Thermal Power Station Advice

- Fixed & Variable O&M Costs

Report for the Electricity Commission

SEPTEMBER 2009

Prepared By:
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This report has been prepared exclusively for the benefit of the Electricity Commission.
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or the accuracy or completeness of any conclusion and such other parties should make
their own enquiries and obtain independent advice in relation to such matters.

Reliance on Data

In preparing this Report, PB has relied on information supplied by and gathered from a
number of sources including public domain and proprietary data services, internet sites,
news services as well as parties involved in the industry. Any projections are estimates
only and may not be realised in the future. No blame or responsibility should be
attached to any of these sources for any factual errors or misinterpretation of data in the
Report. PB has not independently verified the accuracy of this information and has not
audited any financial information presented in this Report.

Limitations

This Report covers technical data relating to thermal generating plants and is based on
the facts known to PB at the time of preparation. This report does not purport to contain
all relevant information on all plant. PB has made a number of assumptive statements
throughout the Report, and the Report is accordingly subject to and qualified by those
assumptions. The uncertainties necessarily inherent in relying on assumptions and
projections mean that it should be anticipated that certain circumstances and events
may differ from those assumed and described herein and that such will affect the results.

PB Quality System:

Document Reference : 153012A Task 002 Thermal Power Station Advice Report -
O&M costs 002 final.doc

Report Revision : 002

Report Status : Final
Prepared by : Neil Wembridge
Reviewed by : Nick Barneveld
Approved by : Nick Barneveld
Date Issued : 8th September 2009
Over a Century of Engineering Excellence Quality Management System Certified to ISO 9001: 2000

PARSONS BRINCKERHOFF
Thermal Power Station Advice
PB Report for the Electricity Commission

Contents

Page Number
1 Introduction ..................................................................................................................... 1
1.1 Background 1
1.2 Methodology 1
1.3 Scope 1
1.4 Exchange rates 2
2 O&M cost comparisons................................................................................................... 3
2.1 Introduction 3
2.2 Definitions 3
2.3 GEM assumptions 4
2.4 Other Energy markets 5
2.5 Previous PB reports 6
2.6 Other reference information 8
3 Analysis ......................................................................................................................... 10
3.1 Technology specific cost comparison 10
3.2 O&M costs & exchange rate movements 12
3.3 Summary 12
4 Glossary ......................................................................................................................... 14

List of tables
Table 1 Technology specific O&M costs iii
Table 2 NZ thermal plant O&M costs iii
Table 2.1 GEM technology specific O&M costs 4
Table 2.2 NZ thermal plant O&M costs GEM 4
Table 2.3 NEM generator O&M costs existing plant 5
Table 2.4 NEM new entrant O&M costs 5
Table 2.5 US generator O&M costs technology specific 6
Table 2.6 SOO O&M cost assumptions technology specific 6
Table 2.7 SOO O&M cost assumptions NZ thermal plant 7
Table 2.8 Peaking report O&M costs technology specific 7
Table 2.9 East Harbour report: O&M cost assumptions 8
Table 2.10 Marsden et al report O&M costs 8
Table 2.11 Poyry UK report O&M costs 9
Table 3.1 ST O&M costs comparison 10
Table 3.2 CCGT O&M costs comparison 10
Table 3.3 OCGT gas fuelled O&M costs comparison 11
Table 3.4 OCGT liquid fuelled O&M costs comparison 11
Table 3.5 Technology specific O&M cost recommendations 12
Table 3.6 NZ thermal plant O&M cost recommendations 13

PARSONS BRINCKERHOFF Page i

Thermal Power Station Advice
PB Report for the Electricity Commission

PARSONS BRINCKERHOFF Page ii

Thermal Power Station Advice
PB Report for the Electricity Commission

Executive Summary
The Electricity Commission has engaged PB New Zealand Ltd to provide estimates of non-fuel,
fixed and variable O&M costs for thermal plant in New Zealand. A broad literature review of
comparative information from the Australian, North American and European energy markets
has been used in recommending appropriate estimates for thermal plant O&M cost
assumptions used in the Electricity Commissions Generation Expansion Model (GEM).

