Work Breakdown Structure

Transcription

1 Work Breakdown Structure The work breakdown structure shown on the following chart shows the major components comprising the PPS 250 powerplant and who is responsible for the work to produce them. Proe Power Systems has the overall responsibility to produce the powerplants. We will also produce, in house, the CRU assembly, the expander, and the system integration hardware (the mechanical packaging, interconnect tubing and electrical interface). We will procure the synchronous generator and controls from commercial suppliers of this equipment for diesel generators. We will procure, or build under license, the combustor. There are already many solid biofuel combustors in use for generating steam and hot water. At the start of the program, we will provide those candidate suppliers with a requirements specification and request for proposal. Our requirement is unique because we will provide the fire with a hot air blast, instead of room temperature air. Consequently, we will have to work with the selected supplier(s) to modify their existing equipment for our requirement. Most of the combustor suppliers also provide the conveyors and equipment needed to move the solid fuel in and take the ash out of the combustor. We will go out for bid for the air heater with a request for proposal that contains drawings for build-to-print as well as a requirement specification. If a supplier has a heat exchanger design that can meet our requirements and price point we will use their design. Otherwise they can bid fabricating our design. The fuel dryer will be procured from one of the many producers of hay dryers and similar agricultural dryers. Some of the combustor candidates also have fuel dryers in their inventory as well.

2 250 kwe Powerplant Project Work Breakdown Structure PPS Biofuel Powerplant System Combined Rotating Unit Air Heater Combustor Fuel Dryer Fly Ash & Soot Collection Fuel Feed System Integration Hardware Field Operations Mechanical Packaging Compressor Combustion Chamber Hoppers Water Heater and/or Absorption Chiller Marketing Expander Air Valves Conveyors Interconnect Tubing Financing Synchronous Generator Ash Removal Air Locks Electrical Interfaces Installation & Setup Control Control Control Satellite Internet Connection (Where Required) Logistics Support System Control Maintenance Air Heater RFP Plan Combustor RFP Plan Responsibility Company 1Aerofin 2AIC 3 Alloy Engineering 4Ambassador Heat Transfer Co 5American Power Services Inc 6AMS 7API 8Aprovis 9 Ascension Industries 10 Babcock Power 11 Blakeslee equipment/hughes Anderson 12 Cincinnati Heat Exchanger 13 Econotherm 14 Exothermics 15 Fintube Technologies 16 GEA Rainey 17 General Air Products 18 Heat Exchange Applied Tech 19 Heatric 20 Hebeler Manufacturing 21 J.D. Cousins 22 Lytron 23 Potts Welding & Boiler Company Abbott Energy Systems ACT Bioenergy (BTEC) Alternative Energy Solutions International (AESI), Inc (BTEC) American Eco Boilers BHSL Biomass Combustion Systems (BTEC) BIOFOUR Chip Tec Dragonheat Energy Unlimited Firebird Froling Energy (BTEC) Gasek Heuristic Engineering Hurst Jackson Lumber Harvestor Lei Products Moench Inc New Horizon (BTEC) Phonix Energy Phoenix Energy PRM Energy Systems Skanden (BTEC) Swebo BioEnergy Tarm Biomass (BTEC) Total Energy Solutions uniconfort Vecoplan Industrial Shredders (BTEC) (Mtl Handling Only) Viessmann (BTEC) Wellons, Inc. Wood Master (BTEC) Proe Power Systems and AMS Combustor Supplier Proe Power Systems & Air Heater Supplier Synchronous Generator Supplier System Control Supplier BTEC Indicates a Member of the Biomass Thermal Energy Council Proe Power Systems, AMS & Compressor Head Supplier Agricultural Dryer Supplier skycasters satellite internet Water Heater & Chiller Suppliers Colorado Forest & Energy, Advanced BioEnergy Solutions, EverGreen, etal. In Respective Markets Finance Group(s)

3 Detailed Schedule Description Page 52 of the business plan shows a schedule overview for the PPS 250 program. This document contains a more detailed schedule with corresponding task descriptions. 1-18) Pre Phase A Tasks These tasks include raising the initial $8M funding needed to secure our loan as well as to perform mainline project preparation tasks. 21) Mainline Funding This task is to obtain the funding needed as shown on page 11 and 36 of the business plan. Key Milestones are: 22) Phase A Funded - OFFICIAL PROGRAM START $1.48 M committed by 6/30/ ) Phase B Funded $16.5 M committed by 9/19/ ) Phase C Funded $32 M committed by 7/13/ ) Setup and System Engineering These tasks consist of setting up the business and engineering offices, staffing and initiating detailed design. 30) System Engineering (Phase A) Comprises the Engine Concept Definition and specific System Engineering tasks

