal System; 7-day storage silo w/blowers 

9 New Compressed Air System (pulse jet); also feeds new ancillary air users

Conceptual Design Description – Mechanical Systems Arvind Patel – S&L

Summary (Refer to Slides 101 – 109 for additional details)
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• General

9 Auxiliary power system sized sufficiently to support the new system load requirements 

under all plant operating modes. 

9 Auxiliary power system designed to utilize existing sources where applicable.

9 Auxiliary power system designed such that failure of a single component (such as 

transformer) will not cause plant operation to be limited.

• SCR Option

9 Utilization of existing ID fan motors.

9 New system additions at 480-V level.

9 Utilization of existing Pump Building and small PDCs to house new elect. equipment.

9 Relocation of two precipitator transformers

• SCR and Baghouse Option

9 New ID Booster Fans requirements can not be supported from existing auxiliary power 

system

9 Elect. System Additions at 13.8-kV, 4.16-kV and 480-V levels

9 New UAT per each unit is required.

9 Utilization of existing Pump Building, small PDCs, and large PDCs to house new 

electrical equipment.

9 Significant Cable and Equipment Relocation.

Conceptual Design Description – Electrical Systems Arvind Patel – S&L

Summary (Refer to Slides 110 – 121 for additional details)

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• Significant Assumption

9 Relocation of the electrical conduits / cables with the pipe rack on the north side of Unit 1, 

only affects Unit 1.

9 Relocation of cable tray / rack between Unit 2 & 3, only affects Unit 2.

9 Detailed study / evaluation must be performed to identify service of each cable

Conceptual Design Description – Electrical Systems Arvind Patel – S&L
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• Control Systems Design

9 DCS - New SCR/Baghouse equipment controls will be integrated 

into existing Plant’s Foxboro Distributed Control System (DCS) via 

new DCS equipment

9 Vendor PLC will be provided for the following, and will 

communicate with the Foxboro DCS via datalink:

• Baghouse cleaning systems

• Flue Gas SCR Duct Instruments

9 New in-situ NOx and O2 instruments installed on inlet and outlet of 

each SCR Reactor

• BOP Instruments

9 Ammonia System

9 SCR / Baghouse

9 Flue Gas Duct / ID Fans

Conceptual Design Description – Instrumentation & Controls

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Conceptual Design Description

Questions?
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CONSTRUCTABILITY REVIEW CONSTRUCTABILITY REVIEW

Steve Maryanski - FWC

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• Foster Wheeler engaged to provide input into construction related 

aspects of the project, including

9 Input regarding constructability 

• Methods

• Equipment

9 Input into Construction Schedule (as addressed in schedule discussion)

• Sequence

• Durations

• Estimated craft labor histogram

9 Input into cost estimate (as discussed in cost estimate discussion)

• Installation rates by commodity (e.g. MH/ton of steel erected) 

• Craft crew mixes and crew cost rates

• Productivity factors

Constructability Review Steve Maryanski - FWC 
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Constructability Review Steve Maryanski - FWC

CLIENT PLANT UNIT 

CAPACITY 

 YEAR 

COMPLETED 

CINERGY GIBSON - UNIT 2 660 2001

CINERGY GIBSON - UNIT 3 660 2002

CINERGY GIBSON - UNIT 4 660 2003

INDIANAPOLIS POWER & LIGHT (IPL) PETERSBURG - 

UNIT 2 460 2003

INDIANAPOLIS POWER & LIGHT (IPL) PETERSBURG - 

UNIT 3 560 2004

CINERGY GIBSON - UNIT 5 660 2004

AMERICAN ELECTRIC POWER (AEP) MUSKINGUM RIVER 

- UNIT 5 600 2005

CINERGY GIBSON - UNIT 1 660 2005

FW EXPERIENCE BASED ON SCR RETROFITS FOR: 

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Constructability Review Steve Maryanski - FWC

CLIENT PLANT UNIT 

CAPACITY 

 YEAR 

COMPLETED 

FORT HOWARD PAPER COMPANY RINCON - UNIT 5 50 1997

TOLEDO EDISON BAYSHORE - UNIT 

1 175 2000

JACKSONVILLE ELECTRIC AUTHORITY (JEA) NORTHSIDE - UNIT 

1 300 2003

JACKSONVILLE ELECTRIC AUTHORITY (JEA) NORTHSIDE - UNIT 

2 300 2003

FW EXPERIENCE BASED ON BAGHOUSE RETROFITS FOR: 
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\

IPL Petersburg

Unit 4 Unit 3 Unit 2 Unit 1

SCRs

ADDED

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IPL Petersburg
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IPL Petersburg

