DRY FGD AND ID FAN & AUXILIARY POWER 

CONCEPTUAL DESIGN COSTS 

CONCEPTUAL COST ESTIMATE 

PREPARED FOR 

NEBRASKA PUBLIC POWER DISTRICT 

GERALD GENTLEMAN STATION, UNITS 1&2 

Project No. 12194-001 

February 7, 2008 
Nebraska Public Power District 

General Gentleman Station, Units 1&2 

 Project No. 12194-001 

2/7/2008 

Table of Contents

 

BART Revised Capital and O&M Costs 

 ProForma 

Basis of Estimate 

Technical Basis 

Estimate Summary 

Estimates by Area: 

- Unit 1 Spray Dryer Absorber Area (Estimate No. 22993B) 

- Unit 2 Spray Dryer Absorber Area (Estimate No. 22999B) 

- Units 1&2 Common (Estimate No. 22994B) 

- Auxiliary Power and Booster ID Fans (Estimate No. 22998B) 

General Arrangement of Dry FGD 

Color 3-D General Arrangement of Dry FGD (New Equipment in Teal)
Spray Dryer Absorber

Capital and O&M Costs

GGS Unit 1 GGS Unit 2 Common Facilities Auxiliary Power/ID Fans TOTAL STATION

Capital Costs

Spray Dryer Absorber Area 48,377,000 $ 48,377,000 $ - $ - $ 96,754,000 $ 

Civil/SiteWork 2,457,000 $ 2,530,000 $ - $ - $ 4,987,000 $ 

Flue Gas System/Ductwork 48,404,000 $ 49,824,000 $ - $ - $ 98,228,000 $ 

Baghouse Modifications 13,284,000 $ 13,284,000 $ - $ - $ 26,568,000 $ 

Reagent Preparation System - $ - $ 19,671,000 $ - $ 19,671,000 $ 

Waste Recycle System - $ - $ 12,518,000 $ - $ 12,518,000 $ 

Common Structures/Buildings - $ - $ 14,616,000 $ - $ 14,616,000 $ 

Reagent Handling System - $ - $ 16,284,000 $ - $ 16,284,000 $ 

Fly Ash Handling Modifications - $ - $ 21,529,000 $ - $ 21,529,000 $ 

Track Ladders and Switches - $ - $ 2,604,000 $ - $ 2,604,000 $ 

Miscellaneous Mechanical Items 2,764,000 $ 2,391,000 $ 3,557,000 $ - $ 8,712,000 $ 

Pipe Rack - $ - $ 6,570,000 $ - $ 6,570,000 $ 

Booster Fans - $ - $ - $ 13,006,000 $ 13,006,000 $ 

Instrumentation and Controls - $ - $ 3,513,000 $ - $ 3,513,000 $ 

Electrical Modifications - $ - $ - $ 25,816,000 $ 25,816,000 $ 

Mobilization/Demobilization - 1% of Labor 636,000 $ 646,000 $ 462,000 $ 146,000 $ 1,890,000 $ 

Cost Due to Overtime - 5-10's 8,540,000 $ 8,673,000 $ 6,196,000 $ 1,959,000 $ 25,368,000 $ 

Per Diem 7,921,000 $ 7,880,000 $ 7,109,000 $ 2,746,000 $ 25,656,000 $ 

Spare Parts - 3% of Equipment 801,000 $ 801,000 $ 1,064,000 $ 596,000 $ 3,262,000 $ 

Freight 1,248,000 $ 1,255,000 $ 961,000 $ 1,242,000 $ 4,706,000 $ 

General & Administration - 5% of Material and Labor 4,857,000 $ 4,919,000 $ 3,579,000 $ 1,046,000 $ 14,401,000 $ 

Profit - 10% of Material and Labor 9,713,000 $ 9,838,000 $ 7,159,000 $ 2,091,000 $ 28,801,000 $ 

EPC Fee - 20% of Total Cost 29,800,000 $ 30,084,000 $ 30,754,000 $ 9,729,000 $ 100,367,000 $ 

Subtotal $ 180,502,000 178,802,000 $ 158,146,000 $ 58,377,000 $ 575,827,000 $ 

Other Costs

Indirect 3,573,000 $ 3,610,000 $ 39,101,000 $ 1,168,000 $ 47,452,000 $ 

Escalation 33,071,000 $ 35,590,000 $ 40,232,000 $ 11,556,000 $ 120,449,000 $ 

Sales/Use Tax 3,160,000 $ 3,169,000 $ 3,278,000 $ 1,470,000 $ 11,077,000 $ 

Contingency 43,089,000 $ 43,940,000 $ 47,496,000 $ 14,220,000 $ 148,745,000 $ 

AFUDC 21,889,000 $ 25,989,000 $ 26,973,000 $ 8,451,000 $ 83,302,000 $ 

Subtotal $ 112,298,000 104,782,000 $ 157,080,000 $ 36,865,000 $ 411,025,000 $ 

Total Capital Cost $ 292,800,000 283,584,000 $ 315,226,000 $ 95,242,000 $ 986,852,000 $ 

Levelized Capital Cost -- -- -- -- 80,875,000 $ 

Total Capital Cost (w/ fan sized for FGD only) -- -- -- 89,982,000 $ 981,592,000 $ 

Levelized Capital Cost (w/ fan sized for FGD only) -- -- -- -- 80,013,000 $ 

O&M Costs

Levelized Fixed O&M -- -- -- -- 7,812,000 $ 

Levelized Variable O&M -- -- -- -- 19,994,000 $ 

Levelized O&M Cost -- -- -- -- 27,806,000 $ 

Levelized Outage Cost -- -- -- -- 698,000 $ 

Total Levelized Capital, Outage and O&M Cost -- -- -- -- 108,517,000 $ 
Pro Forma FInancial Model NPPD Multi-Pollutant Removal StudyRevenue Requirement Determination

