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B&V E-2 and E-4 1 

San Juan Generation Station BART Project 

Review and Update of 2007 BART Cost Estimates 

1.0 Introduction 

The purpose of this document is to update the cost estimates for application of 

SCR at the San Juan Generating Station that were performed by B&V in May of 2007 in 

support of PNM’s BART application. The following items were assessed in this update: 

• Impact of escalation on the prices included in the original BART estimate. 

• Impact of auxiliary power limitations at San Juan Generation Station. 

• Impact of changes to the draft system resulting from the addition of the 

consent decree air quality control equipment. 

• Impact of other general changes to the price. 

It should be noted that the potential impact of lead and asbestos abatement on the 

price of SCR upgrades at San Juan was not assessed by B&V. These costs are site 

specific and can not be determined until the project is under construction. 

This document presents a discussion of each impact. The last section of this 

document presents the revised cost estimates that incorporate all impacts to the costs. 

2.0 Price Escalation 

The estimates developed by B&V for the BART project were completed in May 

2007. PNM requested B&V to perform an escalation analysis to update the BART 

estimates from May 2007 to current day dollars (Oct 2010). First, B&V utilized the 

corporate escalation tool for this analysis. The tool was jointly developed by Black & 

Veatch and an outside consulting firm that specializes in financial analysis and 

forecasting. For the purposes of this analysis the costs were grouped into three major 

categories: 

• Materials (steel, pipe, cable, etc.) 

• Equipment (pumps, tanks, switchgear, etc) 

• Labor 
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The resulting price escalation between May 2007 and October 2010 is shown in 

Table 1. It should be noted that the escalation shown is cumulative over the period. 

There were portions of this period where escalation was negative. However, there were 

also periods where escalation was extremely high. 

Table 1 

Escalation Calculation Using 

B&V’s Corporate Escalation Tool 

May 2007 to October 2010 

Cost Item Cumulative Escalation Rate 

Materials 10.0 percent increase 

Equipment 10.0 percent increase 

Labor 9.7 percent increase 

Average 10.0 percent increase 

B&V also compared the values from the corporate escalation tool to values 

available from the United States Bureau of Labor Statistics, “Producer Price Index” and 

the “Employer Cost for Employee Compensation Index”. To do this comparison, B&V 

selected several representative cost categories and checked the index for those categories 

between May 2007 and September 2010 (latest data available). Table 2 is a summary of 

that investigation. The screen shots from the Bureau of Labor Statistics website that form 

the basis for Table 2 have been included for reference in Appendix A of this document. 

The data in Table 1 and Table 2 are relatively comparable. However, since the 

data from the U.S. Bureau of Labor Statistics can be independently verified, B&V has 

utilized the values in Table 2 to escalate the BART estimates for San Juan Generating 

Station. The quantitative impacts to the costs will be presented in Section 5.0. 
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Table 2 

Escalation Calculation Using 

Data from U.S. Bureau of Labor Statistics 

Index Value 

Cost item May 2007 Sept 2007 

Change 

(Escalation) 

Materials 

 Plate Steel 119.2 137.5 15.4 

 Cable 160.8 166.1 3.3 

 Steel Pipe 170.1 195.7 15.0

Average 11.2 

Equipment 

 Pumps 117.9 129.7 10.0 

 Switchgear 179.1 195.2 9.0 

 Tanks 132.6 140.8 6.2

Average 8.4 

Construction Labor 

(see note) $29.48/hr $31.43/hr 6.6 

Note: 

Values for construction labor are in $/hour. The Bureau of Labor Statistics only has data 

available by quarter (1st quarter, 2nd quarter, etc.) and only has data through 2nd quarter of 

2010 (not 3rd quarter 2010). 

3.0 Auxiliary Power 

The original BART estimate included limited costs for upgrades to the auxiliary 

power systems that will be needed to address the increased loads resulting from the 

addition of SCR and associated equipment. The SCR results in additional parasitic load 

at the site due to the additional fan power needed to overcome the pressure drop 

associated with the SCR and to provide additional power for ancillary equipment needed 

to operate the SCR. In the initial 2007 estimate, PNM expected the existing auxiliary 

power to be sufficient. However, now that the consent decree AQC equipment has been 
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installed, B&V has determined that the current auxiliary power system is not sufficient to 

power the additional loads that would result from adding SCR and associated equipment. 

B&V anticipates the following minimum load changes (no balanced draft 

conversion) as a result of the SCR’s: 

• Unit 1 - ID fan increase of 4,400 hp 

• Unit 2 - ID fan increase of 4,400 hp (same as Unit 1) 

• Unit 3 - ID fan increase of 13,000 hp 

• Unit 4 - ID fan increase of 13,000 hp (same as Unit 3) 

• Other aux loads are as 140 kW (each) for Units 1 and 2 and 190 kW (each 

for Units 3 and 4. 

From these minimum auxiliary power requirements, the following assumptions 

were made about the station. These assumptions are based on the information available 

at this time. 

• The existing start-up buses are limited. 

• The startup issues are transformer limitations that require the additional 

power to be fed from the 345 kV switchyard. 

• When motors are started, 85 percent bus undervoltage is acceptable and 80 

percent motor undervoltage is acceptable. 

• Two 3-breaker connection bays can be added to the 345 kV yard. 

• The Units 1 and 2 ID fans will be 6,000 hp, three per unit, at 6.9 kV. 

• The Units 3 and 4 ID fans will be 9,000 hp, three per unit, at 6.9 kV. 

• Two additional bays (to feed the four new transformers) can be added to 

the 345 kV switchyard. 

• Four new transformers will be required because of the new fan sizes. The 

transformers would be sized to power and start across the line fans for 

both sister units. In other words, Units 1 and 2 would be coupled together 

and Units 3 and 4 would be coupled together. 