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• Construction Methods

9General approach/methods

• All material delivered by highway/truck

• Material (ductwork, structural steel, SCR and baghouse

components) field assembled at grade into larger modules 

(roughly 35 to 55 ton sections) for erection by relatively large

cranes

• Immediate construction area (especially Unit 2) congested

• Work done around operating equipment, including the coal 

conveyor between Units 2 and 3

Constructability Review Steve Maryanski - FWC
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• Construction Equipment

9 Heavy lift crane plan and costs developed by Mammoet USA North Inc.

9 Units 1 and 3 utilize two 660 ton cranes

• U1 crane plan

• U3 crane plan

9 Unit 2 utilizes one 1250 ton and one 660 ton crane

• U2 crane plan

9 Construction cranes (200 ton and under) are included under 

Construction Equipment Supplement

9 New transformers (UAT’s) to be set using multi-axeled transporter, and 

jack and slide system 

Constructability Review Steve Maryanski - FWC 

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Constructability Review Steve Maryanski - FWC

CLIENT PLANT COST BASIS HL&T COST 

CINERGY GIBSON - UNIT 3 2002 $8,474,000

INDIANAPOLIS POWER & LIGHT (IPL) PETERSBURG - UNIT 2 2003 $3,227,000

INDIANAPOLIS POWER & LIGHT (IPL) PETERSBURG - UNIT 3 2004 $2,678,000

SALT RIVER PROJECT NAVAJO - UNIT 1 2010 $2,878,000

SALT RIVER PROJECT NAVAJO - UNIT 2 2010 $6,547,000

SALT RIVER PROJECT NAVAJO - UNIT 3 2010 $2,878,000

HEAVY LIFT CRANE AND TRANSPORT EQUIPMENT COSTS FOR SCR'S

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Constructability Review Steve Maryanski - FWC

 WORK AREA PRODUCTIVITY 

FACTOR COMMENT 

NAVAJO UNIT 1 SCR 1.00 GOOD ACCESS FOR MAJORITY OF WORK

NAVAJO UNIT 1 BAGHOUSE 1.15 ACCESS LIMITATIONSIN THE EXISTING 

WATER TREATMENT AREA

NAVAJO UNIT 1 ELECTRICAL 1.08 AVERAGE OF THE FACTORS FOR SCR AND 

BAGHOUSE AREAS

NAVAJO UNIT 2 ALL WORK 1.25 VERY LIMITED ACCESS AND CONGESTION 

FOR VIRTUALLY ALL WORK AREAS

NAVAJO UNIT 3 ALL WORK 1.00 GOOD ACCESS FOR MAJORITY OF WORK

UNIT PRODUCTIVITY FACTORS FOR DIFFICULTY OF WORK
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• Construction Methods (continued)

9 SCR tie-ins

• To be completed within an 8 week outage duration

• Tie-in area inaccessible for overhead crane lifts

• Pre-stage as much material in place as possible

• Set up platforms/rollers for the SCR tie-ins to allow ductwork to be 

rolled in and out of the area 

• Model cut of Units 1 or 3 tie-in

• Model cut of Unit 2 tie-in

Constructability Review Steve Maryanski - FWC 

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Constructability Review Steve Maryanski - FWC 

Questions?
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SCHEDULE SCHEDULE

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• Schedule Basis 

9 Multiple lump sum contracts

9 Based on construction quality drawings for bid

9 Detailed design of ductwork & steel completed after final flow model results

9 Construction schedule developed with Foster Wheeler input

• Concurrent Design & Construction of SCR & Baghouse

• Utility Relocation Tie-In Outage – 1 week forced outage per unit

• Major Tie-In Outages – 8 week planned outage

• Construction / Services Contracts 

9 Survey Work

9 Substructure Installation Work*

9 Mechanical & Structural General Work*

9 Electrical & Instrumentation General Work* 

9 Construction Testing & Inspection

9 Final Site Work

Schedule (Refer to Slides 122 – 125 for additional details) Arvind Patel – S&L
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• Major Equipment / Materials Contracts

SCR Only

9 SCR Catalyst & Flow Modeling

9 Ammonia Storage & Transfer

9 ID Fan Upgrade* 

9 Flue Gas Dampers*

9 Structural Steel Fabrication*

9 Ductwork Fabrication*

SCR and Baghouse (same as SCR Only list above w/following additional)

9 Baghouse

9 ID Booster Fans*

9 Sorbent Injection

9 Unit Auxiliary Transformers

9 Power Distribution Center (PDC)*

*separate specifications for Units 1, 2, and 3

Schedule Arvind Patel – S&L

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Schedule

Questions?