Operating and maintenance costs are subject to wide variation depending on the make and
model of plant, the operating regime, and whether coal, gas or liquid fuel is used. The
recommended values for non-fuel, fixed and variable O&M costs for new entrant thermal plant
technology types are presented in Table 1.
Table 1 Technology specific O&M costs

Technology Existing GEM values PB recommendation1

Variable Fixed Variable Fixed
$/MWh $/kW/year $/MWh $/kW/year
ST (coal fuelled) 9 100 9 70
CCGT 4.25 50 4.25 35
OCGT (100 MW, gas fuelled) 6 14 8 16
OCGT (100 MW, liquid fuelled) 14 14 9.6 16

1
Values in 2009 New Zealand dollars.

The recommended values for non-fuel, fixed and variable O&M costs for existing New Zealand
thermal power stations are presented in Table 2.
Table 2 NZ thermal plant O&M costs

Asset Technology Existing GEM values PB recommendation1

Variable Fixed Variable Fixed
$/MWh $/kW/year $/MWh $/kW/year
Southdown CCGT 4.3 50 4.25 35
TCC CCGT 4.3 50 4.25 35
Otahuhu B CCGT 4.3 50 4.25 35
Huntly unit 5 (E3P) CCGT 4.25 50 4.25 35
Huntly unit 6 (P40) OCGT 6.4 90 8 16
Southdown (E105) OCGT 6.4 90 8 16
Huntly PS (Units 1-4) ST (Coal) 9.6 60 9.6 70
Whirinaki OCGT (liquid) 10 90 9.6 20

1
Values in 2009 New Zealand dollars.

PARSONS BRINCKERHOFF Page iii

Thermal Power Station Advice
PB Report for the Electricity Commission

PARSONS BRINCKERHOFF Page iv

1 Introduction
1.1 Background
This review of non-fuel operations and maintenance (O&M) costs for thermal plant
accompanies the previous report1 on thermal plant lives and LRMCs submitted to
the Electricity Commission (Commission), dated July 2009.

The Commissions Generation Expansion Model (GEM) uses assumptions

regarding the non-fuel O&M costs for existing and potential future generic thermal
plant in its modelling. PB has been engaged to provide a review of existing
assumptions and provide updated recommendations based on publicly available
information.

1.2 Methodology
In order to provide the required information to the Commission, a broad literature
review of comparative information from the Australian, North American and
European energy markets has been performed supplementing PBs knowledge
and experience of working with thermal power station costs. This provides a basis
for the reconciliation and update of the existing GEM assumptions.

1.3 Scope
Thermal technologies considered are:

Steam Turbine, coal fuelled, CFB or PC, > 500MW;

CCGT, gas fuelled, 400 MW;

OCGT, gas fuelled, 100 MW; and

OCGT, liquid fuelled, 100 MW.

The above technologies cover the breadth of existing thermal plant in New
Zealand, and provide coverage for the generic main types of new thermal
generation included in the GEM modelling assumptions.

Specific New Zealand thermal plants included in the review are:

Huntly Power Station - Units 1 to 4;

Huntly CCGT - E3p;

Huntly OCGT - P40;

1
PB New Zealand Ltd. Thermal Power Station Advice: Report for the Electricity Commission. July 2009.

PARSONS BRINCKERHOFF Page 1

 Taranaki CCGT;

Otahuhu B CCGT;

Southdown CCGT;

Southdown OCGT (E105); and

Whirinaki OCGT liquid fuelled, dry year reserve plant.

1.4 Exchange rates

All dollar values are quoted in 2009 New Zealand Dollars unless otherwise stated.

Currency conversion rates used for the purposes of this report are as follows:

1 USD = 1.5 NZD

1 GBP = 2.5 NZD

1 AUD = 1.2 NZD

PARSONS BRINCKERHOFF Page 2

2 O&M cost comparisons
2.1 Introduction
In order to provide accurate estimates of the non-fuel, fixed and variable O&M
costs for thermal plant in New Zealand, PB has performed a review of available
reference information.

As definition of the terms relating to O&M costs varies widely, it has been
important to understand the assumptions made by each source of information as
to what has been included and excluded for each comparative value.

2.2 Definitions
All fixed and variable O&M costs referred to in the report exclude any costs
associated with fuel supply, transport and handling, Capex and major
refurbishment.