4 31) Engine Concept Definition 32) and 33) Engineering Office Setup and Engineering Staffing Locate a suitable office and recruit engineering personnel for prototype and production design engineering. 34) Phase 1 - Concept Definition Review Review the overall powerplant concept drawings and specifications with the newly formed engineering staff, discuss possible alternatives, and establish the prototype design baseline at the system level. 35) Phase 2A-CRU Preliminary Design Review the Combined Rotating Unit (CRU; the compressor, expander and generator) concept drawings and specifications with the newly formed engineering staff, discuss possible alternatives, and establish the prototype design baseline at the CRU level. 36) Phase 2B-Expander Preliminary Design Review the Expander concept drawings and specifications with the newly formed engineering staff, discuss possible alternatives, and establish the prototype design baseline at the details of the expander level. 37) Internal Concept Reviews A summary of the results of the previous tasks for top management (including investor) approval prior to commit to prototype detailed design. 38) System Engineering System level design and special evaluation 39)Preliminary Design Review A final review of the virtual prototype performance predictions prior to committing to the prototype detailed design. 40) Combustor Subscale Development Our plan is to directly procure or manufacture under license an existing combustor from the list in the Combustor RFP Plan. However, the existing combustors operate on room temperature air and we will be using a 900 o F blast air. This task will consist of sub-scale test and CFD/DEM analytical evaluation of our unique requirements. This effort will be performed by the supplier(s) in conjunction with our combustion consulting partner, Tridiagonal tm Solutions.

5 41) Materials Evaluation This task will consist of a review of all the high temperature material selections for the air heater, combustor, and expander. The major focus will be on selection of expander valve poppet and seat material. The task will be performed by the air heater supplier and the engine valve supplier. 43) First Unit Build and Test (Phase B) 45) Make System Integration Drawings This consists of making detailed design drawings for fabrication from the layouts of task 13. These drawing comprise the system level drawings for each of the 4 pallets: CRU Pallet, Combustor & Air Heater Pallet, Fuel Dryer and Water Heater Pallet, and Fuel Storage Bin Pallet; as well as the top integration drawing for the complete powerplant. 46) and 47) System Integration Design Review and Approval This is the detailed design review leading to authorization to build the prototype. Approval is a major project milestone (12/4/2014) 49) 1st Unit Engine (CRU Engineering) 48) Phase 3A - CRU Detailed Design Preparation of detailed fabrication drawings at the CRU assembly level. Compressor detailed design drawings are included in this task. The compressor heads will be procured or built under license from a compressor manufacturer. 49) Phase 3B - Expander Detailed Design Preparation of detailed fabrication drawings of the expander. 52) and 53) CRU Critical Design Review and Approval The detailed design review at the CRU level supporting the next higher assembly review and approval of task 24 and ) Phase 4A CRU Procurement and Build Procurement of supplier parts and fabrication of the first Combined Rotating Unit

6 56) Integration Equipment Procurement and Build Procurement of supplier parts and fabrication of the first set of integration equipment. 59) 1st Unit Air Heater Procurement and fabrication of the first Air Heater 64) 1st Unit Combustor/Dryer Procurement and fabrication of the first Combustor and Fuel Dryer 69) 1st Unit Final Assembly Final assembly of the prototype powerplant culminating in "Ready for Test" on 7/1/ ) First Unit Test 74) Initial Test and Checkout An initial manufacturing verification test to verify that the prototype operates, has been correctly assembled, and meets the performance specifications. After 3 weeks of shake-down and checkout we will begin to bring customers in to see the unit in operation and to review test data. 75) 1 Year Life Demonstration A one year life test at a selected location to demonstrate the 24/7 power generation capability under field operation conditions. The test will be performed over a range of loads, with various fuels, and with various fuel moisture content. 77 Pre-Production Planning Our marketing partners have an immediate demand for hundreds of our powerplants. It is extremely important that we design producibility into both the engineering drawings and the program plans by working with our manufacturing partner, AMS, as well as our supply chain. These vital tasks will allow them to work in parallel with our engineers to define not only the powerplant, but the facilities needed for rapid, economical, production. 78) PPS Pre-Production Planning (Michigan Android Pilot Plant) Pre-production planning for AMS at their facilities.

