appendix d cost estimate - us department of energy · total project cost (tpc) was not addressed,...

Appendix D

Cost Estimate

------- D- I Conceptual Design Report for Ex Situ Chemical OxidatiodReduction and Stabilization of the V-Tanks

Conceptual Design Report for Ex Situ Chemical OxidatiodReduction and Stabilization of the V-Tanks

Bechtel BWXT Idaho, LLC I COST ESTIMATE SUPPORT DATA RECAPITULATION

Project Title:

IEstimator : Date: June 6,2003 Estimate Type: Project Support

‘Approved By:

WAG- 1 V-TANKS EX-SITU CHEMICAL OXIDATION / REDUCTION / STABILIZATION B. W. Wallace/R. D. Roseland

File: 6304-A Page 1 of 6

I. PURPOSE: Brief description of the intent of how the estimate is to be used, i.e., for engineering study, comparative analysis, D WP, LCB out-year planning, BCP, etc.

The purpose of this estimate is to provide an “updated” planning position for the project. The estimate is not intended for use in funding determination. It has not been subjected to the rigor of a formal jury review nor has an additional contingency analysis been performed.

11. SCOPE OF WORK: Brief statement of the project’s objective. Thorough overview and description of the proposed project. Identifj, work to be accomplished, as well as any specijk work to be excluded.

Prepare a revised Project Support estimate to address the current knowledge and processes identified for use in the performance of chemical oxidation with grout stabilization of the V-Tanks contents. It is understood and recognized that the technology and processes required to perform the work are dynamic in nature and rapidly evolving. It is intended that this estimate will create an intermediate record of the costs associated with performance of the work as we currently define it. It is recognized that the most probable process direction will not be completely identified until the results of a cold bench test are available. The requester has limited the elements addressed in this estimate to those associated with a subcontractor’s performance according to the CDR design. Total Project Cost (TPC) was not addressed, as it was in the Technical Evaluation Report (TER) estimate and a Net Present Value (NPV) calculation has not been performed. Both of these actions will be performed for the 30% design where funding for the process will be affected.

The requester has directed Estimating Services to perform this work using minimal resources. All costs that represent Other Project Costs (OPC) have not been included in this estimate in order to provide partial compliance with this request.

This estimate reflects subcontractor costs to treat and dispose of waste that is currently residing in the Test Area North (TAN) V-tanks (tanks V-1, V-2, V-3, and V-9) using an ex-situ chemical oxidation and stabilization (COS) process. This waste, the tanks and interconnecting piping, contaminated soil surrounding the tanks, and equipment

COST ESTIMATE SUPPORT DATA RECAPITULATION - Continued-

Project Title: WAG- 1 V-TANKS EX-SITU CHEMICAL OXIDATION / REDUCTION / STABILIZATION


contaminated during the process will be disposed of at the INEEL CERCLA Disposal Facility (ICDF). Off-gas residuals are shipped to an off-site facility for treatment and disposal. The excavated area is then backfilled, graded and restored to original condition.

The CDR does not address removal of tanks, soils, etc., but these items are integral to the project requirements and have been included. Full documentation for the original TER estimate (Estimating Services file #6304) resides in Estimating Services files and can be consulted for additional information if required.

111. BASIS OF THE ESTIMATE: Overall methodology and rationale of how the estimate was developed. Source documents to include drawings, design reports, engineers’ notes andor other documentation upon which the estimate is originated. Overall explanation of sources for resource pricing.

The estimate is based on conceptual level drawings and specifications, process flow diagrams, and discussions with the principle investigators for the COS process and other Waste Area Group One (WAG-1) personnel. Following is a listing of principle investigators and WAG 1 personnel. These subject matter experts and engineers consulted with Estimating Services for the purpose of producing this estimate. E. C. Miller D. A. Cresap M. D. Elliot R. K. Farnsworth G. E. McDannel J. J. Jessmore A. E. Jantz K. F. Childs J. D. Harris R. A. Montgomery

Following is a listing of contributing designers responsible for the CDR. These engineers consulted with Estimating Services for the purpose of producing this estimate. S. M. Allen P. W. Bragassa K. R. Ward R. K. Farnsworth D. L. Eaton E. B. Thompson D. S. Wendt B. D. Raivo



Production labor rates and materiaVequipment costs or allowances have been provided using a combination of estimator projections and estimating guides such as Richardsons and Means. The level of detail available during the production of these estimates precluded producing more detailed bills of material.