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COST ESTIMATE COST ESTIMATE
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• Major Considerations

9 Cost Estimate is Specific to Navajo Generating Station

9 Significant Consideration Given to Site Restrictions & Constraints 

9 Consideration Given to Construction Difficulty 

Reflected by multiplier in productivity factor

- Unit 3: 1.00 Base: All Work; SCR and/or Baghouse)

- Unit 1: 1.08 Electrical: 8% more than base

- Unit 1: 1.15 Baghouse: 15% more than base

- Unit 2: 1.25 All Work: 25% more than base

9 Based on 3,600 Man-hours of Engineering Completed (4 Month Duration)

- Approximately 1% of detailed engineering required for project

Capital Cost Estimate (Refer to Slides 126 – 129 for additional details) Arvind Patel – S&L

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• Overview of Included Items

9 SCR

- Low Oxidation Catalyst*

- Anhydrous Ammonia Storage & Transfer System*

- Dry Sorbent Injection System* (for SCR and Baghouse Option Only)

- Flue Gas Ductwork & Structural Steel

- Relocation of Existing Utilities / Infrastructure (Ex.: U3 Maintenance Building)

9 Baghouse 

- Baghouse & Waste Collection Systems *

- Induced Draft Booster Fans*

- Compressed Air System*

- Flue Gas Ductwork & Structural Steel

- Relocation of Existing Utilities / Infrastructure (Ex.: U1 Pipe Rack & U/G, U2 Precip Xformers, etc.)

9 Electrical / I&C

- Transformers*

- Pre-Fabricated Power Distribution Centers

- Switchgear / Motor Control Centers

- Cables & Cable Tray

Cost Estimate Arvind Patel – S&L

* Estimate is based on Q1 2010 

budgetary prices provided by suppliers.
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• Overview of Included Items

9 Construction Equipment & Scaffolding

- General Construction Equipment: small cranes, trucks, dozers, excavators, etc.

- Heavy Construction Equipment: major crane rental 

- Scaffolding

9 Other Direct & Construction Indirect Costs

- Indirect Craft Labor: safety, security, warehousing, & construction support activites

- Overtime & Per Diem

- Contractor General & Administrative and Profit

- Freight

9 Indirect Costs

- Engineering & Procurement

- Construction Management & Start-up / Commissioning

- Owners Costs 

= Construction Management

= Operations and Maintenance Support During Commissioning

= Legal Support & Owner’s Insurance

= Lost Generation During Relocation Outages (7 days / unit)

= Ammonia unloading facility at rail head

= Spare Parts

= Taxes

Cost Estimate Arvind Patel – S&L

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• Overview of Included Items

9 Contingency

- Determined using a range analysis

- Based on 95% confidence level of not exceeding the budget

9 Allowance for Funds Used During Construction (AFUDC)

• Excluded Costs Items

9 Escalation

Cost Estimate Arvind Patel – S&L
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• Exposures / Risks

9 Ammonia System (anhydrous ammonia vs. urea system)

- Urea systems have additional equipment / processes resulting in increased capital costs

9 Underground Utilities & Infrastructure

- Additional expenditures would be required to relocate unknown U/G utilities or work 

around critical ones

9 Equipment Size & Available Footprint for Installation

- Conceptual general arrangements are based on representative data from previous 

projects; detail design must be based on project specific drawings for purchased 

equipment

9 Implementation Schedule

- May result in loss of generation if a planned minor outage has to be extended

9 Risks to Operating Unit(s)

- May result in unexpected unit trips or damage to existing equipment / infrastructure

Cost Estimate Arvind Patel – S&L

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Cost Estimate Arvind Patel – S&L