• There is adequate space near the new ID Fans is available to install new 

switchgear and transformers. 

With these assumptions, the following additional equipment would be needed to 

power the SCR new equipment. The quantities listed are for the entire plant. 
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• Two 345kV bays (includes 6 – 345 kV 3-phase breakers, 16 – 345 kV 3-

phase motorized disconnect switches) 

• Two 40 MVA 345 kV to 6.9 kV transformers (for Units 1 and 2) 

• Two 60 MVA 345 kV to 12.47 kV transformers (for Units 3 and 4) 

• One 6.9 kV Switchgear lineup Main-Tie-Main with 8 feeder breakers, 

3000 A bus for Units 1 and 2. 

• One 12.49kV Switchgear lineup Main-Tie-Main with 8 feeder breakers, 

3000 A bus for Units 3 and 4. 

• Four 480 V single ended secondary unit substations (SUS), with motor 

control center (MCC) sections. 

Figure 1 is a conceptual one-line diagram showing this configuration. The cost 

for this additional equipment is summarized in Table 3. These costs are conceptual, 

based on in-house data. B&V did not obtain outside quotations specifically for this 

project to develop these costs. These costs are included in the overall update of the SCR 

costs that are presented in Section 5.0. 

Table 3 

Presentation of Costs for Auxiliary Electrical Equipment Requirements 

for SCR Systems at San Juan Station 

Equipment Cost Item Estimate Amount 

345 kV Bays $3,500,000

Transformers (for Units 1 and 2) $2,000,000

Transformers (for Units 3 and 4) $3,000,000

6.9 kV Switchgear Line Up (Units 1 and 2) $7,000,000

12.49 kV Switchgear Line Up (Units 3 and 4) $10,000,000

Four Secondary Unit Substations with Motor Control Centers $4,000,000

Total $29,500,000

Amount Attributable to Units 1 and 2 $6,400,000 (each)

Amount Attributable to Units 3 and 4 $8,350,000 (each)
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Figure 1 

Conceptual One-Line Diagram for 

New Auxiliary Electrical Equipment Associated with SCR Systems 

4.0 Assessment of Draft Systems 

Implosion studies were performed for Units 1-4 at SJGS for the implementation 

of the modifications required by the consent decree of 2005, which included the 

installation of new pollution control equipment and new induced draft (ID) booster fans 

(although the furnace continued operation in pressurized mode). These studies modeled 

various transient conditions that could potentially occur during unit operation (including 

upset conditions) and reviewed the corresponding pressures across the furnace and flue 

gas stream. The studies did not consider the effect of operating the booster fans with a 

loss of airside gas path that could occur with air side damper failure. This analysis was 

not required at the time but would be required to be in compliance with the current code. 

This is discussed in more detail below. 

B&V has reviewed the implosion studies and their impact on the original BART 

estimate for the balance draft conversion. The design basis from each implosion study 
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was also validated against current plant operating data. B&V used this design basis 

information as the basis for updated recommendations concerning the draft system. The 

figures in Appendix B show the current draft configuration as well as the draft 

configuration after addition of SCR. 

As a result of the implosion studies, PNM made some physical modifications to 

the boilers and some modifications to the controls during the installation of the new 

control equipment required by the consent decree. These modifications brought Units 1-4 

into compliance with the National Fire Protection Association (NFPA) Code 85 for the 

2004 revision of the code. The following is a summary of the modifications that were 

made to the draft systems as part of the consent decree work: 

• The open stack system upstream of the FGD system was permanently 

closed in conjunction with the fabric filter addition. 

• The boiler penthouse floor (furnace roof) was stiffened with the addition 

of beams. 

• Buckstay clips (connections to furnace walls) were added and cover plates 

were placed over some of the buckstay webs. 

• The inlet ductwork penetration to the ESP was stiffened using internal 

bracing. 

• Based on the stiffening modifications made, the control system was 

programmed to “trip” (shut the unit down) if the pressure in the units 

exceeded a range of -2 / +18 inches wg. 

The following modifications were not made to the draft system: 

• Buckstays were not installed in the corners of the boiler. 

• Trusses were not installed in the windbox. 

At the time of the consent decree work, the NFPA requirements (2004 revision) 

were unclear on how to handle the addition of ID booster fans on units that were still to 

be operated in a pressurized furnace mode. In 2007 the requirements were clarified to 

define that any unit with a fan between the boiler and stack must meet the same 

requirements as a “balanced draft” unit and be stiffened accordingly. This requires that 
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the furnace either be designed for +/- 35 inches or the ratings of the ID/booster fans 

corrected to ambient temperature (whichever is less). The key provisions of the NFPA 

85 code are quoted below: 

Article 1.3.1: The code shall apply to new installations and to major 

alterations or extensions that are contracted for subsequent to the effective 

date of this code. 

 

Article 1.4.1 Unless otherwise specified, the provisions in this code shall 

not apply to facilities equipment, structures, or installations that existed or 

were approved for construction or installation prior to the effective date of 

the code. 

 

Article 4.6.1: The furnace shall be capable of withstanding transient 

design pressures and normal operating pressures without permanent 

deformation due to yield or buckling of any support member. Transient 

pressures to be considered shall include but shall not necessarily be 

limited to misoperation of fans or dampers and a master fuel trip while 

operating at maximum design load.

 

Article 6.5.1.3: Balanced Draft Units. All boilers with a fan located in the 

flue gas path downstream of the boiler enclosure shall be designed in 

accordance with either 6.5.1.3.1 or 6.5.1.3.2. 

 6.5.1.3.1 The furnace and flue gas removal system shall be designed so 

that the maximum head capability of the induced draft fan system with 

ambient air does not exceed the continuous design pressure of furnace, 

ducts, and associated equipment.