IV. ASSUMPTIONS: Condition statements accepted or supposed true without proof of demonstration; statements adding clarlJication to scope. An assumption has a direct impact on total estimated cost.

A.

B.

C.

D.

E.

F.

G. H.

I.

J.

All materials, equipment, etc., will be provided by a subcontractor and not by Bechtel BWXT Idaho, LLC. All sample analysis and secondary waste disposal will be accomplished using existing Bechtel BWXT Idaho, LLC subcontracts. No provisions for G&A costs have been included for these items. This project will be awarded to a subcontractor/subcontractors through the competitive bidding process. A sufficient number of respondents will be available to provide a competitive bidding climate. The subcontractor’s proposal will include the engineering effort required to treat and dispose of the V-tank contents and the soils around them. This effort will be based on procurement specifications developed by BBWI. The subcontractor will purchase waste treatment equipment selected from commercially available technologies, assembled and compartmentalized on skids (with enclosures as required) that can be easily assembled at the job site. It was also assumed the subcontractor would fabricate these equipment skids from new equipment and materials for this project specific waste treatment endeavor. The subcontractor will be required to assemble and successfully demonstrate the operations of the waste treatment equipment prior to the actual on-site treatment of the V-tank contents. It was assumed that the demonstration would be completed at or adjacent to the V-tank location. This project will provide for clean closure of the site. At the completion of the remediation work, the entire site will be backfilled with clean soil and contoured to match existing surroundings. It was assumed this soil would be available from an on-site source near TAN. All soils shipped to the ICDF will be transported in roll-off containers. It was assumed these containers would be provided to the subcontractor by ICDF at no cost. Treatment/disposal and shipping costs for waste shipped off-site will not be included in the subcontractor proposals. Costs associated with off-site disposal will be borne by BBWI.




K. Samples from the waste streams will be collected by the subcontractor and delivered to BBWI for analysis. It was also assumed that no automated sampling extraction system would be required.

L. An allowance has been included in the estimate for confirmation sample analysis of the soil to be excavated. Costs for sampling the loads of soil being transported to the ICDF are not included in the estimate.

M. Contents in the V-tanks can be readily extracted into the batch reaction tank. N. It was assumed that all process equipment will be housed in a 30’ x 60’ x 15’

“sprung-type” enclosure. 0. A small allowance for radiation shielding has been included in the estimate. P. Shoring will be required for a portion of the excavation. Q. The subcontractor will be responsible to provide adequate oversight for safety,

radiation monitoring, engineering, and quality assurance. These activities will also be monitored and supervised by BBWI personnel.

R. Grout mix proportions have been assumed to be approximately one part Portland cement to one part sand.

S. Equipment sizing information and material quantities per the equipment list provided by the principle investigators are accurate.

T. It was assumed that the four V-tanks will be decontaminated and size reduced (vs. grouted) for disposal at the ICDF.

U. The chemical oxidation and groutingkontainerization processes for each tank will be performed on an “around the clock” basis until completion.

V. Jacketed, glass-lined, stainless steel reactor vessels with agitators, heating and cooling provisions, and instrumentation will be required.

W. Stainless steel feedlmake-up tanks with pumps, mixers, and instrumentation will be required.

X. An “AEA” fluidic jet mixing sludge removal system will be required. While it is possible this system may be obtained from others within the DOE system for little or no cost, it can not be guaranteed that the system will be available in a manner that best facilitates prosecution of this work. Until such time when that can be determined, the full cost for the system will remain in this estimate.

Y. A grout mixedextruder will be required. Z. An off-gas and exhaust system will be required. AA. Activity specific assumptions that are considered to also reflect the basis of this

estimate have been included within the estimate body (reference cost estimating detail sheets).

BB. Weather conditions experienced during the processing of the waste will be such that the completion of the project is not unduly impacted.


Project Title: WAG-1 V-TANKS EX-SITU CHEMICAL OXIDATION / REDUCTION / STABILIZATION

File: 6304-A I Page 5 of 6 I

V. CONTINGENCY GUIDELINE IMPLEMENTATION: Explanation of methodology used in determining overall contingency. Identi& any spec@ drivers or items of concern.