Analysis Year 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Calendar Year 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032Discount factor 0.9501 0.9027 0.8577 0.8149 0.7743 0.7356 0.6989 0.6641 0.6310 0.5995 0.5696 0.5412 0.5142 0.4885 0.4642 0.4410 0.4190 0.3981 0.3783 0.3594Capacity factor 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00%Energy production, GWh (with NPV) 56,866 4,660 4,660 4,660 4,660 4,660 4,660 4,660 4,660 4,660 4,660 4,660 4,660 4,660 4,660 4,660 4,660 4,660 4,660 4,660 4,660Available SOX allowances, tons 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977SOX allowance surrender rate 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00Equivalent available SOX allowances, tons 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977Equivalent SOX allowances used, tons (i.e., emissions) (2,128) (2,128) (2,128) (2,128) (2,128) (2,128) (2,128) (2,128) (2,128) (2,128) (2,128) (2,128) (2,128) (2,128) (2,128) (2,128) (2,128) (2,128) (2,128) (2,128)Equivalent SOX allowances sold(+)/bought(-) 12,849 12,849 12,849 12,849 12,849 12,849 12,849 12,849 12,849 12,849 12,849 12,849 12,849 12,849 12,849 12,849 12,849 12,849 12,849 12,849Tons SOX removed 40,426 40,426 40,426 40,426 40,426 40,426 40,426 40,426 40,426 40,426 40,426 40,426 40,426 40,426 40,426 40,426 40,426 40,426 40,426 40,426Available Hg allowances, oz. 2,984 2,984 3,047 3,047 3,047 3,047 3,047 1,201 1,201 1,201 1,201 1,201 1,201 1,201 1,201 1,201 1,201 1,201 1,201 1,201Hg allowance surrender rate 1.0000 1.0000 1.0000 1.0000 1.0000 1.0000 1.0000 2.5305 2.5305 2.5305 2.5305 2.5305 2.5305 2.5305 2.5305 2.5305 2.5305 2.5305 2.5305 2.5305Equivalent available Hg allowances, oz. 2,984 2,984 3,047 3,047 3,047 3,047 3,047 475 475 475 475 475 475 475 475 475 475 475 475 475Hg allowances used, oz. (i.e., emissions) (10,549) (10,549) (10,549) (10,549) (10,549) (10,549) (10,549) (10,549) (10,549) (10,549) (10,549) (10,549) (10,549) (10,549) (10,549) (10,549) (10,549) (10,549) (10,549) (10,549)Hg allowances sold(+)/bought(-) (4,580) (4,580) (4,454) (4,454) (4,454) (4,454) (4,454) (8,871) (8,871) (8,871) (8,871) (8,871) (8,871) (8,871) (8,871) (8,871) (8,871) (8,871) (8,871) (8,871)Ounces Hg removed 00000000000000000000Tons NOX removed 00000000000000000000Tons particulates removed 00000000000000000000SOX allowance cost, $/ton (escalated values) $337 $357 $265 $282 $299 $317 $333 $351 $368 $387 $407 $428 $450 $450 $450 $450 $450 $450 $450 $450Hg allowance cost, $/oz.(escalated values) $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Control system operating period masks

SOX 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Hg 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20NOX 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Particulates 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Fixed charge rates

SOX 10.25% 9.99% 9.73% 9.46% 9.20% 8.94% 8.68% 8.41% 8.15% 7.89% 7.63% 7.36% 7.10% 6.84% 6.58% 6.31% 6.05% 5.79% 5.53% 5.26%

Hg 10.25% 9.99% 9.73% 9.46% 9.20% 8.94% 8.68% 8.41% 8.15% 7.89% 7.63% 7.36% 7.10% 6.84% 6.58% 6.31% 6.05% 5.79% 5.53% 5.26%NOX 10.25% 9.99% 9.73% 9.46% 9.20% 8.94% 8.68% 8.41% 8.15% 7.89% 7.63% 7.36% 7.10% 6.84% 6.58% 6.31% 6.05% 5.79% 5.53% 5.26%Particulates 10.25% 9.99% 9.73% 9.46% 9.20% 8.94% 8.68% 8.41% 8.15% 7.89% 7.63% 7.36% 7.10% 6.84% 6.58% 6.31% 6.05% 5.79% 5.53% 5.26%

Total

Fixed charges on investment, $1000s NPV RR Levelized

SOX $483,558 $39,629 $49,565 $48,295 $47,026 $45,757 $44,487 $43,218 $41,949 $40,679 $39,410 $38,141 $36,871 $35,602 $34,333 $33,063 $31,794 $30,525 $29,255 $27,986 $26,717 $25,447

Hg $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0NOX $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Particulates $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0

Total $483,558 $39,629 $49,565 $48,295 $47,026 $45,757 $44,487 $43,218 $41,949 $40,679 $39,410 $38,141 $36,871 $35,602 $34,333 $33,063 $31,794 $30,525 $29,255 $27,986 $26,717 $25,447

Extended outage purch power, $1000s

SOX $4,152 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340Hg $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0NOX $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Particulates $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0

Total $4,152 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340

Fixed O&M expense, $1000s

For SOX control:

Maintenance (labor + mat'l) $35,519 $2,911 $2,376 $2,435 $2,496 $2,559 $2,623 $2,688 $2,755 $2,824 $2,895 $2,967 $3,041 $3,117 $3,195 $3,275 $3,357 $3,441 $3,527 $3,615 $3,706 $3,798

Operating labor $12,141 $995 $812 $832 $853 $875 $896 $919 $942 $965 $990 $1,014 $1,040 $1,066 $1,092 $1,120 $1,148 $1,176 $1,206 $1,236 $1,267 $1,298

For Hg control:

Maintenance (labor + mat'l) $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Operating labor $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0

For NOX control:

Maintenance (labor + mat'l) $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Operating labor $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Total fixed O&M cost $47,660 $3,906 $3,188 $3,268 $3,349 $3,433 $3,519 $3,607 $3,697 $3,790 $3,884 $3,981 $4,081 $4,183 $4,288 $4,395 $4,505 $4,617 $4,733 $4,851 $4,972 $5,097

Variable O&M expense, $1000s

For SOX control:

Limestone $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Lime (90% available CaO) $89,268 $7,316 $5,971 $6,121 $6,274 $6,431 $6,591 $6,756 $6,925 $7,098 $7,276 $7,457 $7,644 $7,835 $8,031 $8,232 $8,437 $8,648 $8,865 $9,086 $9,313 $9,546