Cost Estimate Risk Analysis - Ranges for Individual Cost Elements

Cost Element Minimum Maximum Minimum Maximum Minimum Maximum

Equipment -5% +35% -5% +35% -5% +35%

Catalyst -5% +15% -5% +15% -5% +15%

Str. Steel & Ductwork -5% +20% -5% +25% -5% +20%

Other Materials -10% +20% -10% +25% -10% +20%

Labor -10% +30% -10% +30% -10% +30%

C/M & S-U -10% +20% -10% +20% -10% +20%

A/E Engineering -10% +20% -10% +25% -10% +15%

SRP Costs -10% +20% -10% +25% -10% +15%

Overall Contingency 

After Simulation

Cost Element Minimum Maximum Minimum Maximum Minimum Maximum

Equipment -5% +45% -5% +45% -5% +45%

Catalyst -5% +15% -5% +15% -5% +15%

Str. Steel & Ductwork -5% +25% -5% +35% -5% +20%

Other Materials -10% +20% -10% +30% -10% +20%

Labor -10% +30% -10% +30% -10% +30%

C/M & S-U -10% +20% -10% +20% -10% +20%

A/E Engineering -10% +20% -10% +30% -10% +15%

SRP Costs -10% +20% -10% +30% -10% +15%

Overall Contingency 

After Simulation

Ranges for SCR and Baghouse Option

U1 U2 U3 & Common

U1 U2 U3 & Common

Ranges for SCR Only Option

11.4% 12.9% 11.3%

13.2% 14.6% 12.6%
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Cost Estimate Arvind Patel – S&L

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Cost Estimate Arvind Patel – S&L
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Cost Estimate Arvind Patel – S&L

 Unit 1 Unit 2 Unit 3 & Common Total 

SCR $ 50,386,000 $ 63,860,000 $ 60,661,000 $ 174,907,000 

Electrical and I&C $ 3,478,000 $ 3,888,000 $ 5,297,000 $ 12,663,000 

Construction Equipment & Scaffolding $ 11,471,000 $ 18,934,000 $ 14,091,000 $ 44,496,000 

Other Direct & Construction Indirect Costs $ 29,731,000 $ 41,879,000 $ 37,491,000 $ 109,101,000 

Indirect Costs $ 38,481,000 $ 50,135,000 $ 46,699,000 $ 135,315,000 

Contingency $ 15,224,000 $ 23,052,000 $ 18,559,000 $ 56,835,000 

AFUDC $ 6,357,000 $ 8,450,000 $ 7,763,000 $ 22,570,000 

Total Project Costs $ 155,128,000 $ 210,198,000 $ 190,561,000 $ 555,887,000 

$/kW (812MW Gross) $ 191 $ 259 $ 235 $ 228 

$/kW (750MW Net) $ 207 $ 280 $ 254 $ 247 

Intermediate Level Summary of SCR Only Capital Cost Estimate

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Cost Estimate Arvind Patel – S&L

 Unit 1 Unit 2 Unit 3 & Common Total 

SCR $ 49,653,000 $ 63,370,000 $ 60,514,000 $ 173,537,000 

Baghouse $ 71,095,000 $ 67,771,000 $ 52,948,000 $ 191,814,000 

Electrical and I&C $ 14,977,000 $ 14,831,000 $ 18,437,000 $ 48,245,000 

Construction Equipment & Scaffolding $ 29,345,000 $ 33,270,000 $ 26,577,000 $ 89,192,000 

Other Direct & Construction Indirect Costs $ 78,797,000 $ 85,736,000 $ 70,100,000 $ 234,633,000 

Indirect Costs $ 77,981,000 $ 86,030,000 $ 73,737,000 $ 237,748,000 

Contingency $ 42,484,000 $ 51,247,000 $ 38,092,000 $ 131,823,000 

AFUDC $ 16,371,000 $ 18,064,000 $ 15,562,000 $ 49,997,000 

Total Project Costs $ 380,703,000 $ 420,319,000 $ 355,967,000 $ 1,156,989,000 

$/kW (812MW Gross) $ 469 $ 518 $ 438 $ 475 

$/kW (750MW Net) $ 508 $ 560 $ 475 $ 514 

Intermediate Level Summary of SCR and Baghouse Capital Cost Estimate
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Cost Estimate Arvind Patel – S&L

High Level Capital Cost Estimate Summary

*For SCR Option, costs were obtained from 10/06/08 “SCR & SNCR Cost Study”. For SCR and Baghouse Option, 

costs were developed from 10/02/09 “Fabric Filter Cost Study”. These studies were developed by S&L. 

The “Previuos Cost Estimate values shown include loss of generation due to outage extension and $5M of Owner’s 

costs. AFUDC and escalation were not included. 

SCR Option 2010 Cost Estimate Previous Cost Estimate

 Unit 1 $155M $198M

 Unit 2 $210M $267M

 Unit 3 & Common $191M $198M

 Total $556M $663M

SCR and Baghouse Option 2010 Cost Estimate Previous Cost Estimate

 Unit 1 $381M $318M

 Unit 2 $420M $402M

 Unit 3 & Common $356M $303M

 Total $1,157M $1,023M

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• Notable Differences Between 2010 & Previous Cost Estimates

General

9 Current 2010 cost estimate is significantly more detailed

9 Previous estimates had distributed the costs of site common items (e.g. ammonia storage, etc) among all 

units. Current estimate has these common costs grouped with Unit 3

SCR Option

9 Previous Estimates:

- were based on identical layouts for Unit 1 & 3 SCRs ..........different arrangements for U1 & U3