2.2.1 Variable O&M (VOM) costs

These costs, defined as $/MWh, refer to the incremental operations and

maintenance costs incurred upon increasing the level of production by one unit.
Variable O&M (VOM) costs will include minor unplanned maintenance, water
usage, chemicals, limestone (where FGD is used), auxiliary energy use and ash
disposal costs.

Major maintenance costs for gas turbine plant can also be included in the VOM
cost values. This is because maintenance is based on the equivalent operating
hours of the plant as opposed to coal fuelled steam turbine plant where
maintenance is periodic and treated as a fixed operating cost. Where the
reference information allows, the report will indicate whether major maintenance
has been included in the variable or fixed portion of gas turbine plant O&M costs.

Typically, gas fired plant has the lowest variable O&M costs and coal fuelled plant
has the highest costs associated with the costs of ash disposal and requirements
2
for flue gas desulphurisation (FGD).

2.2.2 Fixed O&M (FOM) costs

These costs, defined as $/kW/year, typically include all fixed operating costs such
as spares, major periodic maintenance, insurance, O&M fees, property taxes and
leases and owners costs such as wages. Fixed costs should not vary with
changes in electricity generation levels.

2
No New Zealand plant currently have FGD installed.

PARSONS BRINCKERHOFF Page 3

 2.3 GEM assumptions
The values included in Table 2.1 and Table 2.2 were provided by the Commission
in an email to PB dated 18th August 2009.

Table 2.1 GEM technology specific O&M costs

Technology Existing GEM values

Variable Fixed
$/MWh $/kW
ST (coal fuelled) 9 100
CCGT 4.25 50
OCGT (100 MW, gas fuelled) 6 14
OCGT (100 MW, liquid fuelled) 14 14

Table 2.2 NZ thermal plant O&M costs GEM

Asset Technology Existing GEM values

Variable Fixed
$/MWh $/kW
Southdown CCGT 4.3 50
TCC CCGT 4.3 50
Otahuhu B CCGT 4.3 50
Huntly unit 5 (E3P) CCGT 4.25 50
Huntly unit 6 (P40) OCGT 6.4 90
Southdown (E105) OCGT 6.4 90
Huntly PS (Units 1-4) ST (Coal) 9.6 60
Whirinaki OCGT (liquid) 10 90

The existing GEM cost assumptions have used a variety of sources, with some
reports more recent than others. Whilst some input O&M costs for thermal plant
do change over time, in general plant running costs are not expected to change
significantly due to the cost savings derived from technology advances off setting
any inflationary effects.

PARSONS BRINCKERHOFF Page 4

 2.4 Other Energy markets
2.4.1 Australia - Generation costs in the NEM

An ACIL Tasman report3 for NEMMCO estimated the costs of generation for
existing and future thermal assets. Information contained in the report on O&M
costs for existing and new entrant plant in the NEM are summarised in Table 2.3
and Table 2.4.

Table 2.3 NEM generator O&M costs existing plant

Technology Variable Fixed

AU$/MWh AU$/kW
ST Coal fuelled e.g. Bayswater, NSW 1.19 49
CCGT e.g. Tallawarra, NSW 1.05 31
OCGT Liquid fuelled Hunter Valley, 9.61 13
NSW
OCGT gas fuelled Roma, QLD 9.61 13

Technology Variable Fixed

$/MWh1 $/kW1
ST Coal fuelled e.g. Bayswater, NSW 1.43 59
CCGT e.g. Tallawarra, NSW 1.26 37
OCGT Liquid fuelled Hunter Valley, 11.53 16
NSW
OCGT gas fuelled Roma, QLD 11.53 16

1Values converted using an exchange rate of AU$ 1 = NZ$1.2.

Table 2.4 NEM new entrant O&M costs

Technology Variable Fixed

AU$/MWh AU$/kW/year
ST 500MW, coal fuelled 1.25 48
CCGT 400MW, gas fuelled 1.05 31
OCGT 150MW, gas fuelled 7.70 13

Technology Variable Fixed

$/MWh1 $/kW/year1
ST 500MW, coal fuelled 1.50 58
CCGT 400MW, gas fuelled 1.26 37
OCGT 150MW, gas fuelled 9.24 16
1
Values converted using an exchange rate of AU$1 = NZ$1.2.