 6.5.1.3.2 Where a furnace pressure control system in accordance with 

6.5.2 is provided, the furnace shall be designed for the transient design 

pressures in 6.5.1.3.2.1 and 6.5.1.3.2.2.
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 6.5.1.3.2.1 Positive Transient Design Pressure. The positive transient 

design pressure shall be at least, but shall not be required to exceed, +8.7 

kPa (+35 in. of water).

 6.5.1.3.2.2 Negative Transient Design Pressure. The negative transient 

design pressure shall be at least as negative as, but shall not be required 

to be more negative than, −8.7 kPa (−35 in. of water).

Accordingly, NFPA 85 now requires SJGS to increase the pressure ratings of the 

boilers to +/- 35 inches wg if the capacity of the ID /booster fans is increased. To comply 

with NFPA 85, and increase the pressure rating of the units to +/- 35 inches wg, SJGS 

will have to install buckstay corner connections, buckstay over-turning posts, and will 

likely have to install air heater stiffening as well. While some buckstay clips were added 

for the consent decree work, the spacing of those clips is unknown. Therefore, it is 

assumed that some additional clips would be needed to increase the pressure rating from 

the current level of -2 / +18 inches wg to +/- 35 inches wg. 

The fabric filters will also require additional stiffening to increase the continuous 

pressure rating to that of the new ID fan test block suction pressure. B&V expects that 

the hot ESP casing will require stiffening as well. B&V continues to recommend a 

balanced draft conversion be performed on all four units at SJGS if SCR installation is 

required. Due to the 2007 NFPA 85 revisions, stiffening of the boiler and other 

components will be required regardless of whether a balanced draft conversion is 

performed (the majority of the costs associated with the balanced draft conversion are 

related to boiler stiffening). 

Table 4 and Table 5 provide the updated cost estimates for the balanced draft 

conversion. Costs for stiffening the fabric filters have been added as it was determined 

that the fabric filters will also need to be stiffened if the capacity of the booster fans is 

increased to allow for SCR operation. Tables 4 and 5 also show a column for deleting 

the balance draft conversion portion of the work. In this scenario, the boiler would 

remain a positive pressure boiler, but the stiffening work, required by NFPA 85, would 

still need to be completed. As a result, the long outage associated with the boiler 

stiffening would also be required regardless of whether the units remain pressurized or 
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are converted to balanced draft. If a balanced draft conversion is not performed, new, 

low-speed motors for the FD fans would not be required and the ID fans would be 

smaller, resulting in a total cost savings of $1.5 million. 

Table 4 

Updated Costs for Balanced Draft Conversion 

Units 1 and 2 (2007 Dollars)

 Units 1 & 2 BART Study Updated 

Balanced Draft Conversion 

Engineering 

& Material 

Construction 

Labor Costs 

Engineering 

& Material 

Construction 

Labor Costs 

Pressurized 

Furnace 

Differential

Boiler 

Stiffening $1,335,000 $1,418,000 $1,335,000 $1,418,000 (Same)

Scaffolding -- $195,000 -- $195,000 (Same)

Insulation & Lagging $139,000 $1,197,000 $139,000 $1,197,000 (Same)

Ductwork & Casing Repairs 

(Allowance) $182,000 $1,008,000 $182,000 $1,008,000 (Same)

Air Heater 

Stiffening $106,000 $195,000 $106,000 $195,000 (Same)

Electrostatic Precipitator 

Stiffening (Excludes 

Casing Repairs) $341,000 $1,114,000 $341,000 $1,114,000 (Same)

Insulation & Lagging 

(Allowance) $84,000 $418,000 $84,000 $418,000 (Same)

Electrical/Control 

Modifications $159,000 $334,000 $159,000 $334,000 (Same)

New Transformer (Note 2) $1,000,000 $0 

Fan Modifications 

FD Fans (new motors only) $490,000 $86,000 $490,000 $86,000 ($576,000)

ID Fans $2,400,000 $840,000 $2,400,000 $840,000 ($500,000)

Fabric Filter (assumed same 

as ESP) 

Stiffening (Excludes Casing 

Repairs) $341,000 $1,114,000 (Same)

Insulation & Lagging 

(Allowance) $84,000 $418,000 (Same)

Miscellaneous Mech 

Commodities & 

 Instrumentation $325,000 -- $325,000 -- (Same)

Subtotal $6,561,000 $6,805,000 $5,986,000 $8,337,000 ($1,076,000)

Notes: 

1. Excludes Contingency and Indirects 

2. Auxiliary electric costs are being accounted for in a separate analysis. Refer to Section 3.0 of this report. 

Therefore, they are being deleted from the balanced draft conversion estimate. 
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Table 5 

Updated Costs for Balanced Draft Conversion 

Units 3 and 4 (2007 Dollars)

Units 3&4 BART Study Updated 

Balanced Draft Conversion 

Engineering 

& Material 

Construction 

Labor Costs 

Engineering 

& Material 

Construction 

Labor Costs 

Pressurized 

Furnace 

Differential

Boiler 

Stiffening $1,537,000 $1,908,000 $1,537,000 $1,908,000 (Same)

Scaffolding - - $262,000 - - $263,000 (Same)

Insulation & Lagging $188,000 $1,438,000 $188,000 $1,438,000 (Same)

Ductwork & Casing 

Repairs (Allowance) $182,000 $1,009,000 $182,000 $1,009,000 (Same)

Air Heater 

Stiffening $125,000 $263,000 $125,000 $263,000 (Same)

Electrostatic Precipitator 

Stiffening (Excludes 

Casing Repairs) $416,000 $1,500,000 $416,000 $1,500,000 (Same)

Insulation & Lagging 

(Allowance) $113,000 $563,000 $113,000 $563,000 (Same)