Dibasic acid $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Water for SOX removal $5,889 $483 $394 $404 $414 $424 $435 $446 $457 $468 $480 $492 $504 $517 $530 $543 $557 $570 $585 $599 $614 $630SO3 reduction agent (Na2CO3) $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0

Solid waste sales revenue $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Solid waste landfill cost $19,772 $1,620 $1,323 $1,356 $1,390 $1,424 $1,460 $1,496 $1,534 $1,572 $1,611 $1,652 $1,693 $1,735 $1,779 $1,823 $1,869 $1,915 $1,963 $2,012 $2,063 $2,114

Gypsum sales revenue $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Gypsum landfill cost $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Purchases (+) or sales (-) of allowances ($58,026) ($4,755) ($4,330) ($4,587) ($3,405) ($3,623) ($3,842) ($4,073) ($4,279) ($4,510) ($4,729) ($4,973) ($5,230) ($5,499) ($5,782) ($5,782) ($5,782) ($5,782) ($5,782) ($5,782) ($5,782) ($5,782)Aux. power, energy charge $57,519 $4,714 $3,848 $3,944 $4,042 $4,143 $4,247 $4,353 $4,462 $4,574 $4,688 $4,805 $4,925 $5,048 $5,175 $5,304 $5,437 $5,572 $5,712 $5,855 $6,001 $6,151Aux. power, capacity charge $6,616 $542 $443 $454 $465 $477 $489 $501 $513 $526 $539 $553 $567 $581 $595 $610 $625 $641 $657 $673 $690 $708

For Hg control:

Powdered activated carbon $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Brominated activated carbon $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Fuel additive $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Purchases (+) or sales (-) of allowances $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Aux. power, energy charge $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Aux. power, capacity charge $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0

For NOX control:

Urea $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Catalyst $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Water for NOX removal $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Purchases (+) or sales (-) of allowances $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Aux. power, energy charge $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Aux. power, capacity charge $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0

For particulate control:

Bags $9,084 $744 $0 $0 $0 $0 $3,539 $0 $0 $0 $0 $4,004 $0 $0 $0 $0 $4,530 $0 $0 $0 $0 $5,125Cages $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Flyash sales $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Flyash landfill cost $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Aux. power, energy charge $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Aux. power, capacity charge $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Total variable O&M cost $130,122 $10,664 $7,648 $7,690 $9,179 $9,276 $12,918 $9,479 $9,612 $9,728 $9,866 $13,990 $10,103 $10,217 $10,327 $10,730 $15,672 $11,566 $11,999 $12,444 $12,899 $18,492

Fuel expense, $1000 $0 $0Total revenue requirement, $1000s $661,340 $54,198 $60,401 $59,253 $59,555 $58,465 $60,925 $56,304 $55,258 $54,197 $53,160 $56,112 $51,056 $50,002 $48,947 $48,188 $51,971 $46,707 $45,987 $45,281 $44,588 $49,035

Summary Revenue Requirements NPV RR LevelizedInvestment cost $483,558 $39,629 $49,565 $48,295 $47,026 $45,757 $44,487 $43,218 $41,949 $40,679 $39,410 $38,141 $36,871 $35,602 $34,333 $33,063 $31,794 $30,525 $29,255 $27,986 $26,717 $25,447Extended outage purchased power $4,152 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340 $340Fixed O&M $47,660 $3,906 $3,188 $3,268 $3,349 $3,433 $3,519 $3,607 $3,697 $3,790 $3,884 $3,981 $4,081 $4,183 $4,288 $4,395 $4,505 $4,617 $4,733 $4,851 $4,972 $5,097Variable O&M w/o allowances or aux. pwr. $124,013 $10,163 $7,688 $7,880 $8,077 $8,279 $12,025 $8,698 $8,916 $9,138 $9,367 $13,605 $9,841 $10,087 $10,339 $10,598 $15,393 $11,134 $11,413 $11,698 $11,990 $17,415Auxiliary power, energy charge $57,519 $4,714 $3,848 $3,944 $4,042 $4,143 $4,247 $4,353 $4,462 $4,574 $4,688 $4,805 $4,925 $5,048 $5,175 $5,304 $5,437 $5,572 $5,712 $5,855 $6,001 $6,151Auxiliary power, capacity charge $6,616 $542 $443 $454 $465 $477 $489 $501 $513 $526 $539 $553 $567 $581 $595 $610 $625 $641 $657 $673 $690 $708Allowances ($58,026) ($4,755) ($4,330) ($4,587) ($3,405) ($3,623) ($3,842) ($4,073) ($4,279) ($4,510) ($4,729) ($4,973) ($5,230) ($5,499) ($5,782) ($5,782) ($5,782) ($5,782) ($5,782) ($5,782) ($5,782) ($5,782)Fuel $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Total $665,493 $54,539 $60,741 $59,594 $59,895 $58,806 $61,265 $56,644 $55,598 $54,537 $53,500 $56,452 $51,396 $50,342 $49,287 $48,528 $52,311 $47,048 $46,328 $45,621 $44,929 $49,376

Case 13: Dry FGD0.7% Sulfur Fuel, Unit 1

Base NPPDMultiPol_Rev16-SOXNOX Levelized with Smaller Fan.xls, ProForma Page 1 of 1 
Pro Forma FInancial Model NPPD Multi-Pollutant Removal StudyRevenue Requirement Determination