7 79 )Supplier Pre-Production Planning (Michigan Android Pilot Plant) Pre-production planning with our supply chain. 81) Production Setup (Phase C) Setup of the production tooling and assembly lines, both at Proe Power Systems and the major suppliers. 82) PPS Tooling Setup (Michigan Android Pilot Plant) Setup of the tooling needed to build the internally produced parts and assemblies and to perform the final assembly. 83) Supplier Production Setup (Michigan Android Pilot Plant) Setup of the tooling needed at the suppliers so that they can meet production rate goals 85) and 86) Unit 2 and Unit 3 Completion Milestones (12/2/2015 and 1/1/2016 respectively) Completion of the first production units on the new production lines and the beginning of commercial production. 88) Follow-On Production Enhancement 89) PPS Tooling Setup (Ohio) and 90) Supplier Production Setup (Ohio ) Setup of the production tooling and assembly lines at Proe Power Systems Ohio plant and the major suppliers to support an additional production rate of 65 units per month

8 ID Task Name Start Finish 1 Pre Phase A Tasks Mon 3/24/14 Fri 6/27/ kwe Powerplant Development and Production Startup Plan 2014a M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N Administrative Mon 3/24/14 Tue 6/24/14 4 Secure Initiial Funding Mon 3/24/14 Mon 3/24/14 3/24 5 Enter Loan Process Mon 3/24/14 Mon 3/24/14 3/24 6 Coordinate Primary Funding Initiation Mon 3/24/14 Fri 6/13/14 7 Coordinate Start-up With Manufacturing & Marketing Mon 3/24/14 Fri 6/20/14 8 Locate Office and Initiate Lease Tue 5/13/14 Tue 6/24/ Engineering Mon 3/24/14 Fri 6/27/14 11 System Specification Mon 3/24/14 Fri 4/11/14 12 Release System Specification Fri 4/11/14 Fri 4/11/14 4/11 13 Finalize Preliminary Design Layout Drawings Mon 4/14/14 Fri 5/16/14 14 Make Air Heater Drawings/Stress Analysis Mon 5/19/14 Fri 6/6/14 15 Air Heater Specification Mon 6/9/14 Fri 6/20/14 16 Combustor Specification Mon 6/23/14 Fri 6/27/14 17 Release Air Heater and Combustor RFP's Fri 6/27/14 Fri 6/27/14 6/ * Loan Closes: Mainline Funding Obtained * Fri 6/27/14 Fri 6/27/14 6/ Mainline Funding Mon 6/30/14 Mon 7/13/15 22 Loan Funded - OFFICIAL PROGRAM START Mon 6/30/14 Mon 6/30/14 6/30 23 Phase B Funding Review Fri 9/19/14 Fri 9/19/14 9/19 24 Phase C Funding Review Mon 7/13/15 Mon 7/13/15 7/ Mainline Project Tue 7/1/14 Wed 10/4/ Setup & System Engineering Tue 7/1/14 Thu 1/8/ System Engineering (Phase A) Tue 7/1/14 Thu 1/8/15 31 Engine Concept Definition Tue 7/1/14 Thu 9/18/14 32 Engineering Office Setup Tue 7/1/14 Mon 8/4/14 33 Engineering Staffing, Training and Familiarization Tue 7/1/14 Mon 9/8/14 34 Phase 1 - Concept definition Review Tue 9/2/14 Tue 9/2/14 Project: 250 kwe Powerplant Date: Mon 12/30/13 Task Progress Milestone Summary Rolled Up Task Rolled Up Milestone Rolled Up Progress Split External Tasks Project Summary Group By Summary Deadline Page 1 Initial Funding: March 24, 2014 Start: July 1, 2014