Electrical/Control 

Modifications $214,000 $450,000 $214,000 $450,000 (Same)

New Transformer (Note 2) $1,000,000 $0 

Fan Modifications 

FD Fans (new motors only) $660,000 $116,000 $660,000 $116,000 ($776,000)

ID Fans $3,600,000 $1,260,000 $3,600,000 $1,260,000 ($800,000)

Fabric Filter (assumed 

same as ESP) 

Stiffening (Excludes 

Casing Repairs) $416,000 $1,500,000 (Same)

Insulation & Lagging 

(Allowance) $113,000 $563,000 (Same)

Miscellaneous Mech 

Commodities & 

 Instrumentation $325,000 - - $325,000 - - (Same)

Subtotal $8,357,000 $8,765,000 $7,886,000 $10,828,000 ($1,576,000)

Notes: 

1. Excludes Contingency and Indirects. 

2. Auxiliary electric costs are being accounted for in a separate analysis. Refer to Section 3.0 of this report. 

Therefore, they are being deleted from the balanced draft conversion estimate. 
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The values presented in Tables 4 and 5 are in 2007 dollars and will be included in 

the revised estimates presented in Section 5.0. 

5.0 Updated Cost Estimates 

This section of the document will present the updated capital cost estimates for 

the SCR systems on San Juan Generating Station. A summary of the updates is shown in 

Table 6. The details of the updated costs are presented in Tables 7 through 10. The 

following updates were made to the original BART cost estimates: 

• Escalation to 2010 dollars, as described in Section 2.0 of this document. 

• Auxiliary power system costs, as described in Section 3.0 of this 

document. 

• Balanced draft conversion updates, as described in Section 4.0 of this 

document. 

• Correction to the error in expansion joint costs, noted to the EPA on 

October 8, 2010. 

• Correction to air heater costs for Units 3 and 4. The costs for 

modifications to the secondary air heaters were inadvertently double 

counted. 

• Reduction in ductwork steel costs to move to the use of ASTM A572 duct 

material instead of ASTM A588 Grade B material. This issue is 

discussed in greater detail in the follow up responses to the conference call 

held with the EPA on October 13, 2010. 

Line items in Tables 7 through 10 that have changes as a direct result of one of 

the items listed above are shown in red in the tables. Since the estimate is a factored 

estimate, a change to one line item will change other line items that are factors. For 

example, as the total purchased equipment cost (PEC) changes, the cost for “handling and 

erection” will also change because it is a multiplication factor of the purchased 

equipment cost. 
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Table 6

Summary of SCR Capital Cost Updates

for San Juan Station

Unit No. 2007 BART Estimate 2010 Updated Cost Estimate Change

1 $156,805,000 $194,101,000 +23.8 %

2 $169,251,000 $209,652,000 +23.9 %

3 $215,568,000 $261,954,000 +21.5 %

4 $199,558,000 $242,377,000 +21.5 %

Total $741,182,000 $908,084,000 +22.5 %

As can be seen in Table 6, the costs for SCR are higher than the original estimate. 

The two main causes of these changes are the escalation to 2010 dollars and the auxiliary 

power system upgrades that are required 

The cost increases shown above include the recommended balanced draft 

conversion costs. For comparison purposes, B&V did examine the impact to the costs if 

only the “boiler stiffening” work discussed in Section 4.0 is done (boiler, duct, ESP, air 

heater, and fabric filter stiffening in accordance with NFPA 85) but not the additional fan 

work that would be associated with the balance draft conversion. The result of this 

analysis showed that the updated costs will be only slightly different when the costs 

solely attributable to the balanced draft conversion are excluded -- an increase of 21.3 

percent (for the whole station) compared with 22.5 percent, for a total difference of 

$9,192,000 (about 1 percent of the project cost). As discussed in Section 4.0, the 

difference is slight because all of the boiler stiffening work is required (with or without 

balance draft conversion). The only difference in the total price for including the 

balanced draft conversion is the difference in fan costs. 
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Table 7 - PNM SJGS BART Analysis - Updated Cost Analysis

Technology: Selective Catalytic Reduction - SJGS Unit 1 Date: 10/21/2010Cost Item $ Remarks/Cost BasisOriginal 2007 BART Cost Estimate Escalation EscalatDirect Costs Current Value Comments on Updates to Oct 2010 Percenta

Purchased equipment costs

Anhydrous Ammonia Injection System $437,000 B&V cost estimate $437,000 $473,708 8.

Anhydrous Ammonia Vaporization System $436,000 B&V cost estimate $436,000 $472,624 8.

Reactor Box, Breeching and Ductwork $4,451,000 B&V cost estimate $4,005,900 Adjustement for ASTM A572 $4,454,561 11.Ductwork Expansion Joints $294,000 B&V cost estimate $147,000 Correction $159,348 8.

Catalyst $2,557,000 B&V cost estimate $2,557,000 $2,557,000 0.

Sonic Horns $188,000 B&V cost estimate $188,000 $203,792 8.

Elevator $1,236,000 B&V cost estimate $1,236,000 $1,339,824 8.

Structural Steel $4,881,000 B&V cost estimate $4,881,000 $5,427,672 11.SCR Bypass $10,000,000 B&V cost estimate $10,000,000 $10,840,000 8.

NOx Monitoring System $440,000 B&V cost estimate $440,000 $476,960 8.

Electrical System Upgrade $378,000 B&V cost estimate $378,000 $409,752 8.

Auxiliary Electric System Requirements $0 Not in estimate $6,400,000 Added, Refer to Sect. 3.0 $6,400,000 0.Instrumentation and Control System $279,000 B&V cost estimate $279,000 $302,436 8.

