Turbosteam finds high-return investment opportunities to convert waste energy into on-site power at industrial facilities. We recognize that on-site power generation is a non-core activity for our customers, meaning that high returns alone are not enough to make a project pencil. Successful projects need to be as contractually simple as possible, and they must minimize the potential for long-term surprises. Given these needs, Turbosteam uses a project development process designed to quickly quantify the opportunity, and then it stages detailed engineering time and resources only as justified by contracting cycles.

Turbosteam’s development process eliminates the “too many cooks in the kitchen” problems that bedevil many on-site power projects. Throughout the process, Turbosteam takes the lead role in project development and specification in order to ensure that there is always a single point of responsibility and control.

Step One: First-pass engineering

While many businesses have the potential to generate on-site power, relatively few have access to all the necessary data to specify a project. Only a limited number possess the key information—from steam flows and pressures to amperages on distribution networks—needed to finalize a system design.

Over its 20-year history, Turbosteam has developed proprietary software tools and rules-of-thumb to help us quickly assess energy opportunities in a given facility, even where there is not sufficient data to precisely define the overall system. The goal of this first-pass engineering is to identify capital budgeting thresholds, plant requirements, and other “make or break” project provisions, and then to determine whether a given opportunity is likely to pass those tests.

Completing this first-pass engineering usually can be accomplished through a 20-minute telephone interview that allows Turbosteam to understand a customer’s facility and desired objectives. Among the information we will seek during this interview is:

• Overview of facility design and thermal/electrical configurations
• Boiler steam pressure and temperature
• Required process steam pressure and temperature
• Steam flow to the process including any seasonal or process variations
• Site-specific electrical requirements
• Capital budgeting requirements
• Blended electricity rate
• Boiler fuel and price
• Voltage of in-plant distribution systems and likely generator tie-in locations
• Plant control and communication protocols
• Size or other constraints on system design

At this interview’s conclusion, Turbosteam will develop an approximate project definition, including power output, budgetary price, and annual energy savings. In some cases, this definition can be completed during the interview process, but in all cases will be concluded with a written First-Pass Engineering Assessment.

Step Two: System Engineering and Assessment (SE&A)

If the First-Pass Engineering Assessment meets internal criteria, Turbosteam will develop more precise system definitions and pricing. This process requires a site visit and detailed engineering in order to verify initial assumptions, secure any missing information, and review overall plant and system configuration and integration. For this site visit to be productive, Turbosteam needs the following:

• Plant P&IDs
• Electricity and fuel bills for the prior 12 months
• An executed contract for out-of-pocket expenses and a nominal fee that is deducted from the contract sale price upon purchase

Once this information has been received and reviewed, Turbosteam engineers will perform a one-day site visit to complete detailed engineering. Subsequent to the site visit, Turbosteam will provide a detailed report, including the following:

• Multiple options warranted by the project, with a clear explanation of each and Turbosteam’s recommended package
• A complete system design, including descriptions of each specific piece of equipment, complete with manufacturer’s data and performance curves
• Fixed-price contracts for all specified equipment and associated engineering services needed to integrate the equipment into the host facility (steam piping design, electrical coordination, etc.)
• Installation recommendations
• Electric rate structure analysis
• Financial analysis
• Engineering drawings in order to gain budgetary installation costs
• Contract documentation and price suitable for execution
• If appropriate, opportunities for state and federal grants that may be available to offset project capital costs

Turbosteam asks all pertinent individuals involved in the project to attend the site visit, voice any concerns, or ask any questions. We also request that any preferred installation contractors attend the site visit to allow Turbosteam to discuss the project’s details and obtain an installation quote for inclusion in the project economics.

Subsequent to the detailed report’s delivery, Turbosteam will schedule a follow-up site visit to address any outstanding questions and adjust specifications as necessary.

Step Three: Design, construction, and commissioning

Once under contract, Turbosteam takes sole responsibility for all elements of system design and construction, including:

• Mechanical, electrical, and controls designs
• Procurement of all subassemblies and integration
• Wiring and testing of all skid and controls components
• Shipment to the project site
• Complete system commissioning and operator training

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