COST ESTIMATING MANUAL FOR WATER TREATMENT FACILITIES Cost Estimating Manual for Water Treatment Facilities William McGivney and Susumu Kawamura Copyright © 2008 John Wiley & Sons, Inc. ISBN: 978-0-471-72997-6 COST ESTIMATING MANUAL FOR WATER TREATMENT FACILITIES William McGivney Susumu Kawamura John Wiley & Sons, Inc. 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TD434.M382008 628.1060681–dc22 2008003737 PrintedintheUnitedStatesofAmerica 10 9 8 7 6 5 4 3 2 1 Contents Preface xi List of Illustrations xv Chapter 1 Introduction to Construction Cost Estimating 1 1.1 CostEstimating–ArtorScience? 1 1.2 StructureoftheManual 1 1.3 RulesofThumbforGoodEstimates 2 1.4 UseofHistoricData 3 1.5 AdjustingtheNumbers 3 Chapter 2 Water Treatment Processes 5 2.1 BasicPlantDesignPhilosophy 5 2.2 BriefDescriptionofBasicWaterTreatment 6 2.3 BasicConventionalWaterTreatmentProcesses 8 2.4 AdvancedWaterTreatmentProcesses 12 Chapter 3 Solids Handling and Disposal 17 3.1 SolidsHandling 17 3.2 SludgeThickening 17 3.3 SludgeDewateringandDrying 18 v vi CONTENTS Chapter 4 Construction Cost Estimating at Predesign 19 4.1 ConstructionCostEstimating 19 4.2 ClassesandTypesofCostEstimates 20 4.3 PredesignConstructionCostEstimating 21 4.4 DefinitionofTerms 21 4.5 EstimatingMethodology 24 4.6 CapitalImprovementCosts 26 Chapter 5 Water Treatment Predesign Construction Costs 29 5.1 Introduction 29 5.2 TreatmentProcessandCostEstimatingParameters 30 5.3 CostCurves 32 5.4 EstimatingProcessandTotalFacilitiesCost 32 5.5 IndividualTreatmentProcessCostCurves 32 5.5.1 ChlorineStorageandFeedfrom150-lb to1-tonCylinders 32 5.5.2 ChlorineStorageTankwithRailDeliveryor FeedfromRailCar 36 5.5.3 ChlorineDirectFeedfromRailCar 37 5.5.4 OzoneGeneration 37 5.5.5 OzoneContactChamber 39 5.5.6 LiquidAlumFeed 39 5.5.7 DryAlumFeed 40 5.5.8 PolymerFeed 41 5.5.9 LimeFeed 42 5.5.10 PotassiumPermanganateFeed(KMNO4) 42 5.5.11 SulfuricAcidFeed 43 5.5.12 SodiumHydroxideFeed 43 5.5.13 FerricChlorideFeed 45 Contents vii 5.5.14 AnhydrousAmmoniaFeed 46 5.5.15 AquaAmmoniaFeed 46 5.5.16 PowderedActivatedCarbon 47 5.5.17 RapidMixG ¼ 300 48 5.5.18 RapidMixG ¼ 600 49 5.5.19 RapidMixG ¼ 900 49 5.5.20 FlocculatorG ¼ 20 50 5.5.21 FlocculatorG ¼ 50 50 5.5.22 FlocculatorG ¼ 80 52 5.5.23 CircularClarifierwith10-FtSideWaterDepth 52 5.5.24 RectangularClarifier 53 5.5.25 GravityFilterStructure 55 5.5.26 FilterMedia–StratifiedSand 57 5.5.27 FilterMedia–DualMedia 57 5.5.28 FilterMulti-Media 58 5.5.29 FilterBackwashPumping 58 5.5.30 SurfaceWashSystem 59 5.5.31 AirScourWashSystem 59 5.5.32 WashWaterSurgeBasin 60 5.5.33 FilterWasteWashWaterStorageTank 61 5.5.34 ClearwellWaterStorage–BelowGround 62 5.5.35 FinishedWaterPumping–TDH–100Ft 63 5.5.36 RawWaterPumping 64 5.5.37 GravitySludgeThickener 65 5.5.38 SludgeDewateringLagoons 66 5.5.39 SandDryingBeds 68 5.5.40 FilterPress 69 5.5.41 BeltFilterPress 69 5.5.42 CentrifugeFacility 71 