The level of contingency identified during the TER process has been carried forward and included in this estimate. Following is the complete identification of contingency as it was applied in that estimate.

The following identifies the process used in developing/applying contingency during the Technical Evaluation Report (TER) process. These same levels of contingency have been carried to this estimate. The final process is not sufficiently identified nor has sufficient time/resources been allocated to perform an additional contingency analysis for this estimate. This will be performed for the 30% design estimate.

A risk application tool was used, which linked the Success estimating software with @RISK risk analysis software. In the @RISK program, the key estimated cost summary levels were assigned low and high values. These values represent a degree of confidence in the accuracy and completeness of the information provided to the estimator. These bounding values are then run through a Latin Hypercube sampling simulation 10,000 times to arrive at the additional money required to address risk at various levels of confidence. A confidence level of 85% was chosen for this estimate. The risk output is shown both in a tabular format and graphically. The calculated risk amounts, represented as percentages of the appropriate levels, were applied to the estimate levels to give the most-likely cost, including risk, for the chosen level of confidence. Contingencies for the 85% probability level are included in the estimate at an overall rate of 5 1.2 1 %.

Some of the risks considered in addressing these possibilities are as follows:

A.

B.

C.

D.

E.

The work process required is relatively new in the application identified. It has proven to be very dynamic in nature with the final work process uncertain at this time. Requirements for treatment/disposal may differ from those currently expected or the material extracted could prove to require a different level of treatment and disposal from that expected. The estimate does not reflect any costs that may be incurred due to materials being rejected after being treated, stabilized, or packaged for disposal. Extraction of the V-tank contents with the fluidic jet mixing sludge removal system may be more difficult than expected. The chemical oxidation process may not provide the expected results and may take longer than expected. The grout mixing/extruding equipment may not perform as expected.

.




F.

G.

H.

Greater shielding control other than that expected and provided for could be imposed. Greater containment control beyond that expected and provided for could be imposed. Process piping, electrical, and instrumentation requirements could be greater than anticipated.

VI. OTHER COMMENTS/CONCERNS SPECIFIC TO THE ESTIMATE:

A. B.

Costs for current Idaho state sales tax have been included in the estimate. A total markup of 26% for subcontractor overhead, profit, and bond costs has been included in the estimate. A 10% handling fee has been included for subtier contractors.

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Appendix E

Management Self Assessment - Field Operations Checklist

E- I Conceptual Design Report for Ex Situ Chemical OxidatiodReduction and Stabilization of the V-Tanks

-- E-2 Conceptual Design Report for Ex Situ Chemical OxidatiodReduction and Stabilization of the V-Tanks

Management Self Assessment - Field Operations Checklist

ITEM NO DESCRIPTION

1.00 DOCUMENTATION

1 . 0 1

1 .02

1 .03

1 .04

1 .05

1.06 Security Contingency Plan

1.07 Hazards Analysis Document

1 .08

1 .09

1.10 Field Sampling Plan

1.1 1 Laboratory SOW/TOS

1.12 Health and Safety Plan

1.13 Test Plan

1.14 RWP/SWP

1.15 Waste Managemenmaste Mmimization Plan

1.16

1.17

1.18 Outage request

1.19

1 .20 Vendor Data

1 .2 1

1 .22 Organization chart

1.23 Contact phone list

Environmental Checklist

Preliminary Documented Safety Evaluation

Final Fire Hazards Analysis

Final Criticality Safety Evaluation

Physical Security Plan - Operations

Air Permitting Applicability Determination (APAD)

Storm Water Pollution Prevention Plan

Waste Disposition Disposal Form (WDDF)

ALARA committee approval of ALARA review

Storm Water Pollution Prevention Plan

Davis Bacon Determination

E-3 Conceptual Design Report for Ex Situ Chemical OxidatiodReduction and Stabilization of the V-Tanks