3
ACIL Tasman. Fuel Resource, new entry and generation costs in the NEM. April 2009.

PARSONS BRINCKERHOFF Page 5

 2.4.1 North America

O&M cost assumptions provided by the Energy Information Administration to the

Annual Energy Outlook (2009) report, are contained in Table 2.5.

Table 2.5 US generator O&M costs technology specific

Technology Variable Fixed

US$/MWh US$/kW/year
ST coal fuelled, 600MW 4.59 27.5
CCGT 400MW 2.07 12.5
OCGT 150MW 3.57 12.1

Technology Variable Fixed

$/MWh1 $/kW/year1
ST coal fuelled, 600MW 6.9 41
CCGT 400MW 3.1 19
OCGT 150MW 5.3 18
1
2009 $. US Dollar values converted using an exchange rate of US$1 = NZ$1.5.

2.5 Previous PB reports

2.5.1 SOO update 2006

During 2005, the Commission developed an initial Statement of Opportunities

(SOO) which was published in printed form in July 2005. As part of the work in
developing this initial SOO, Parsons Brinckerhoff New Zealand Ltd (PB)
completed a report for the Commission that, amongst other things examined the
capital and O&M costs of coal fuelled STs, and gas fuelled OCGTs and CCGTs in
New Zealand.

All estimates were based in 2004 New Zealand dollars. Information previously
4
supplied is summarised in the following two tables.

Table 2.6 SOO O&M cost assumptions technology specific

Technology O&M costs

$/kW/year
ST - 250 MW subcritical 65
ST 400 MW subcritical 70
OCGT 50 MW, gas fuelled 104
CCGT 410 MW, gas fuelled 75

The values provided in Table 2.6 included both the variable and fixed non-fuel
O&M costs for thermal generating plant, as inputs into calculating the LRMC of
different generating technologies.

4
PB Associates. Electricity Generation Database: Statement of Opportunities update 2006. October 2006.

PARSONS BRINCKERHOFF Page 6

 Values provided in Table 2.7 were provided as an input in calculating the SRMC of
New Zealand thermal generating plant.

Table 2.7 SOO O&M cost assumptions NZ thermal plant

Asset Variable
$/MWh
Huntly Power Station ST (Units 1-4) 9.6
Huntly OCGT (P40) 6.4
Southdown - CCGT 4.3
Otahuhu B - CCGT 4.3
TCC - CCGT 4.3
Whirinaki 6.4
Southdown - OCGT 6.4
Huntly CCGT (e3p) 4.3

2.5.2 Thermal peaking plant report

This PB report5 provided estimates of both fixed and variable annual O&M costs
for gas and diesel fuelled peaking plant (OCGT) in New Zealand. All estimates
were based in 2008 New Zealand dollars. Information supplied as follows:

Table 2.8 Peaking report O&M costs technology specific

Technology Variable Fixed

$/MWh $/kW/Year
OCGT 100MW, gas fuelled 6 14
OCGT 100MW, liquid fuel 7.2 14

The O&M cost estimates were based on a 2% capacity factor and 30 starts per
year with an average duration of 6 hours operation.

The variable O&M costs for liquid fuelled plant are higher due to the reduced
operating hour intervals between scheduled maintenance associated with
operating an engine on liquid fuels.

The overall O&M costs for liquid fuelled plant are very sensitive to increases in
operating hours and rapidly increase if annual operating hours assumptions
increase. The costs are also very specific to the individual engines installed as
each manufacturer specifies different maintenance requirements for their
machines.

5
PB New Zealand Ltd. Cost Estimates for Thermal Peaking Plant, Version 002. June 2008.

PARSONS BRINCKERHOFF Page 7

 2.6 Other reference information
This section contains other non-fuel O&M cost information for thermal plant. The
values observed vary significantly from the results seen above, and are included
here to demonstrate the wide range of values published.

2.6.1 NZ: East Harbour report

The following information6 was prepared for the New Zealand Ministry of
Economic Development.

Table 2.9 East Harbour report: O&M cost assumptions

Technology Variable Fixed

$/MWh1 $/kW/Year1
ST PC with FGD - 400MW 8 45
CCGT 400MW 1.2 30
2
OCGT 160MW 0.2 12
1
Costs are 2001 New Zealand Dollars.
2
Assumes a 20% load factor.