Analysis Year 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Calendar Year 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032Discount factor 0.9501 0.9027 0.8577 0.8149 0.7743 0.7356 0.6989 0.6641 0.6310 0.5995 0.5696 0.5412 0.5142 0.4885 0.4642 0.4410 0.4190 0.3981 0.3783 0.3594Capacity factor 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00% 80.00%Energy production, GWh (with NPV) 59,859 4,906 4,906 4,906 4,906 4,906 4,906 4,906 4,906 4,906 4,906 4,906 4,906 4,906 4,906 4,906 4,906 4,906 4,906 4,906 4,906Available SOX allowances, tons 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977SOX allowance surrender rate 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00Equivalent available SOX allowances, tons 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977 14,977Equivalent SOX allowances used, tons (i.e., emissions) (2,158) (2,158) (2,158) (2,158) (2,158) (2,158) (2,158) (2,158) (2,158) (2,158) (2,158) (2,158) (2,158) (2,158) (2,158) (2,158) (2,158) (2,158) (2,158) (2,158)Equivalent SOX allowances sold(+)/bought(-) 12,819 12,819 12,819 12,819 12,819 12,819 12,819 12,819 12,819 12,819 12,819 12,819 12,819 12,819 12,819 12,819 12,819 12,819 12,819 12,819Tons SOX removed 41,003 41,003 41,003 41,003 41,003 41,003 41,003 41,003 41,003 41,003 41,003 41,003 41,003 41,003 41,003 41,003 41,003 41,003 41,003 41,003Available Hg allowances, oz. 2,984 2,984 3,047 3,047 3,047 3,047 3,047 1,201 1,201 1,201 1,201 1,201 1,201 1,201 1,201 1,201 1,201 1,201 1,201 1,201Hg allowance surrender rate 1.0000 1.0000 1.0000 1.0000 1.0000 1.0000 1.0000 2.5305 2.5305 2.5305 2.5305 2.5305 2.5305 2.5305 2.5305 2.5305 2.5305 2.5305 2.5305 2.5305Equivalent available Hg allowances, oz. 2,984 2,984 3,047 3,047 3,047 3,047 3,047 475 475 475 475 475 475 475 475 475 475 475 475 475Hg allowances used, oz. (i.e., emissions) (10,699) (10,699) (10,699) (10,699) (10,699) (10,699) (10,699) (10,699) (10,699) (10,699) (10,699) (10,699) (10,699) (10,699) (10,699) (10,699) (10,699) (10,699) (10,699) (10,699)Hg allowances sold(+)/bought(-) (4,730) (4,730) (4,604) (4,604) (4,604) (4,604) (4,604) (9,021) (9,021) (9,021) (9,021) (9,021) (9,021) (9,021) (9,021) (9,021) (9,021) (9,021) (9,021) (9,021)Ounces Hg removed 00000000000000000000Tons NOX removed 00000000000000000000Tons particulates removed 00000000000000000000SOX allowance cost, $/ton (escalated values) $337 $357 $265 $282 $299 $317 $333 $351 $368 $387 $407 $428 $450 $450 $450 $450 $450 $450 $450 $450Hg allowance cost, $/oz.(escalated values) $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Control system operating period masks

SOX 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Hg 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20NOX 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Particulates 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Fixed charge rates

SOX 10.25% 9.99% 9.73% 9.46% 9.20% 8.94% 8.68% 8.41% 8.15% 7.89% 7.63% 7.36% 7.10% 6.84% 6.58% 6.31% 6.05% 5.79% 5.53% 5.26%

Hg 10.25% 9.99% 9.73% 9.46% 9.20% 8.94% 8.68% 8.41% 8.15% 7.89% 7.63% 7.36% 7.10% 6.84% 6.58% 6.31% 6.05% 5.79% 5.53% 5.26%NOX 10.25% 9.99% 9.73% 9.46% 9.20% 8.94% 8.68% 8.41% 8.15% 7.89% 7.63% 7.36% 7.10% 6.84% 6.58% 6.31% 6.05% 5.79% 5.53% 5.26%Particulates 10.25% 9.99% 9.73% 9.46% 9.20% 8.94% 8.68% 8.41% 8.15% 7.89% 7.63% 7.36% 7.10% 6.84% 6.58% 6.31% 6.05% 5.79% 5.53% 5.26%

Total

Fixed charges on investment, $1000s NPV RR Levelized

SOX $492,774 $40,384 $50,509 $49,216 $47,922 $46,629 $45,335 $44,042 $42,748 $41,455 $40,161 $38,868 $37,574 $36,280 $34,987 $33,693 $32,400 $31,106 $29,813 $28,519 $27,226 $25,932

Hg $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0NOX $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Particulates $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0

Total $492,774 $40,384 $50,509 $49,216 $47,922 $46,629 $45,335 $44,042 $42,748 $41,455 $40,161 $38,868 $37,574 $36,280 $34,987 $33,693 $32,400 $31,106 $29,813 $28,519 $27,226 $25,932

Extended outage purch power, $1000s

SOX $4,371 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358Hg $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0NOX $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Particulates $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0

Total $4,371 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358

Fixed O&M expense, $1000s

For SOX control:

Maintenance (labor + mat'l) $35,519 $2,911 $2,376 $2,435 $2,496 $2,559 $2,623 $2,688 $2,755 $2,824 $2,895 $2,967 $3,041 $3,117 $3,195 $3,275 $3,357 $3,441 $3,527 $3,615 $3,706 $3,798

Operating labor $12,141 $995 $812 $832 $853 $875 $896 $919 $942 $965 $990 $1,014 $1,040 $1,066 $1,092 $1,120 $1,148 $1,176 $1,206 $1,236 $1,267 $1,298

For Hg control:

Maintenance (labor + mat'l) $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Operating labor $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0

For NOX control:

Maintenance (labor + mat'l) $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Operating labor $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Total fixed O&M cost $47,660 $3,906 $3,188 $3,268 $3,349 $3,433 $3,519 $3,607 $3,697 $3,790 $3,884 $3,981 $4,081 $4,183 $4,288 $4,395 $4,505 $4,617 $4,733 $4,851 $4,972 $5,097

Variable O&M expense, $1000s

For SOX control:

Limestone $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Lime (90% available CaO) $90,541 $7,420 $6,056 $6,208 $6,363 $6,522 $6,685 $6,852 $7,024 $7,199 $7,379 $7,564 $7,753 $7,947 $8,145 $8,349 $8,558 $8,772 $8,991 $9,216 $9,446 $9,682

Dibasic acid $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Water for SOX removal $6,088 $499 $407 $417 $428 $439 $450 $461 $472 $484 $496 $509 $521 $534 $548 $561 $575 $590 $605 $620 $635 $651SO3 reduction agent (Na2CO3) $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0

Solid waste sales revenue $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Solid waste landfill cost $20,054 $1,643 $1,341 $1,375 $1,409 $1,445 $1,481 $1,518 $1,556 $1,595 $1,634 $1,675 $1,717 $1,760 $1,804 $1,849 $1,895 $1,943 $1,991 $2,041 $2,092 $2,144