1 24 Miscellaneous

2.00 EQUIPMENT

2.0 1 Equipment list available

2.02 Spare parts on hand

2.03 All maintenance current

2.04 Preventative maintenance scheduled

2.05 All calibrations current

2.06 Equipment walkdown completed

2.07

2.08 Preoperational checklist(s) available

2.09 All PPE available

2.10 MSDSs available

2.1 1

2.12

2.13 Logbook(s) available and utilized

Operations and maintenance manuals available

Eye wash, first aid kits, and fire extinguishers current

Cell phones and radios operable

3.00 TRAINING

3.0 1 Training needs identified

3.02

3.03 Pre-job briefing completed

3.04

3.05

Needed training documented in TRAW

Personnel know location of MSDSs

Personnel demonstrate appropriate level of conduct

of operations

3.06 Miscellaneous

4.00 MCP-3562 Procedures

E-4 Conceptual Design Report for Ex Situ Chemical OxidatiodReduction and Stabilization of the V-Tanks

4.01

4.02

4.03

4.04

4.05

4.06

4.07

4.08

4.09

Walkdown conducted of TPR and MCP-3562 Hazard

Screening Checklist completed

JSA completed (wlapproved DAR)

JSA training completed

TPR approved by OSB and issued by

document control

TSRs implemented in procedure

S A R commitments implemented

Miscellaneous

5.00 SCHEDULING

5.01 Appropriate resources scheduled

5.02 OnPOW

5.03

5.04

5.05

5.06 Turnover checklist

Arrangements for POD & POW updates

Check in wlShft Supervisor prior to start

Check out each day wlShi€t Supervisor

6.00 SITE

6.01

6.02

6.03 Housekeeping checked

6.04

6.05 Emergency evacuation routes posted

6.06

6.07 Labelling complete

6.08 All equipment installed

6.09

Site access controls in place

Site access restrictions on signs

Noise signs in hearing protection areas

Personnel complying with posted signs

Backup alarms on all heavy equipment

E-5 -*--


7.00 MISCELLANEOUS

7.01 Any outstanding NCRs or DRs

Signature Date

-- E-6 Conceptual Design Report for Ex Situ Chemical OxidatiodReduction and Stabilization of the V-Tanks

Appendix F

Relevant Engineering Design Files

F- 1 ------ Conceptual Design Report for Ex Situ Chemical OxidatiodReduction and Stabilization of the V-Tanks

Relevant Engineering Design Files

The following list of Engineering Design Files (EDF) were developed in coordination with the conceptual design. These EDFs document the design decisions made in conceptual design in greater detail than the CDR and provide proof of concept information not found in this document. EDFs are INEEL controlled documents and may be designated for external release.

EDF-3650,2003, “Offgas System Conceptual Design, ExSitu Chemical Oxidation, Reduction, Stabilization of the V Tanks at Test Area North Operable Unit 1-10”, Rev. 0, June 2003.

EDF-3697,2003, “Removal, Oxidation, and Grouting of Liquid Waste from TAN Tanks V-1, V-2, V-3, and V-9 WAG 1, OU 1-10”, Rev. 0, June 2003.

EDF 37 19, 2003, “Exposure Estimates for TAN V-Tanks Ex Situ Treatment Shipping Containers” Rev. 0, June 2003.

EDF-3780,2003, “TAN V Tanks Civil Site Design”, Rev. 0, June 2003.

EDF 3781, 2003, “Exposure Estimates TAN V-Tanks Process Equipment”, Rev. 0, June2003.

EDF-3782,2003, “Assessment of Corrosion Issues Associated with the Processing and Storage of V- Tank Waste”, Rev. 0, June 2003.

EDF-3783,2003, “Grout Formulation for the Stabilization of Oxidized V-Tank Waste”, Rev. 0, June 2003.

EDF-3784,2003, “Reaction Vessel and Waste Processing Campaign for Chemical Oxidation of V-Tank Waste”, Rev. 0, June 2003.

EDF-379 1,2003, “Mass Balance, Reaction Kinetics, and Vapor Pressure Calculations Supporting the Chemical Oxidation of V-Tank Wastes”, Rev. 0, June 2003.

EDF- 3795, 2003, “LDR Treatment Requirements for Chemical Oxidation and Stabilization of the V- Tank Waste”, Rev. 0, June 2003.

F-3 Conceptual Design Report for Ex Situ Chemical OxidatiodReduction and Stabilization of the V-Tanks

Appendix G

Project Risks and Mitigation

------- G- I Conceptual Design Report for Ex Situ Chemical OxidatiodReduction and Stabilization of the V-Tanks

3 0 0 + I-

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0

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2

appendix d cost estimate - us department of energy · total project cost (tpc) was not addressed,...

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