Subtotal capital cost (CC) $25,577,000 $31,384,900 $33,517,677

Gross Receipt Tax $1,583,000 (CC) X 6.2% $1,942,000 $2,074,000Freight $1,279,000 (CC) X 5.0% $1,569,000 $1,676,000

Total purchased equipment cost (PEC) $28,439,000 $34,896,000 $37,268,000

Direct installation costs

Foundation & supports $8,532,000 (PEC) X 30.0% $10,468,800 $11,117,866 6.Handling & erection $8,532,000 (PEC) X 30.0% $10,468,800 $11,117,866 6.Electrical $4,266,000 (PEC) X 15.0% $5,234,400 $5,558,933 6.Piping $711,000 (PEC) X 2.5% $872,400 $926,489 6.Insulation $2,844,000 (PEC) X 10.0% $3,489,600 $3,705,955 6.Painting $284,000 (PEC) X 1.0% $348,960 $370,596 6.Demolition $2,844,000 (PEC) X 10.0% $3,489,600 $3,705,955 6.Relocation $1,422,000 (PEC) X 5.0% $1,744,800 $1,852,978 6.

Total direct installation costs (DIC) $29,435,000 $36,117,360 $38,356,636

Air preheater modifications $1,071,000 B&V cost estimate $1,071,000 $1,160,964 8.

Balanced draft conversion $13,366,000 B&V cost estimate $14,323,000 Refer to Section 4.0 $15,526,132 8.

Site preparation $2,000,000 Engineering estimate $2,000,000 $2,000,000 0.Buildings & enclosures $500,000 Engineering estimate $500,000 $500,000 0.

Total direct costs (DC) = (PEC) + (DIC) $74,811,000 $88,907,000 $94,812,000

Indirect Costs

Engineering $5,237,000 (DC) X 7.0% $6,223,490 $6,636,840Owner's cost $3,741,000 (DC) X 5.0% $4,445,350 $4,740,600Construction management $7,481,000 (DC) X 10.0% $8,890,700 $9,481,200Construction indirect $18,344,000 B&V labor market review $22,507,920 $23,903,411 6.Start-up and spare parts $2,244,000 (DC) X 3.0% $2,667,210 $2,844,360Performance test $200,000 Engineering estimate $200,000 $200,000Contingencies $14,962,000 (DC) X 20.0% $17,781,400 $18,962,400

Total indirect costs (IC) $52,209,000 $62,716,000 $66,769,000

Interest During Construction (IDC) $14,118,000 [(DC)+(IC)] X 7.41% $16,853,000 $16,853,000Loss Generation during Outage (GEN) $15,667,000 $15,667,000 $15,667,000Total Capital Investment (TCI) = (DC) + (IC) + (IDC) + (GEN) $156,805,000 $184,143,000 $194,101,000
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Table 8 - PNM SJGS BART Analysis - Updated Cost Analysis

Technology: Selective Catalytic Reduction - SJGS Unit 2 Date: 10/21/2010

Cost Item $ Remarks/Cost BasisOriginal 2007 BART Cost Estimate

CAPITAL COST Escalation EscalationDirect Costs Current Value Comments on Updates to Oct 2010 Percentage

Purchased equipment costs

Anhydrous Ammonia Injection System $429,000 B&V cost estimate $429,000 $465,036 8.4%Anhydrous Ammonia Vaporization System $429,000 B&V cost estimate $429,000 $465,036 8.4%Reactor Box, Breeching and Ductwork $4,444,000 B&V cost estimate $3,999,600 Adjustement for ASTM A572 $4,447,555 11.2%

Ductwork Expansion Joints $294,000 B&V cost estimate $147,000 Correction $159,348 8.4%

Catalyst $2,553,000 B&V cost estimate $2,553,000 $2,553,000 0.0%Sonic Horns $188,000 B&V cost estimate $188,000 $203,792 8.4%Elevator $1,236,000 B&V cost estimate $1,236,000 $1,339,824 8.4%Structural Steel $5,998,000 B&V cost estimate $5,998,000 $6,669,776 11.2%SCR Bypass $10,000,000 B&V cost estimate $10,000,000 $10,840,000 8.4%NOx Monitoring System $440,000 B&V cost estimate $440,000 $476,960 8.4%Electrical System Upgrade $372,000 B&V cost estimate $372,000 $403,248 8.4%Auxiliary Electric System Requirements $0 Not in estimate $6,400,000 Added, Refer to Sect. 3.0 $6,400,000 0.0%Instrumentation and Control System $278,000 B&V cost estimate $278,000 $301,352 8.4%

Subtotal capital cost (CC) $26,661,000 $32,469,600 $34,724,927

Gross Receipt Tax $1,650,000 (CC) X 6.2% $2,009,000 $2,149,000Freight $1,333,000 (CC) X 5.0% $1,623,000 $1,736,000

Total purchased equipment cost (PEC) $29,644,000 $36,102,000 $38,610,000

Direct installation costs

Foundation & supports $8,893,000 (PEC) X 30.0% $10,830,600 $11,502,097 6.2%Handling & erection $11,858,000 (PEC) X 40.0% $14,440,800 $15,336,130 6.2%

Electrical $4,447,000 (PEC) X 15.0% $5,415,300 $5,751,049 6.2%Piping $741,000 (PEC) X 2.5% $902,550 $958,508 6.2%Insulation $2,964,000 (PEC) X 10.0% $3,610,200 $3,834,032 6.2%Painting $296,000 (PEC) X 1.0% $361,020 $383,403 6.2%Demolition $2,964,000 (PEC) X 10.0% $3,610,200 $3,834,032 6.2%Relocation $1,482,000 (PEC) X 5.0% $1,805,100 $1,917,016 6.2%

Total direct installation costs (DIC) $33,645,000 $40,975,770 $43,516,268

Air preheater modifications $1,071,000 B&V cost estimate $1,071,000 $1,160,964 8.4%Balanced draft conversion $13,366,000 B&V cost estimate $14,323,000 Refer to Section 4.0 $15,526,132 8.4%