Gypsum sales revenue $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Gypsum landfill cost $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Purchases (+) or sales (-) of allowances ($57,890) ($4,744) ($4,320) ($4,576) ($3,397) ($3,615) ($3,833) ($4,064) ($4,269) ($4,499) ($4,717) ($4,961) ($5,217) ($5,487) ($5,769) ($5,769) ($5,769) ($5,769) ($5,769) ($5,769) ($5,769) ($5,769)Aux. power, energy charge $57,519 $4,714 $3,848 $3,944 $4,042 $4,143 $4,247 $4,353 $4,462 $4,574 $4,688 $4,805 $4,925 $5,048 $5,175 $5,304 $5,437 $5,572 $5,712 $5,855 $6,001 $6,151Aux. power, capacity charge $6,616 $542 $443 $454 $465 $477 $489 $501 $513 $526 $539 $553 $567 $581 $595 $610 $625 $641 $657 $673 $690 $708

For Hg control:

Powdered activated carbon $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Brominated activated carbon $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Fuel additive $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Purchases (+) or sales (-) of allowances $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Aux. power, energy charge $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Aux. power, capacity charge $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0

For NOX control:

Urea $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Catalyst $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Water for NOX removal $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Purchases (+) or sales (-) of allowances $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Aux. power, energy charge $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Aux. power, capacity charge $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0

For particulate control:

Bags $9,084 $744 $0 $0 $0 $0 $3,539 $0 $0 $0 $0 $4,004 $0 $0 $0 $0 $4,530 $0 $0 $0 $0 $5,125Cages $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Flyash sales $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Flyash landfill cost $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Aux. power, energy charge $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Aux. power, capacity charge $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Total variable O&M cost $132,013 $10,819 $7,775 $7,821 $9,311 $9,410 $13,057 $9,621 $9,758 $9,878 $10,020 $14,148 $10,266 $10,384 $10,498 $10,905 $15,852 $11,749 $12,187 $12,636 $13,096 $18,693

Fuel expense, $1000 $0 $0Total revenue requirement, $1000s $672,447 $55,109 $61,473 $60,305 $60,582 $59,472 $61,911 $57,270 $56,204 $55,122 $54,065 $56,997 $51,921 $50,847 $49,773 $48,993 $52,756 $47,473 $46,733 $46,006 $45,294 $49,722

Summary Revenue Requirements NPV RR LevelizedInvestment cost $492,774 $40,384 $50,509 $49,216 $47,922 $46,629 $45,335 $44,042 $42,748 $41,455 $40,161 $38,868 $37,574 $36,280 $34,987 $33,693 $32,400 $31,106 $29,813 $28,519 $27,226 $25,932Extended outage purchased power $4,371 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358 $358Fixed O&M $47,660 $3,906 $3,188 $3,268 $3,349 $3,433 $3,519 $3,607 $3,697 $3,790 $3,884 $3,981 $4,081 $4,183 $4,288 $4,395 $4,505 $4,617 $4,733 $4,851 $4,972 $5,097Variable O&M w/o allowances or aux. pwr. $125,767 $10,307 $7,805 $8,000 $8,200 $8,405 $12,154 $8,831 $9,052 $9,278 $9,510 $13,751 $9,991 $10,241 $10,497 $10,759 $15,558 $11,304 $11,587 $11,876 $12,173 $17,603Auxiliary power, energy charge $57,519 $4,714 $3,848 $3,944 $4,042 $4,143 $4,247 $4,353 $4,462 $4,574 $4,688 $4,805 $4,925 $5,048 $5,175 $5,304 $5,437 $5,572 $5,712 $5,855 $6,001 $6,151Auxiliary power, capacity charge $6,616 $542 $443 $454 $465 $477 $489 $501 $513 $526 $539 $553 $567 $581 $595 $610 $625 $641 $657 $673 $690 $708Allowances ($57,890) ($4,744) ($4,320) ($4,576) ($3,397) ($3,615) ($3,833) ($4,064) ($4,269) ($4,499) ($4,717) ($4,961) ($5,217) ($5,487) ($5,769) ($5,769) ($5,769) ($5,769) ($5,769) ($5,769) ($5,769) ($5,769)Fuel $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0Total $676,818 $55,467 $61,831 $60,663 $60,941 $59,831 $62,269 $57,628 $56,562 $55,481 $54,423 $57,355 $52,279 $51,205 $50,131 $49,351 $53,114 $47,831 $47,091 $46,364 $45,652 $50,080

Case 14: Dry FGD0.7% Sulfur Fuel, Unit 2

Base NPPDMultiPol_Rev16-SOXNOX Levelized with Smaller Fan.xls, ProForma Page 1 of 1 
Nebraska Public Power District 

General Gentleman Station, Units 1&2 

 Project No. 12194-001 

2/7/2008 

Page 1 of 2 

Basis of Estimate

Scope

This cost is based on installing a spray dryer absorber FGD system on Gerald Gentleman Station, Units 1 & 2. 

Scope includes: 

• Unit 1 Spray Dryer Absorber Area 

• Unit 2 Spray Dryer Absorber Area 

• Units 1&2 Common Areas (Reagent Prep and handling, recycle and waste handling) 

• Auxiliary Power System 

• Booster ID Fans 

Assumptions

1. All work is performed on a 5-day 10-hour workweek. 

2. $10/hour included for per diem. 

3. The following conditions apply: 

• Major design parameters established 

• Major equipment identified 

• Conceptual general arrangement drawings 

• EPC contracting approach for estimate basis 

Commercial Basis

1. Equipment/Material Cost

Based on vendor budgetary quotes, estimated quantities and S&L in-house data base. 

2. Labor Wage Rates

Crew Labor Rates have been developed using the Union Craft rates and fringe benefits from the 

Omaha, Nebraska area. Costs have been added to cover F.I.C.A., workers compensation, all applicable 

taxes, small tools, incidentals, construction equipment and contractor’s overhead. 

3. Labor Crews

The construction/erection labor cost is based on the use of applicable construction crews typically 

required for projects of this type. 

4. Productivity

No allowances have been made to cover items such as the loss in productivity because of inability to 

attract labor, weather conditions, etc. 

5. Quantity Sources

All quantity data was developed internally by S&L Lead Engineers. 

6. Project Schedule

To be determined. 