- included new ID booster fans...ID fan upgrade, new booster fans not required for SCR only option

- included upgrades to electrical aux power system ...............not required for NGS SCR only option

9 Current Estimate:

- includes demolition and relocation of existing maintenance shop for Unit 3

SCR and Baghouse Option

9 Previous Estimates:

- were based on identical layouts for Unit 1 & 3 SCRs ..........different arrangements for U1 & U3

- included upgrades to electrical aux power system ...............not required for NGS SCR only option

9 Current Estimate:

- U1: Incl. relocation of existing utilities, elevated baghouse, and longer duct runs due to water 

treatment area

- U2: Stacked baghouse, electrical cable relocation, and complex ductwork

- U3 & Common: Longer duct runs compared to previous estimates and aux. power upgrades

Cost Estimate Arvind Patel – S&L
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Cost Estimate Arvind Patel – S&L

Predicted Aux. Power Consumption

(per Unit) 

SCR + BAGHOUSE TOTAL 10.8 MW

SCR TOTAL 5.1 MW

Baghouse Loads 0.5 MW

Existing Induced Draft Fan Modification (decrease BHP) and New ID Booster Fan 10.0 MW

Anhydrous Ammonia Storage and Transfer 0.1 MW

SCR + Baghouse SCR and Sorbent Injection System, 0.2 MW

Appx. Cost / Year:

$3.83M per Unit

(90% capacity factor & 

$45 / MW-hr)

Anhydrous Ammonia Storage and Transfer 0.1 MW

SCR Only Existing four (4) Induced Draft Fan Modification (increase BHP) 5.0 MW

Appx. Cost / Year:

$1.81M per Unit

(90% capacity factor & 

$45 / MW-hr)

Option Auxiliary Power User Unit Basis

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Cost Estimate

Questions?
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NATIONAL PARK SERVICE INPUT NATIONAL PARK SERVICE INPUT

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National Park Service Meeting

• SRP, S&L, & FWC met with NPS on 5/19/2010

9 Attendees from NPS: John Vimont, John Bunyak, Pat Brewer, Don Shepherd

• NPS questioned the use of AFUDC

9 Clarification received from US EPA/OAQPS/HEID/ABCG indicates that AFUDC can be 

used for regulated utilities that include AFUDC in the rate base

• SRP questioned the use of the Pollution Control Cost Manual

9 Manual indicates it should only be used for units between 25MW and 600MW

9 NPS agreed that it could not be relied upon for accurate actual costs but it might be able to 

provide consistent comparisons to other projects

• NPS acknowledged that the cost estimate was comprehensive and based on a 

sound methodology.

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National Park Service – BART Related Issues

• NPS recommended use of expected actual emission rates in determining cost 

effectiveness

• NPS questioned SCR outlet NOx values; why not < 0.08 lb/MMBTU? 

9 Discussed differences between guaranteed, design, and permit values,

9 Conceptual design minimizes both SO3 generation and ammonia slip 

9 Lower rates may be achieved w/increase in particulate; could trigger NSR/PSD 

9 Increased operating costs (fan power, catalyst, ammonia, etc.) 

• NPS and SRP agreed that PSD permitting requirements need resolution to 

ensure the BART rulemaking considers all capital costs for implementing 

BART

• NPS questioned if baghouse required for mercury MACT

9 Current control strategy is use of calcium bromide fuel additive

9 Additional control may be required based on final MACT determination

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NPS Input

Questions?
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CLOSING Kevin Wanttaja - SRP

• General discussion Q&A

• Path forward and action items

• Submit final cost estimate report to EPA 

August 06, 2010

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THANK YOU
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SUPPLEMENTAL INFORMATION SUPPLEMENTAL INFORMATION

•• Conceptual Design Description Conceptual Design Description Conceptual Design Description –– BOP Systems BOP Systems

•• Conceptual Design Description Conceptual Design Description Conceptual Design Description –– Electrical Systems Electrical Systems

•• Schedule Requirements Schedule Requirements

•• Cost Estimate Details & Expected Cash Flows Cost Estimate Details & Expected Cash Flows

•• Expected Operating & Maintenance Costs Expected Operating & Maintenance Costs

•• 33--D Model Views D Model Views

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Conceptual Design Description Conceptual Design Description

Mechanical Balance of Plant (BOP) Systems Mechanical Balance of Plant (BOP) Systems
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• Flue Gas System – SCR Option

9 Ducts

• SCR Reactors located downstream of existing HESP and upstream of

existing Air Heater

• Units 1 and 3 ducts routed to SCR Reactors on one side of the unit; 

north for Unit 1 and south for Unit 3 

• Unit 2 SCR Reactors separated, one duct on each side (north and south); 

separate duct trains run to each SCR system.