5.5.43 Administration,Laboratory,and MaintenanceBuilding 72 viii CONTENTS 5.6 EstimatingCapitalCosts 73 5.7 EstimatingCapitalCostsofaConventionalWater TreatmentPlant 75 5.7.1 Two-StageFiltrationPlant 75 5.7.2 DirectFiltrationPlant 80 5.7.3 ConventionalFiltrationPlant 80 5.7.4 DissolvedAirFlotationFiltrationPlant 81 5.7.5 LimeandSodaAshFiltrationPlant 81 5.7.6 IronandManganeseRemovalPlant 82 5.7.7 MicroMembraneFiltrationPlant 83 5.7.8 DirectFiltrationwithPre-ozone FiltrationPlant 84 5.7.9 ConventionalTreatmentwithOzonation andGACFiltrationPlant 84 5.8 EstimatingtheCostofAdvancedWater TreatmentPlants 86 5.8.1 ReverseOsmosis(RO)TreatmentPlant 88 5.8.2 Multiple-EffectDistillation (MED)Treatment Plant 89 5.8.3 MechanicalVaporCompression(MVC) TreatmentPlant 89 5.8.4 Multi-StageFlash(MSF)Distillation TreatmentPlant 90 5.8.5 Ultra-FiltrationandNano-Filtration 91 Chapter 6 Operation and Maintenance Cost Impacts 95 6.1 AnnualOperatingandMaintenanceCost 95 6.2 O&MCostCurves 96 6.2.1a Two-StageFiltration 96 6.2.1b DirectFiltration 97 6.2.1c ConventionalTreatment 97 Contents ix 6.2.2a DissolvedAirFlotation 98 6.2.2b Lime&SodaAshSoftening 98 6.2.2c IronManganeseRemoval 99 6.2.3a MicroMembraneFiltration 99 6.2.3b DirectFiltrationwithPre-Ozonation 100 6.2.3c ConventionalTreatmentwithOzonation andGACFilters 100 6.3 AdvancedWaterTreatment–Seawater Desalination 100 6.3.1 O&MCostsforReverseOsmosisTreatment 101 6.3.2 O&MCostsforMulti-StageFlash 101 6.3.3 O&MCostsforMultipleEffectDistillation (MED)Treatment 102 6.3.4 O&MCostsforMechanicalVapor Compression(MVC)Treatment 102 6.3.5 O&MCostsforUltra-Filtrationand Nano-Filtration 103 Chapter 7 Future Water Supply, Treatment and Distribution 105 Appendices 109 PrefacetotheAppendices 111 AppendixA—DetailedTreatmentPlantCostTables 113 A.1a Two-StageFiltrationProcess10MGD 115 A.1b Two-StageFiltrationProcess100MGD 119 A.2a DirectFiltrationProcess10MGD 123 A.2b DirectFiltrationProcess100MGD 127 A.3a ConventionalWaterTreatmentProcesses 10MGD 131 A.3b ConventionalWaterTreatmentProcesses 100MGD 135 x CONTENTS A.4a DissolvedAirFlotation(DAF)as PretreatmentProcess10MGD 139 A.4b DissolvedAirFlotation(DAF)as PretreatmentProcess100MGD 143 A.5a LimeandSodaAshWaterSofteningProcess 10MGD 147 A.5b LimeandSodaAshWaterSofteningProcess 100MGD 151 A.6a IronandManganeseRemovalProcess 10MGD 155 A.6b IronandManganeseRemovalProcess 100MGD 159 A.7a MicroMembraneFiltrationProcess10MGD 163 A.7b MicroMembraneFiltrationProcess 100MGD 167 A.8a DirectFiltrationwithPre-Ozonation 10MGD 171 A.8b DirectFiltrationwithPre-Ozonation 100MGD 175 A.9a ConventionalTreatmentProcesswith OzonationandGACFilters10MGD 179 A.9b ConventionalTreatmentProcesswith OzonationandGACFilters100MGD 183 AppendixB—TableB1—BasisofOpinionofProbable ConstructionCost 187 AppendixC—ShorthandConversionTablefor Metric(SI)ConversionsandOtherUsefulFactors 190 Glossary 191 Bibliography 197 Index 199