9 250 kwe Powerplant Development and Production Startup Plan 2014a ID Task Name Start Finish M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N Phase 2A - CRU Preliminary design Wed 9/3/14 Tue 9/16/14 36 Phase 2B- Expander Preliminary Design Wed 9/3/14 Tue 9/16/14 37 Internal Concept Reviews Wed 9/17/14 Thu 9/18/14 38 System Engineering Wed 9/3/14 Thu 1/8/15 39 Preliminary Design Review Wed 9/3/14 Tue 9/9/14 PPS Engineering 40 Combustor Subscale Development Fri 11/14/14 Thu 1/8/15 41 Materials Evaluation Fri 11/28/14 Thu 1/8/15 Combustor Development [1] Material Evaluation[1] First Unit Build and Test (Phase B) Fri 9/19/14 Wed 8/31/ Make System Integration Engineering Drawings Fri 10/3/14 Thu 11/27/14 Integration Engineering 46 System Integration Critical Design Review Fri 11/28/14 Thu 12/4/14 47 System Integration Design Approved Thu 12/4/14 Thu 12/4/14 12/ st Unit Engine (CRU Engineering) Fri 9/19/14 Tue 5/5/15 50 Phase 3A - CRU Detailed Design Fri 9/19/14 Thu 11/13/14 51 Phase 3B - Expander Detailed Design Fri 9/19/14 Thu 11/13/14 52 CRU Critical Design Review Fri 11/14/14 Tue 11/18/14 53 CRU Design Approved Tue 11/18/14 Tue 11/18/14 11/18 54 Phase 4A - CRU procurement & Build Wed 11/19/14 Tue 5/5/15 55 First Unit Build Wed 11/19/14 Tue 5/5/15 CRU[1] 56 Phase 4B - Integration Equipment Procurement & Build Wed 11/19/14 Tue 5/5/15 57 First Unit Build Wed 11/19/14 Tue 5/5/15 System Hardware[1] st Unit Air Heater Fri 9/19/14 Thu 4/23/15 60 Procurement Fri 9/19/14 Thu 1/8/15 61 Air Heater Fabrication Fri 1/23/15 Thu 4/23/15 Air Heater Fabricator[1] st Unit Combustor/Dryer Fri 9/19/14 Thu 4/30/15 65 Procurement Fri 9/19/14 Thu 11/13/14 66 Combustor and Feed Fri 11/14/14 Thu 4/30/15 67 Dryer Fri 3/6/15 Thu 4/30/15 Combustor/Feed[1] Dryer[1] st Unit Final Assembly Fri 5/1/15 Wed 7/1/ st Unit Final Assembly Fri 5/1/15 Wed 7/1/15 Assembly Material[1] Project: 250 kwe Powerplant Date: Mon 12/30/13 Task Progress Milestone Summary Rolled Up Task Rolled Up Milestone Rolled Up Progress Split External Tasks Project Summary Group By Summary Deadline Page 2 Initial Funding: March 24, 2014 Start: July 1, 2014

10 ID Task Name Start Finish 71 First Unit ready for Test Wed 7/1/15 Wed 7/1/ kwe Powerplant Development and Production Startup Plan 2014a M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N / st Unit Test Thu 7/2/15 Wed 8/31/16 74 Initial Test and Checkout Thu 7/2/15 Wed 9/2/15 Test Expense 75 1 Year Life Demonstration Thu 9/3/15 Wed 8/31/16 Life Test Expense Pre-Production Planning Wed 3/11/15 Wed 7/15/15 78 PPS Pre-Production Planning (Android Pilot Plant) Wed 6/10/15 Wed 7/15/15 79 Supplier Pre-Production Planning (Android Pilot Plant) Wed 3/11/15 Wed 7/15/15 PPS Pre-Production Planning Supplier Pre-Production Planning Production Setup (Phase C) Thu 7/16/15 Wed 10/4/17 82 PPS Tooling Setup (Android Pilot Plant) Thu 7/16/15 Wed 11/11/15 83 Supplier Production Setup (Android Pilot Plant) Thu 7/16/15 Wed 11/11/15 PPS 250 Tooling Supplier 250 Setup Unit 2 (First Production Unit) Wed 12/2/15 Wed 12/2/15 12/2 86 Unit 3 (2nd Production Unit) Fri 1/1/16 Fri 1/1/16 1/ Follow-on Production Enhancement Wed 2/1/17 Wed 10/4/17 89 PPS Tooling Setup (Ohio) Mon 5/1/17 Mon 10/2/17 90 Supplier Production Setup (Ohio) Wed 2/1/17 Wed 10/4/17 Project: 250 kwe Powerplant Date: Mon 12/30/13 Task Progress Milestone Summary Rolled Up Task Rolled Up Milestone Rolled Up Progress Split External Tasks Project Summary Group By Summary Deadline Page 3 Initial Funding: March 24, 2014 Start: July 1, 2014