7. Indirect Expenses

The engineering costs included herein are estimated and are not to be interpreted as a proposal by S&L 

to perform engineering services. 

BOP engineering is included and would be part of the EPC price. Also included, Owner’s A-E 

Engineering, Owner’s Construction Management, General Owner’s Costs and Owner’s Bond Fees. 
Nebraska Public Power District 

General Gentleman Station, Units 1&2 

 Project No. 12194-001 

2/7/2008 

Page 2 of 2 

8. Escalation Rates (See Cost Summary for rates)

Estimated at 5.0% for Equipment, 7.0% for Material, 4.0% for Labor and 6.0% for Indirects. 

9. Sales/Use Taxes (See Cost Summary for rates)

Estimated at 5.50% of Equipment and Material. 

10. Contingency (See Cost Summary for rates)

Estimated at 20% for Equipment, Material, Labor and Indirects. 

11. AFUDC Rate (See Cost Summary for rates)

Estimated at 5.0% from 2009. 

12. Bond Fees (See Cost Summary for rates)

Estimated at 2.5% of $200,000,000. 

13. General Owner’s Cost (See Cost Summary for rates)

Estimated at 2.0% of Total Construction Cost. 
Nebraska Public Power District Project No, 12194-001 

Gerald Gentleman Station Unit 1&2 2/7/2008 

 

Page 1 of 5 

Technical Basis

The following is a summary of the technical basis of the Phase 1 spray dryer absorber 

FGD system capital cost estimate and the Unit 1 and 2 ID Fan and Aux Power system 

capital cost estimate. 

1. Lime Handling common to both Units 

a. Lime rail car unloader 

i. Lime will be brought on site as a 128 car unit train 

ii. The unloading system will unload a car in 1.5 hrs. The station will be 

able to unload in 16-20 working days, using one 12 hour shift 

iii. The system will consist of vacuum pneumatic equipment to unload the 

rail car through the three hoppers. 

iv. Rail car unloading building 

v. Three (3) vacuum systems operate (one per rail car hopper) to unload a 

car in 1.5 hrs 

vi. Blowers 

vii. Dust control using ventilation system and dust collector 

viii. Blower building 

ix. Vendor quote from Chicago Conveyor Corp 

b. Lime storage silo 

i. Concrete Silo 

ii. Two silos, 14 day storage per Unit and capable of storing a unit train 

of lime, 4 days spare capacity, 12,800 tons storage total 

iii. Diameter (60’) and height (145’) to top 

iv. 7,500 ton storage each 

v. Concrete silo with bin vent for dust control 

vi. Two hopper outlet 

vii. Vendor quote from Chicago Conveyor Corp 

c. Lime transfer systems 

i. From silo to lime prep day bins 

ii. Pneumatic, pressurized, two 750 lineal feet of pipe 

iii. Pneumatic transport piping located on an above grade pipe rack 

iv. Vendor quote from Chicago Conveyor Corp 

2. Lime Preparation per Unit 

a. Two (2) ball mill lime slakers at 100% capacity, each with a grit screen, 

gravimetric feeder 

b. Two (2) lime transfer tanks 

c. Two (2) lime slurry storage tanks 

d. Two (2) slurry feed centrifugal pumps 

e. Two(2) slurry transfer centrifugal pumps 

f. Lime day bin 

g. Lime prep building, 60 x 100 x 125 ft 

f. Vendor quote from B&W and Alstom 
Nebraska Public Power District Project No, 12194-001 

Gerald Gentleman Station Unit 1&2 2/7/2008 

 

Page 2 of 5 

3. Absorber Area per Unit 

a. Three (3) absorber vessels per unit, with access doors 

b. Rotary atomizers or dual fluid nozzles, spare atomizer included 

c. Vessel material carbon steel, 1⁄4 in. – 5/8 in. carbon steel 

d. Penthouse enclosure 

e. 6” insulation with lagging 

f. Heating and ventilation 

g. Vacuum piping 

h. Vendor quote from B&W and Alstom 

i. B&W was contacted to determine if two SDA modules could be installed in 

lieu of three. Due to the high gas flow rate, B&W stated that two SDAs 

would not feasible. 

4. Recycle Area per Unit

a. One (1) recycle storage silo 

b. Two (2) recycle mix tanks 

c. Two (2) recycle slurry tanks each with two (2) recycle slurry centrifugal 

pumps per tank 

d. Agitators for each tank 

e. Vendor quote from B&W and Alstom 

5. Baghouse Ash Handling System common to both Units 

a. Modifications of existing pipe and blowers 

b. Addition of two (2) new 3-day storage flyash silos located near track for truck 

or rail loading, 222,730 ft3 of active storage total; 58’ diameter 

c. Addition of two (2) new 4-hour intermediate silos located near the crusher 

building. These are separate from the recycle silos. 

d. Addition of two (2) new pressure conveying systems from the intermediate 

silos to the flyash silos 

e. Silos have damp unloading at silo exit and bin vent filters 

f. Vendor quote from Allen-Sherman-Hoff 

6. Flues including support steel per Unit

a. Air Heater outlet to absorber inlet 

i. Carbon steel, 1⁄4 in. 

ii. Velocity = 4000 to 4500 fpm 

iii. 6” insulation with lagging 

b. Absorber outlet to baghouse inlet 

i. Carbon steel, 1⁄4 in. 

ii. Velocity 4000 fpm 

iii. 6” insulation with lagging 

c. ID Fan outlet to new booster ID fan 

i. Carbon steel, 1⁄4 in. 

ii. 4000 fpm 

iii. 4” insulation with lagging 
Nebraska Public Power District Project No, 12194-001 

Gerald Gentleman Station Unit 1&2 2/7/2008 

 

Page 3 of 5 

d. Flue path reinforcement 

i. Reinforce baghouse outlet header duct 

e. Completion of Unit 2 hot duct including expansion joints and insulation and 

lagging. 

 

7. Control System Modifications per Unit

a. Based on number of I/O points. Approximately 1,004 per Unit including 

SDA’s and reagent prep. The common area will need approx. 2,000 I/O 

points. The dry FGD will have approx. 4,000 I/O points total. 