• Flue gas velocities generally maintained to 60 ft/sec

• Economizer inlet flue gas side bypass

9 Fans

• Existing (4 x 25%) centrifugal ID Fan rotating assembly (impeller, 

rotor, bearings) replaced to support SCR Reactor installation

• Replacement impeller with tipped blades resulting in performance

increase: 7.5% flow, 15% pressure, 27.5% brake horsepower

• Preliminary calculations show existing 8,000 HP fan motors suitable for 

rotating assembly replacement

• Air Heater evaluation

Conceptual Design Description - BOP Systems

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• Flue Gas System – SCR and Baghouse Option

9 Ducts

• Ducting to SCRs equivalent to SCR Option

• Baghouse located downstream of existing HESP / new SCR and 

upstream of existing Scrubber

• Units 1 and 3 ducts routed to Baghouse along one side of unit, north for 

Unit 1 and south for Unit 3

• Unit 2 ducting unique due to site constraints and new Axial ID Fan 

location 

• Economizer inlet flue gas side bypass

9 Fans

• Existing centrifugal ID fans remain in operation without modifications

• New 2 x 50% Axial ID Booster Fans & Motors; including lube and 

hydraulic systems

• New Axial ID Fans located downstream of Baghouse

• New duct dampers (w/seal air) for fan isolation 

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• Sorbent Injection System 

9 SCR and Baghouse Option

• Sodium based product, such as trona, utilized as the dry sorbent

• Sorbent delivered to one of three 7-day storage silos located near 

each unit’s injection point. 

• Sorbent pneumatically conveyed from silo to duct via 2 x 100% 

blowers located at each storage silo.

• Injection point located upstream of air heaters.

• Dry product will be collected in new baghouse

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• SCR Reactor

9 2 x 50% SCR reactors required per unit 

9 Four catalyst layer design (2 operating and 2 spare) utilizing 

ultra-low SO2-to-SO3 conversion catalyst.

• Anhydrous Ammonia Delivery & Storage

9 Anhydrous ammonia chosen as the reagent for the SCR 

system. 

9 Anhydrous ammonia delivered via truck to a common 

unloading area located south of Unit 3 

9 Storage will be in one of three bullet-type storage tanks, sized 

for 14 days of continuous operation

Conceptual Design Description - BOP Systems

MSK-3003-02.pdf

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• Anhydrous Ammonia Transfer

9 4 x 33% pump arrangement at common unloading area 

9 Transfer piping constructed of double walled pipe utilizing 

leak detection cable 

• Anhydrous Ammonia Vaporization and Injection

9 Two vaporizer skids provided per unit. 

9 1,500 lbs/hr of low pressure steam required per skid

9 2 x 100% dilution air blowers (with heaters) per skid to 

convey ammonia gas to injection point

9 Steam used for vaporization will be discharged to local 

condensate storage tank and admitted to the FGD Process for 

reuse 

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• Baghouse

9 Gross air-to-cloth ratio designed to be 6:1

9 Two casings required per unit; eight compartments per 

casing

9 2 x 100% pulse jet air compressor systems for bag cleaning.

9 Internal bypass and dampers provided to protect the bags 

from flue gas temperature excursions greater than 375oF

9 PPS fabric bags

• Waste Collection

9 Baghouse waste transported from each compartment to a 7-

day storage silo (1 per unit)

9 Unit 1 will utilize 2 x 100% pneumatic blowers

9 Units 2 & 3 will utilize 3 x 50% pneumatic blowers

9 Wastes transported via truck to plant landfill

Conceptual Design Description - BOP Systems

MSK-3006-01.pdf
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• General

9 Service Water System

• Service water utilized for wash down hose stations

• Service water utilized as the cooling medium for new pulse jet 

compressors; cooling water collected and admitted to the FGD 

process

9 Fire Protection System

• Fire hydrants located within 50 feet of new structures

• Fire water extended to ammonia storage/transfer area for leak 

suppression

• Deluge system for new Unit Auxiliary Transformers

• Baghouse designed with polyphenylene sulfide (PPS) fabric bags; 

fire water standpipe in penthouse for use during outages 

9 Potable Water System

• Emergency eyewash/shower stations located at new structures; 

ammonia storage, sorbent injection and waste collection areas

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9 Compressed Air

• Compressed air demand for SCR Option minimal and supported 

from existing plant compressed air system

• High volume compressed air demand for Pulse Jet cleaning

– 2 x 100% compressor train

» Oil free, centrifugal compressors

» 2 x 100% regenerative dryer skid w/pre-filters and after filters

» 2 x 100% Air receivers (wet/dry)

– Compressed air system would provide air to all new SCR/Baghouse 

users (valves, instruments, tools, etc.)