Site preparation $2,000,000 Engineering estimate $2,000,000 $2,000,000 0.0%Buildings & enclosures $500,000 Engineering estimate $500,000 $500,000 0.0%

Total direct costs (DC) = (PEC) + (DIC) $80,226,000 $94,972,000 $101,313,000

Indirect Costs

Engineering $5,616,000 (DC) X 7.0% $6,648,040 $7,091,910Owner's cost $4,011,000 (DC) X 5.0% $4,748,600 $5,065,650Construction management $8,023,000 (DC) X 10.0% $9,497,200 $10,131,300Construction indirect $22,085,000 B&V labor market review $26,895,990 $28,563,541 6.2%Start-up and spare parts $2,407,000 (DC) X 3.0% $2,849,160 $3,039,390Performance test $200,000 Engineering estimate $200,000 $200,000Contingencies $16,045,000 (DC) X 20.0% $18,994,400 $20,262,600

Total indirect costs (IC) $58,387,000 $69,833,000 $74,354,000

Interest During Construction (IDC) $15,407,000 [(DC)+(IC)] X 7.41% $18,318,000 $18,318,000Loss Generation during Outage (GEN) $15,231,000 $15,667,000 $15,667,000Total Capital Investment (TCI) = (DC) + (IC) + (IDC) + (GEN) $169,251,000 $198,790,000 $209,652,000
10/22/2010 

B&V E-2 and E-4 16 

Table 9 - PNM SJGS BART Analysis - Updated Cost Analysis

Technology: Selective Catalytic Reduction - SJGS Unit 3 Date: 10/21/2010

Cost Item $ Remarks/Cost BasisOriginal 2007 BART Cost Estimate

CAPITAL COST Escalation EscalationDirect Costs Current Value Comments on Updates to Oct 2010 Percentage

Purchased equipment costs

Anhydrous Ammonia Injection System $559,000 B&V cost estimate $559,000 $605,956 8.4%Anhydrous Ammonia Vaporization System $559,000 B&V cost estimate $559,000 $605,956 8.4%Reactor Box, Breeching and Ductwork $5,613,000 B&V cost estimate $5,051,700 Adjustement for ASTM A572 $5,617,490 11.2%

Ductwork Expansion Joints $371,000 B&V cost estimate $185,500 Correction $201,082 8.4%

Catalyst $3,225,000 B&V cost estimate $3,225,000 $3,225,000 0.0%Sonic Horns $188,000 B&V cost estimate $188,000 $203,792 8.4%Elevator $1,236,000 B&V cost estimate $1,236,000 $1,339,824 8.4%SCR Bypass $10,000,000 B&V cost estimate $10,000,000 $11,120,000 11.2%Structural Steel $7,816,000 B&V cost estimate $7,816,000 $8,472,544 8.4%NOx Monitoring System $440,000 B&V cost estimate $440,000 $476,960 8.4%Electrical System Upgrade $484,000 B&V cost estimate $484,000 $524,656 8.4%Auxiliary Electric System Requirements $0 Not in estimate $8,350,000 Added, Refer to Sect. 3.0 $8,350,000 0.0%Instrumentation and Control System $291,000 B&V cost estimate $291,000 $315,444 8.4%

Subtotal capital cost (CC) $30,782,000 $38,385,200 $41,058,704

Gross Receipt Tax $1,905,000 (CC) X 6.2% $2,375,000 $2,541,000Freight $1,539,000 (CC) X 5.0% $1,919,000 $2,053,000

Total purchased equipment cost (PEC) $34,226,000 $42,679,000 $45,653,000

Direct installation costs

Foundation & supports $10,268,000 (PEC) X 30.0% $12,803,700 $13,597,529 6.2%Handling & erection $13,690,000 (PEC) X 40.0% $17,071,600 $18,130,039 6.2%Electrical $5,134,000 (PEC) X 15.0% $6,401,850 $6,798,765 6.2%Piping $856,000 (PEC) X 2.5% $1,066,975 $1,133,127 6.2%Insulation $3,423,000 (PEC) X 10.0% $4,267,900 $4,532,510 6.2%Painting $342,000 (PEC) X 1.0% $426,790 $453,251 6.2%Demolition $3,423,000 (PEC) X 10.0% $4,267,900 $4,532,510 6.2%Relocation $1,711,000 (PEC) X 5.0% $2,133,950 $2,266,255 6.2%

Total direct installation costs (DIC) $38,847,000 $48,440,665 $51,443,986

Air preheater modifications $8,685,000 B&V cost estimate $5,090,000 Correction $5,517,560 8.4%

Balanced draft conversion $17,122,000 B&V cost estimate $18,714,000 Refer to Section 4.0 $20,285,976 8.4%Site preparation $2,000,000 Engineering estimate $2,000,000 $2,000,000 0.0%Buildings & enclosures $500,000 Engineering estimate $500,000 $500,000 0.0%

Total direct costs (DC) = (PEC) + (DIC) $101,380,000 $117,424,000 $125,401,000

Indirect Costs

Engineering $7,097,000 (DC) X 7.0% $8,219,680 $8,778,070Owner's cost $5,069,000 (DC) X 5.0% $5,871,200 $6,270,050Construction management $10,138,000 (DC) X 10.0% $11,742,400 $12,540,100Construction indirect $25,498,000 B&V labor market review $31,795,855 $33,767,198 6.2%Start-up and spare parts $3,041,000 (DC) X 3.0% $3,522,720 $3,762,030Performance test $200,000 Engineering estimate $200,000 $200,000Contingencies $20,276,000 (DC) X 20.0% $23,484,800 $25,080,200