8. Rail Yard Extension common to both Units

a. Use NPPD’s planned phase 2 additional rail loop to receive a unit train once 

per month 

b. Extend the rail spur to the west to allow the unit train to be unloaded and cars 

to be stored on site. 

c. Add three ladder tracks to hold a unit train (128 cars) 

9. Subsurface and Foundation Work- All

a. Foundation system consists of drilled caissons 

10. Civil Work- All

a. Roads. 

b. White rock surfacing. 

11. Construction Work- All

a. Union labor 

b. Premiums and per diems included 

c. Outage time at two 12 hour shifts, included in the project manhours and 

premium time 

12. Pipe Racks common to both Units 

a. Between lime unloading and lime silo 

b. Between lime silo, reagent prep and fly ash silos 

13. Chimney per Unit

a. Put trowel coating on top 50 ft. of inside of each chimney liner to help with 

condensation 

16. Baghouse Modifications per Unit

a. Reverse the inlet plenum so that the direction of the inlet flow is now from 

the rear of the baghouse 

b. Add hopper heaters at 13 kW per hopper 

c. Relocate the reverse gas duct and platforms 

d. Expect the baghouse to operate at 1-2” w.c. greater pressure drop with dry 

FGD ahead of baghouse 

e. Reinforce the baghouse outlet header, approx. 30 tons 
Nebraska Public Power District Project No, 12194-001 

Gerald Gentleman Station Unit 1&2 2/7/2008 

 

Page 4 of 5 

f. Reinforce baghouse structure for increased pressure drop. 

g. Includes removal and installation of insulation and lagging 

f. Vendor input from Siemens (WAPC) 

17. Demolition and Relocation

a. Demolition of warehouse east of Unit 2 baghouse and addition of new 

warehouse next to GGS main plant warehouse. 

b. Demolition of existing fly ash silos 

c. Demolition of existing four hydrobins 

d. Demolition of existing air heater to baghouse inlet duct would cost approx. 

$1,860,000 per Unit. 

18. CEMS per Unit

 a. No change, use existing CEMS in chimney 

19. Water Treatment common to both Units

a. None included. Water having less than 200 mg/L sulfate content is good and 

less than 500 mg/L is acceptable. Sutherland Reservoir and well water have less 

than 200 mg/L so no treatment is necessary. 

b. An in-line water heater is included because slaking water needs to be 

between 50degF and 90degF to sustain good slaking. 

20. Instrument air compressor and dryer common to both Units 

 a. Air Compressors; 2 x 100%, 250 scfm ea. @ 100 psig 

 b. IA dryers w/filters; 2 x 100%, 250 net scfm ea 

21. Field Painting – All

 a. Multiple coat system used for exposed ductwork only. 

 b. Inorganic zinc primer and polyurethane system used for steel. 

22. Performance Testing- All

 a. Part of Owner’s costs 

23. Construction Support- All

 a. 12 months, 1.5 persons 

24. Piping per Unit

a. Instrument air piping to every silo or day bin, bin vent and reagent 

preparation/recycle area 

b. Heat traced piping 

25. Installation- All

 a. Included 

26. New booster ID fans-All
Nebraska Public Power District Project No, 12194-001 

Gerald Gentleman Station Unit 1&2 2/7/2008 

 

Page 5 of 5 

a. Two 10,000 hp axial ID fans per Unit. Duplicate of the existing ID fans. 

These fans are sized to overcome pressure drop associated with both an SCR and 

FGD. If only one system is installed, the hp and price can be reduced. 

b. Includes foundations and motors. No spare motor is included. 

c. Vendor quote from TLT Babcock. 

27. Electrical-All

 a. One start up transformer. 

 b. Two unit auxiliary transformer. 

 c. Medium voltage switch-gear. 

 d. 480 V switch-gear for reagent prep, recycle, spray dryer absorber and SCR. 

 e. One reagent prep electrical equipment building. 

 f. Two transformer electrical equipment building. 

g. Two main electrical equipment building located north of Unit 1 and south of 

Unit 2 baghouses. 
Nebraska Public Power District

Gerald Gentleman Station Unit 1 & 2 Estimate Summary for Dry FGD 

Equipment Cost 

($ Millions)

Material Cost 

($ Millions)

Labor Cost 

($ Millions)

Erection Labor 

Man-Hours

Total Cost 

($ Millions)

Normalized Cost 

($/kW)

Unit 1 Absorber Area (Estimate No. 229934B)

Direct 27.501 29.947 91.554 728,726 149.002EPC portion 0.000 0.000 29.800 0 29.800Indirect 0.000 0.000 0.000 0 3.573Escalation 0.000 0.000 0.000 0 33.071Sales/Use Tax 0.000 0.000 0.000 0 3.160AFUDC 0.000 0.000 0.000 0 21.889Contingency @ 20% 0.000 0.000 0.000 0 43.089

283.584

Unit 2 Absorber Area (Estimate No. 22999B)

Direct 27.501 30.109 92.808 742,964 150.418EPC portion 0.000 0.000 30.084 0 30.084Indirect 0.000 0.000 0.000 0 3.610Escalation 0.000 0.000 0.000 0 35.590Sales/Use Tax 0.000 0.000 0.000 0 3.169AFUDC 0.000 0.000 0.000 0 25.989Contingency @ 20% 0.000 0.000 0.000 0 43.940

292.800

Unit 1 & 2 Common Area (Estimate No. 22994B)

Direct 36.534 23.074 67.784 653,986 127.392EPC portion 0.000 0.000 30.754 0 30.754Indirect 0.000 0.000 0.000 0 39.101Escalation 0.000 0.000 0.000 0 40.232Sales/Use Tax 0.000 0.000 0.000 0 3.278AFUDC 0.000 0.000 0.000 0 26.973Contingency @ 20% 0.000 0.000 0.000 0 47.496

315.226

Unit 1 & 2 Auxil. Power & ID Fans (Estimate No. 22998B)

Direct 21.495 5.228 21.925 252,640 48.648EPC portion 0.000 0.000 9.729 0 9.729Indirect 0.000 0.000 0.000 0 1.168Escalation 0.000 0.000 0.000 0 11.556Sales/Use Tax 0.000 0.000 0.000 0 1.470AFUDC 0.000 0.000 0.000 0 8.451Contingency @ 20% 0.000 0.000 0.000 0 14.220

95.242

Project Totals

Direct 113.031 88.358 274.071 2,378,316 475.460EPC portion 0.000 0.000 100.367 0 100.367Indirect 0.000 0.000 0.000 0 47.452Escalation 0.000 0.000 0.000 0 120.449Sales/Use Tax 0.000 0.000 0.000 0 11.077AFUDC 0.000 0.000 0.000 0 83.302Contingency @ 20% 0.000 0.000 0.000 0 148.745

"All In" Grand Total with EPC Fee = 986.852 658

Grand Total without EPC Fee = 886.485 591

Price Level = Q4, 2007

Page 1 of 1






















A

REV. DATE REL’D. PREPARED REVIEWED APPROVED PURPOSE

DRAWING RELEASE RECORD

SHEET OF

DRAWING NO. REV.