Conceptual Design Description - BOP Systems

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Conceptual Design Description Conceptual Design Description

Electrical Systems Electrical Systems

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• Basic Electrical System – SCR Option

9 Utilization of existing ID fan motors

• Existing motors have sufficient capacity to overcome the 

additional pressure drop due to SCR addition.

9 System Loads

• SCR System

• Sorbent Injection System

• Anhydrous Ammonia Transfer System

9 Electrical System Additions

• Refer to ESK-1000 Sht. 1.

• Refer to general arrangement on MSK-1000

Conceptual Design Description - Electrical
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• Basic Electrical System – SCR & Baghouse Option

9 New ID Booster Fans requirements can not be supported from 

existing auxiliary power system

• New UAT per each unit is required.

• New 13.8-kV Station Service bus is required to distribute power 

to all 3 units for startup and shutdown.

• PDC buildings required to house electrical equipment.

9 System Loads

• SCR System

• Sorbent Injection System

• ID Booster Fans

• Baghouse System

• Anhydrous Ammonia Transfer System

9 Elect. System Additions at 13.8-kV, 4.16-kV and 480-V levels

• Refer to one-lines on ESK-1001 Sht. 1, 2, 3.

• Refer to general arrangement on MSK-1001.

Conceptual Design Description - Electrical
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• Auxiliary Power System Equipment – SCR Option

9 Major Equipment

• Two (2) new 4160/480V Unit Substation Transformers (USTs) 

per unit, fed from existing FGD 4.16-kV Switchgear.

• 480-V switchgears and motor control centers (MCCs) per unit.

• 480-V MCCs for common loads 

• Refer to one-lines on ESK-1000 Sht. 1.

9 Equipment Location

• PDC

• Existing Pump Building.

• Refer to general arrangement on MSK-1000

Conceptual Design Description - Electrical
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• Auxiliary Power System Equipment - SCR & Baghouse Option

9 Major Equipment

• One (1) three-winding unit auxiliary transformer (UAT) per unit.

• Two (2) 13.8-kV switchgears per unit.

• Two (2) 13.8-kV common switchgears for startup and shutdown.

• Two (2) 4.16-kV FGD switchgear extensions per unit

• Two (2) new 4.16/0.48-kV Unit Substation Transformers (USTs) per 

unit, fed from new 4.16-kV FGD switchgear extensions.

• 480-V switchgears and motor control centers (MCCs) per unit.

• 480-V MCCs for common loads 

• Refer to one-lines on ESK-1001 Sht. 1, 2, 3.

9 Equipment Location

• PDC

• Existing Pump Building.

• Refer to general arrangement on MSK-1001.

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• DC Power Supply System

9 Power for uninterruptible power supply

9 Control power for switchgear

9 ID booster fan DC pumps.

• Uninterruptible AC Power Supply

9 Uninterruptible power to DCS and other critical loads

• Electrical Control and Protection

9 Protective relaying systems will be designed to protect all 

electrical equipment in the auxiliary power system

9 Protective relay system will be coordinated and will remove and 

alarm abnormal operating conditions as well as limit damage to 

faulted or overloaded equipment

• Communication System

9 Extend existing plant communication systems (paging system, fire

alarm system, telephone system, etc.), to the new facilities.

Conceptual Design Description - Electrical
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• Other Systems Considered

9 Lighting and Maintenance Power System

9 Grounding System

9 Lightning Protection System

9 Cathodic Protection System

9 Freeze Protection System

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• Electrical Relocation – SCR Option

9 U/G construction work will affect the cathodic protection system.

9 Two precipitator transformers will be relocated from existing platform 

between Unit 1 and Unit 2 to area under precipitator, to allow for the 

demolishing of the platform.

• Electrical Relocation – SCR & Baghouse Option

9 U/G construction work will affect the cathodic protection system. 

9 Pipes relocated from U/G to A/G will require heat tracing.

9 Cables along the pipe rack north of Unit 1 will be relocated to allow for the 

relocation of the pipe rack to the north side of the road.

9 Two precipitator transformers will be relocated from existing platform 

between Unit 1 and Unit 2 to area under precipitator, to allow for the 

demolishing of the platform.