Total indirect costs (IC) $71,319,000 $84,837,000 $90,398,000

Interest During Construction (IDC) $19,195,000 [(DC)+(IC)] X 7.41% $22,481,000 $22,481,000Loss Generation during Outage (GEN) $23,674,000 $23,674,000 $23,674,000Total Capital Investment (TCI) = (DC) + (IC) + (IDC) + (GEN) $215,568,000 $248,416,000 $261,954,000
10/22/2010 

B&V E-2 and E-4 17 

Table 10 - PNM SJGS BART Analysis - Updated Cost Analysis

Technology: Selective Catalytic Reduction - SJGS Unit 4 Date: 10/21/2010

Cost Item $ Remarks/Cost BasisOriginal 2007 BART Cost Estimate

CAPITAL COST Escalation EscalationDirect Costs Current Value Comments on Updates to Oct 2010 Percentage

Purchased equipment costs

Anhydrous Ammonia Injection System $559,000 B&V cost estimate $559,000 $605,956 8.4%Anhydrous Ammonia Vaporization System $559,000 B&V cost estimate $559,000 $605,956 8.4%Reactor Box, Breeching and Ductwork $5,648,000 B&V cost estimate $5,083,200 Adjustement for ASTM A572 $5,652,518 11.2%

Ductwork Expansion Joints $373,000 B&V cost estimate $186,500 Correction $202,166 8.4%

Catalyst $3,245,000 B&V cost estimate $3,245,000 $3,245,000 0.0%Sonic Horns $188,000 B&V cost estimate $188,000 $203,792 8.4%Elevator $1,236,000 B&V cost estimate $1,236,000 $1,339,824 8.4%Structural Steel $6,252,000 B&V cost estimate $6,252,000 $6,952,224 11.2%SCR Bypass $10,000,000 B&V cost estimate $10,000,000 $10,840,000 8.4%NOx Monitoring System $440,000 B&V cost estimate $440,000 $476,960 8.4%Electrical System Upgrade $484,000 B&V cost estimate $484,000 $524,656 8.4%Auxiliary Electric System Requirements $0 Not in estimate $8,350,000 Added, Refer to Sect. 3.0 $8,350,000 0.0%Instrumentation and Control System $291,000 B&V cost estimate $291,000 $315,444 8.4%

Subtotal capital cost (CC) $29,275,000 $36,873,700 $39,314,496

Gross Receipt Tax $1,811,000 (CC) X 6.2% $2,282,000 $2,433,000Freight $1,464,000 (CC) X 5.0% $1,844,000 $1,966,000

Total purchased equipment cost (PEC) $32,550,000 $41,000,000 $43,713,000

Direct installation costs

Foundation & supports $9,765,000 (PEC) X 30.0% $12,300,000 $13,062,600 6.2%Handling & erection $9,765,000 (PEC) X 30.0% $12,300,000 $13,062,600 6.2%Electrical $4,883,000 (PEC) X 15.0% $6,150,000 $6,531,300 6.2%Piping $814,000 (PEC) X 2.5% $1,025,000 $1,088,550 6.2%Insulation $3,255,000 (PEC) X 10.0% $4,100,000 $4,354,200 6.2%Painting $326,000 (PEC) X 1.0% $410,000 $435,420 6.2%Demolition $3,255,000 (PEC) X 10.0% $4,100,000 $4,354,200 6.2%Relocation $1,628,000 (PEC) X 5.0% $2,050,000 $2,177,100 6.2%

Total direct installation costs (DIC) $33,691,000 $42,435,000 $45,065,970

Air preheater modifications $8,685,000 B&V cost estimate $5,090,000 Correction $5,517,560 8.4%

Balanced draft conversion $17,122,000 B&V cost estimate $18,714,000 Refer to Section 4.0 $20,285,976 8.4%Site preparation $2,000,000 Engineering estimate $2,000,000 $2,000,000 0.0%Buildings & enclosures $500,000 Engineering estimate $500,000 $500,000 0.0%

Total direct costs (DC) = (PEC) + (DIC) $94,548,000 $109,739,000 $117,083,000

Indirect Costs

Engineering $6,618,000 (DC) X 7.0% $7,681,730 $8,195,810Owner's cost $4,727,000 (DC) X 5.0% $5,486,950 $5,854,150Construction management $9,455,000 (DC) X 10.0% $10,973,900 $11,708,300Construction indirect $20,996,000 B&V labor market review $26,445,000 $28,084,590 6.2%Start-up and spare parts $2,836,000 (DC) X 3.0% $3,292,170 $3,512,490Performance test $200,000 Engineering estimate $200,000 $200,000Contingencies $18,910,000 (DC) X 20.0% $21,947,800 $23,416,600

Total indirect costs (IC) $63,742,000 $76,028,000 $80,972,000

Interest During Construction (IDC) $17,594,000 [(DC)+(IC)] X 7.41% $20,648,000 $20,648,000Loss Generation during Outage (GEN) $23,674,000 $23,674,000 $23,674,000Total Capital Investment (TCI) = (DC) + (IC) + (IDC) + (GEN) $199,558,000 $230,089,000 $242,377,000
10/22/2010 

B&V E-2 and E-4 

Appendix A 

Data from the U.S. Bureau of Labor Statistics 
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Data extracted on: October 20, 2010 (4:43:35 PM)

Producer Price Index Industry Data

Year Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Annual

2007 118.3 118.3 119.6 118.9 119.2 119.8 119.8 120.9 120.9 120.9 121.7 124.3 120.2

2008 130.1 136.7 137.3 139.0 143.3 146.6 148.4 152.4 151.3 151.7 151.2 151.0 144.9

2009 148.4 145.8 143.5 141.7 138.6 136.5 136.0 135.8 136.7 136.8 134.3 134.6 139.1

2010 134.7 135.0 135.1 136.2 136.9 136.7(P) 136.3(P) 136.2(P) 137.5(P) 

P : Preliminary. All indexes are subject to revision four months after original publication. 