SCALE

B

C

D

E

F

A

B

C

D

E

F

8 7 6 5 4 3 2 1

8 7 6 5 4 3 2 1

PROJECT

NUMBER

REV. DATE REL’D. PREPARED REVIEWED APPROVED PURPOSE

DRAWING RELEASE RECORD

 POWER DISTRICT 

 NEBRASKA PUBLIC 

 GERALD GENTLEMAN STATION 

 EQUIPMENT PROJECT 

 MULTI-POLLUTANT CONTROL 

 DRY FGD SYSTEM- OPTION 1 

 GENERAL ARRANGEMENT 

MS-DRYFGD01

B 

 1 

12194-001

 

 

 

 

 

CONTRACTOR/INSTALLER SHALL TAKE ALL APPROPRIATE

PRECAUTIONS TO ENSURE THE SAFETY OF ALL PEOPLE

LOCATED ON THE WORK SITE, INCLUDING 

CONTRACTOR’S/INSTALLER’S PERSONNEL 

(OR THAT OF ITS SUBCONTRACTOR(S)) PERFORMING 

THE WORK.

 A 10-08-2007 D.SKOIRCHET D.G.SLOAT -------- 

 B 11-21-2007 D.SKOIRCHET D.G.SLOAT -------- 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FILENAME:MSDRYFGD0101.DGN 

 

 

DESIGN FREEZE 

FOR COMMENTS 

1"=100’ 

1 2

6

7

100’ 0’ 100’ 200’ 300’ 400’

8

9

10

3

3

5

11

12

13

14

15

16 17

18

19 20

21

NORTH

27

28

29

30

31

32

34 35

EXISTING STRUCTURES KEY:

 1. UNIT 1

 2. UNIT 2

 3. PRECIPITATOR (ABANDONED)

 4. CHIMNEY

 5. BAGHOUSE

 6. SERVICE

 7. ADMINISTRATION BUILDING

 8. FUEL OIL PUMP HOUSE

 9. FUEL OIL TANKS

10. HVAC COOLING TOWERS

11. SEWAGE TREATMENT PLANT

12. NEUTRALIZATION BASIN

22

22

26

25

23

24

13. CHEMICAL BUILDING

14. OIL WATER SEPARATOR

15. FLY ASH SILO

16. DEWATERING BIN (ABANDONED)

17. HYDRO BIN (ABANDONED)

18. ASH WATER MAKE-UP TANK (ABANDONED)

19. ASH WATER SURGE TANK

20. ASH WATER SETTLING TANK (ABANDONED)

21. BOTTOM ASH PUMPHOUSE

22. WAREHOUSE

23. WASTE DISPOSAL

24. MOBILE MAINTENANCE

25. BREAK BUILDING

26. TRAINING/SAFETY BUILDING

27. ROTARY COAL CAR DUMPER BUILDING

28. COAL UNLOADING CONVEYORS A-C & B-C

29. TRANSFER BUILDING

30. STACKOUT/RECLAIM BUILDING

31. RECLAIM CONEYORS A-C & B-C

32. CRUSHER BUILDING

33. PLANT CONVEYORS A-C & B-C

34. EMERGENCY RECLAIM HOPPER

35. RECLAIM TRANSFER BUILDING

36. YARD CONVEYOR A-C

36

33

D

A

B

A

B

PLAN

RAIL KEY: 

 EXISTING

 PROPOSED NPPD ADDITIONS

 NEW LIMESTONE UNLOADING

4

4

C

F

C

E

G

H

J

K

K

NEW STRUCTURES KEY:

A. ABSORBER TOWER

B. REAGENT PREPARATION BUILDING

C. DAY SILO

D. LIME RAIL CAR UNLOADING

E. LIME CONVEYOR PIPE RACK

F. LIME STORAGE SILO

G. LIME TRUCK UNLOADING

H. LIME RAIL CAR SIDING

J. FLY ASH SILO (RELOCATED)

K. ELECTRICAL BUILDING

L. WAREHOUSE

M. RESERVE SPACE FOR BOOSTER FAN

N. RESERVE SPACE FOR CO2 RECOVERY SYSTEM

M

M

M

N N

MATCH LINE A-A

MATCH LINE A-A

NOTES:

1. BAGHOUSE INLET PLENUMS REVERSED; INLET 

DUCT CONNECTION MOVED TO EAST SIDE.

2. BAGHOUSE REVERSE AIR DUCTS ON EAST SIDE 

OF BAGHOUSE TO BE RAISED TO PROVIDE CLEARANCE 

FOR NEW DUCTS FROM ABSORBER TOWERS.

3. EXISTING TWO FLY ASH SILOS (ITEM 15) TO BE 

RELOCATED TO THE SOUTH (NEW ITEM J).

4. EXISTING ABANDONED DEWATERING BINS (ITEM 

16) AND HYDRO BINS (ITEM 17) TO BE DEMOLISHED.

5. THE ELEVATED AREA OF THE EXISTING FLY ASH 

SILOS, DEWATERING BINS AND HYDRO BINS AND 

ASSOCIATED APPROACH ROADS TO BE REMOVED.

6. WAREHOUSE EAST OF THE UNIT 2 BAGHOUSE 

DEMOLISHED OR RELOCATED.

7. ROADS IN AREA OF ABORBER TOWERS/REAGENT 

PREPARATION BUILDINGS REWORKED

PARTIAL PLAN

22 22

L

H