9 The cable tray and cables running along side the existing tool room between 

Unit 1 and Unit 2 precipitators will be relocated to allow for the demolition 

of the tool room and installation of the new baghouses. These cables would 

be relocated around the new baghouse by installing termination panels at the 

points where the cable need to be rerouted.

Conceptual Design Description - Electrical

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Schedule Schedule

Requirements Requirements

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SCR Option - Critical Path

Complete Pre-Outage Construction 39

Complete Major Tie In Outage 42

Award E-GWC 30

Release E-GWC Design Package for Bid 26

Initial Ductwork Delivered Onsite 26

Award M-GWC 24

Release M-GWC Design Package for Bid 21

Award Foundations Contract 22

Release Foundation Design Package for Bid 19

Award Structural Steel Package 20

Bid Issue Structural Steel 17

Receive Final Flow Model Report 16

Award Catalyst Contract 10

Bid Issue Catalyst Specification 7

Months After Notice to 

Proceed

Activity

SCR Option Level 1 Schedule 

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SCR and Baghouse Option - Critical Path

Complete Pre-Outage Construction 44

Complete Major Tie In Outage 48

Award E-GWC 33

Release E-GWC Design Package for Bid 30

Initial Ductwork Delivered Onsite 31

Award M-GWC 30

Release M-GWC Design Package for Bid 26

Award Foundations Contract 28

Release Foundation Design Package for Bid 24

Award Structural Steel Package 27

Bid Issue Structural Steel 24

Receive Final Flow Model Report 16

Award Catalyst Contract 10

Bid Issue Catalyst Specification 7

Months After Notice to 

Proceed

Activity

SCR and Baghouse Level 1 Schedule

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Cost Estimate Details Cost Estimate Details Cost Estimate Details 

&&

Expected Cash Flows Expected Cash Flows

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• Cost Estimate Details

9 Cost estimate based on budgetary quotes for major equipment (see table below). 

9 Balance of plant equipment and materials have been estimated based on S&L in-house cost data.

9 Construction costs developed by Foster Wheeler, including installation manhour rates of equipment 

and commodities, craft crew mixes & rates, and productivity factors.

9 Craft wage rates are based on open shop labor, to be recruited primarily from the existing local 

labor pool and supplemented by travelers as required. 

9 Contracting strategy is based on multiple lump sum contracts, administered by the owner.

Capital Cost Estimate

Description Bids 

Solicited

Quotes 

Received

Pricing Used in 

Estimate

Unit of Measure

Ammonia System 2 1 $2.94M per site

Catalyst 5 2 $6,250 per m3

Dry Sorbent Injection 3 2 $1.20M per unit

ID Fan Rotor Replacement 1 1 $535K per fan

ID Booster Fans 1 1 $2.25M per fan

Baghouse 3 3 $8.30M per baghouse

Unit Auxiliary Transformers 3 3 $870K per transformer

Air Compressor 1 1 $320K per A/C pkg
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Cost Estimate

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Cost Estimate
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Expected Operating Expected Operating

&&

Maintenance Costs Maintenance Costs

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Operational & Maintenance Costs – For Reference

Back to Conceptual Design Description – Cost Estimate Summary

Variable O&M Unit Cost SCR Only SCR and Baghouse

Ammonia $475/ton 1,035,000 $ 1,035,000 $ 

Catalyst Replacement $8,000/m3 672,000 $ 672,000 $ 

Auxiliary Power $45/MW-hr 1,880,000 $ 3,832,000 $ 

Steam $5/mmBtu 71,000 $ 71,000 $ 

Sorbent (Hydrated Lime) $200/ton - $ - $ 

Sorbent (Trona) $125/ton - $ 71,000 $ 

Waste Disposal $50/ton 104,000 $ 146,000 $ 

Bag Replacement $100/ton - $ 450,000 $ 

Cage Replacement $30/ton - $ 45,000 $ 

Total Variable O&M* $/year 3,762,000 $ 6,322,000 $ 

Fixed O&M SCR Only SCR and Baghouse

Maintenance Material $/year 237,000 $ 402,000 $ 

Maintenance Labor $/year 158,000 $ 268,000 $ 

Total Fixed O&M $/year 395,000 $ 670,000 $ 

Total O&M Cost* $/year 4,157,000 $ 6,992,000 $ 

* Based on 90% Capacity Factor
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3D Model Views 3D Model Views

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-- SCR Only Option SCR Only Option SCR Only Option --
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-- SCR and Baghouse Option SCR and Baghouse Option SCR and Baghouse Option --
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