Series Id: PCU332313332313 

Industry: Plate work manufacturing 

Product: Plate work manufacturing 

Base Date: 200312 

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Producer Price Index Industry Data

Year Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Annual

2007 153.5 147.6 148.9 154.6 160.8 162.6 166.8 170.3 167.0 169.8 168.5 164.9 161.3

2008 165.8 167.2 175.5 175.4 176.8 174.1 175.9 173.9 171.9 163.4 148.5 146.8 167.9

2009 143.2 142.1 141.2 148.6 153.8 154.6 156.5 159.7 161.2 162.3 164.7 169.8 154.8

2010 169.7 172.5 169.6 173.3 173.6 170.5(P) 169.2(P) 169.7(P) 166.1(P) 

P : Preliminary. All indexes are subject to revision four months after original publication. 

Series Id: PCU33592-33592- 

Industry: Communication & energy wire & cable mfg 

Product: Communication & energy wire & cable mfg 

Base Date: 200312 

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Producer Price Index Industry Data

Year Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Annual

2007 169.4 167.2 168.6 169.8 170.1 169.1 168.8 168.1 167.0 167.1 165.3 166.7 168.1

2008 170.2 176.1 186.0 197.2 207.9 218.9 223.0 225.8 227.7 228.8 214.1 203.0 206.6

2009 182.8 177.4 172.9 161.6 158.1 152.2 153.2 157.3 164.1 166.1 164.8 166.2 164.7

2010 170.8 174.7 185.0 190.0 195.7 194.0(P) 196.6(P) 193.7(P) 195.7(P) 

P : Preliminary. All indexes are subject to revision four months after original publication. 

Series Id: PCU33121-33121- 

Industry: Iron/steel pipe & tube mfg from purch steel 

Product: Iron/steel pipe & tube mfg from purch steel 

Base Date: 200312 

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Producer Price Index Industry Data

Year Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Annual

2007 115.2 116.3 116.7 117.6 117.9 118.0 118.1 118.4 118.6 119.1 119.3 119.5 117.9

2008 120.9 121.5 122.0 121.9 122.4 122.9 123.8 124.8 125.8 125.6 126.0 126.2 123.6

2009 127.0 127.0 127.0 127.2 127.2 127.4 127.7 127.6 127.9 127.8 127.8 127.9 127.5

2010 128.2 128.2 128.4 128.4 128.8 128.7(P) 129.0(P) 129.4(P) 129.7(P) 

P : Preliminary. All indexes are subject to revision four months after original publication. 

Series Id: PCU33391-33391- 

Industry: Pump and compressor manufacturing 

Product: Pump and compressor manufacturing 

Base Date: 200312 

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Producer Price Index Industry Data

Year Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Annual

2007 175.2 177.1 178.4 179.1 179.1 179.2 179.6 177.7 181.7 181.3 182.1 182.5 179.4

2008 180.9 183.3 183.7 185.3 184.8 186.7 188.5 191.1 190.7 191.8 191.0 192.3 187.5

2009 193.9 190.4 193.2 194.7 190.6 191.7 191.7 193.8 193.6 194.2 194.6 194.5 193.1

2010 194.2 193.4 194.5 194.7 194.2 196.2(P) 194.6(P) 195.5(P) 195.2(P) 

P : Preliminary. All indexes are subject to revision four months after original publication. 

Series Id: PCU335313335313 

Industry: Switchgear and switchboard apparatus mfg 

Product: Switchgear and switchboard apparatus mfg 

Base Date: 198506 

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Data extracted on: October 20, 2010 (10:27:59 AM)

Producer Price Index Industry Data

Year Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Annual

2007 128.8 129.3 131.0 131.4 132.6 132.6 132.8 133.3 133.5 133.9 134.3 134.4 132.3

2008 134.6 136.9 138.1 140.3 142.6 144.4 145.5 147.3 147.1 147.6 147.0 146.8 143.2

2009 146.5 145.8 145.6 143.4 142.5 141.2 140.9 140.5 140.2 140.4 140.3 140.2 142.3

2010 139.2 139.1 139.1 140.1 140.5 141.1(P) 141.0(P) 141.0(P) 140.8(P) 

P : Preliminary. All indexes are subject to revision four months after original publication. 

Series Id: PCU33242-33242- 

Industry: Metal tank (heavy gauge) mfg 

Product: Metal tank (heavy gauge) mfg 

Base Date: 200312 

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Employer Costs for Employee Compensation

Year Period Cost of compensation (Cost per hour worked) Percent of total compensation

2007 Qtr1 29.02 100.0

2007 Qtr2 29.48 100.0

2007 Qtr3 29.77 100.0

2007 Qtr4 29.88 100.0

2008 Qtr1 30.33 100.0

2008 Qtr2 30.60 100.0

2008 Qtr3 30.92 100.0

2008 Qtr4 31.21 100.0

2009 Qtr1 31.33 100.0

2009 Qtr2 31.53 100.0

2009 Qtr3 31.65 100.0

2009 Qtr4 30.99 100.0

2010 Qtr1 31.20 100.0

2010 Qtr2 31.43 100.0

V : See www.bls.gov/ncs/ect/mapnote.htm for details regarding the Farming, fishing, and forestry series. 

Series Id: CMU1010000405000D,CMU1010000405000P (V) 

Compensation Component: Total compensation 

Employer/Employee Charac.: Construction, extraction, farming, fishing, and forestry occupations

Sector: All Civilian 

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10/22/2010 

B&V E-2 and E-4 

Appendix B 

Draft System Pressure Curves 
10/22/2010 

B&V E-2 and E-4 
10/22/2010 

B&V E-2 and E-4