2.6.2 NZ: Marsden, Poskitt and Small

Values summarised in Table 2.10 are taken from a report 7 which examined
investment costs for the New Zealand electricity industry.

Table 2.10 Marsden et al report O&M costs

Technology Variable Fixed

$/MWh1 $/kW/Year1
ST 3.1 31
CCGT 3.1 14
OCGT 3.1 12
1
Costs are 2004 New Zealand Dollars.

6
East Harbour Management Services Ltd. Costs of fossil fuel generating plant. May 2002.
7
Marsden, Poskitt and Small. Investment in the New Zealand Electricity Industry. 2004.

PARSONS BRINCKERHOFF Page 8

 2.6.3 UK costs: Poyry report

A Poyry Energy Consulting (PEC) report8 for the UK Government assumes the
non-fuel O&M costs contained in Table 2.11.

Table 2.11 Poyry UK report O&M costs

Technology Variable Fixed

GBP/MWh GBP/kW/Year
ST CFB, coal fuelled 1.10 17
CCGT 400MW 2.00 7

Technology Variable Fixed

$/MWh1 $/kW/Year1
ST CFB, coal fuelled 2.75 42.5
CCGT 400MW 5.00 17.5
1
Values converted using GBP 1 = NZD 2.5.

8
Poyry Energy Consulting. Analysis of carbon capture and storage cost-supply curves for the UK. January 2007.

PARSONS BRINCKERHOFF Page 9

3 Analysis
3.1 Technology specific cost comparison
3.1.1 ST Coal fuelled

Table 3.1 summarises the variance in the O&M costs for coal fuelled ST plant.

Table 3.1 ST O&M costs comparison

Technology Variable Fixed

$/MWh $/kW/Year
GEM current assumption 9 100
Australia, NEM - 2009 $ 1.5 58
USA, EIA 2009 $ 6.9 41
PB reports 2006 $ 9.6 701
East Harbour 2001 $ 8 45
1
Also included variable costs.

PB considers that the current GEM assumption for variable O&M costs is currently
in the correct range. The notable anomaly is the NEM value which appears low
considering the additional variable costs such as ash handling, limestone and FGD
expenses incurred by such plant.

The fixed O&M cost assumption in GEM appears high when compared with the
other values, and therefore PB recommends that $70/kW/year may be more in-
line with typical costs.

3.1.2 CCGT Gas fuelled

Table 3.2 summarises the variance in the O&M costs for gas fuelled CCGT plant.

Table 3.2 CCGT O&M costs comparison

Technology Variable Fixed

$/MWh $/kW/Year
GEM current assumption 4.25 50
2
Australia, NEM 2009 $ 1.26 37
USA, EIA 2009 $ 3.1 19
PB reports 2006 $ 4.3 751
East Harbour 2001 $ 1.2 30
1
Includes variable O&M costs.
2
Excludes major maintenance costs

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 PB considers that the current GEM assumption for variable O&M costs is currently
in the correct range with the assumption it includes the costs of major
maintenance on an equivalent operating hours basis. Given this, PB considers the
GEM fixed O&M cost to be slightly high and recommends that $35/kW/year is
more in-line with actual costs.

3.1.3 OCGT Gas fuelled

Table 3.3 summarises the variance in the O&M costs for gas fuelled OCGT plant.

Table 3.3 OCGT gas fuelled O&M costs comparison

Technology Variable Fixed

$/MWh $/kW/Year
GEM current assumption 6 14
Australia, NEM 2009 $ 9.24 16
USA, EIA 2009 $ 5.3 18
PB reports Peaking 2008 $ 6 14

PB considers that the current GEM assumption for non-fuel variable O&M costs is
currently slightly below the correct range. PB would recommend increasing this to
$8/MWh in order to reflect actual current costs.

The fixed O&M cost assumption in GEM also appears slightly low when compared
with the other values, and therefore PB recommends that $16/kW/year may be
more in-line with typical costs.

3.1.4 OCGT Liquid fuelled

Table 3.4 summarises the variance in the O&M costs for gas fuelled CCGT plant.

Table 3.4 OCGT liquid fuelled O&M costs comparison

Technology Variable Fixed

$/MWh $/kW/Year
GEM current assumption 14 14
Australia, NEM 2009 $ 9.24 16
PB reports Peaking 2008 $ 7.2 14

PB considers that the current GEM assumption for non-fuel variable O&M costs is
currently too high. PB would recommend decreasing this to $9.6/MWh in order to
reflect actual current costs.

PB has assumed a penalty factor of 1.2 on the OCGT plant liquid fuelled
variable O&M costs when compared to the gas fuelled equivalent to account for
the reduction in interval times between major maintenance. Running plant on
liquid fuels decreases the number of operating hours between service intervals.

PARSONS BRINCKERHOFF Page 11

 The fixed O&M cost assumption in GEM also appears slightly low when compared
with the other values, and therefore PB recommends that $16/kW/year may be
more in-line with typical costs.

3.2 O&M costs & exchange rate movements

PB estimates that approximately one-third of fixed O&M costs for New Zealand
thermal plant are influenced by exchange rate movements. As there is a lack of
domestic heavy manufacturing, the majority of maintenance materials for thermal
plant are imported.

Approximately one-third of VOM costs are influenced by movements in exchange

rates. The majority of affected costs comprise consumables such as chemicals.
Where major maintenance has been included in the VOM costs, approximately
two-thirds of the total would be influenced by movements in the USD/NZD or
JPY/NZD exchange rate since OEM servicing agreements typically include
exchange rate considerations.

3.3 Summary
3.3.1 Technology specific O&M cost recommendations

Table 3.5 Summarises the existing GEM assumptions and PB recommendations

based on report findings.

Table 3.5 Technology specific O&M cost recommendations

Technology Existing GEM values PB recommendation

Variable Fixed Variable Fixed
$/MWh $/kW $/MWh $/kW
ST (coal fuelled) 9 100 9 70
CCGT (gas fuelled) 4.25 50 4.25 35
OCGT (100 MW, gas fuelled) 6 14 8 16
OCGT (100 MW, liquid fuelled) 14 14 9.6 16

3.3.2 NZ thermal plant O&M cost recommendations

Table 3.6 summarises the existing GEM assumptions and PB recommendations

based on report findings. In the absence of actual data, PB recommends using
the appropriate generic technology values for each of the NZ thermal assets.

PARSONS BRINCKERHOFF Page 12

 Table 3.6 NZ thermal plant O&M cost recommendations

Asset Technology Existing GEM PB

values recommendation
Variable Fixed Variable Fixed
$/MWh $/kW $/MWh $/kW
Southdown CCGT (gas) 4.3 50 4.25 35
TCC CCGT (gas) 4.3 50 4.25 35
Otahuhu B CCGT (gas) 4.3 50 4.25 35
Huntly (Unit 5) CCGT (gas) 4.25 50 4.25 35
Huntly (Unit 6) OCGT (gas) 6.4 90 8 16
Southdown E105 OCGT (gas) 6.4 90 8 16
Huntly (1-4) ST (coal) 9.6 60 9.6 70
Whirinaki OCGT 10 90 9.6 20
(liquid)

For Huntly Units 1-4, PB considers the variable O&M cost should be slightly higher
given Huntlys non-baseload operational role. For Whirinaki, in its role as dry year
reserve plant, PB considers the fixed O&M costs should be slightly higher due to
the nature of the contracting arrangement for the operation and maintenance of
the plant.

PARSONS BRINCKERHOFF Page 13

4 Glossary
Term Definition
Capex Capital Expenditure
CCGT Combined Cycle Gas Turbine
CDS Centralised Data Set
CFB Circulating Fluidised Bed
CO2 Carbon Dioxide
EOH Equivalent Operating Hours
FGD Flue Gas Desulphurisation
FOM Fixed Operations and Maintenance costs
GE General Electric
GEM Generation Expansion Model
GT Gas Turbine
GWh Gigawatt-hour
HHV Higher Heating Value
HP High Pressure
HRSG Heat Recovery Steam Generator
kWh Kilowatt-hour
MW Megawatt
NCF Net Capacity Factor
O&M Operations and Maintenance
OCGT Open Cycle Gas Turbine
OEM Original Equipment Manufacturer
PB Parsons Brinckerhoff
SOO Statement of Opportunities
ST Steam Turbine
TCC Taranaki Combined Cycle power station
VOM Variable Operations and Maintenance costs

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