BAISCH TEMPLATE

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Baisch Engineering Inc. SPECIAL SERVICES
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TABLE OF CONTENTS Part 1
Process Line Profitability Audits Plant
Inventories/ Updated Drawings Steam System
Modeling Power Systems Analysis Energy
Audits Engineering Outsourcing Client/OEM
Engineering Services Facility Master Plans
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TABLE OF CONTENTS Part 2
Appraisals and Valuations Strategic
Planning Procurement Services EPC Project
Supply Control Panel Supply Plant/ Process
Troubleshooting Owners Engineer Plant Balanced
Process Model
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Process Line Profitability Audits
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Process Line Profitability Audits

• Baisch senior engineers are
• thoroughly experienced at helping
• clients to improve their profits.
• Baisch has developed and proved a
• methodology to do this.
• The goal is to produce a
• customized improvement plan
• based upon the plants current and
• future production strategy that is
• fully justified by ROI financial
• models.

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Process Line Profitability Audits

• A small team of senior Baisch engineers
• together with client production and
• engineering personnel is formed.
• The first step is a confidential end to end
• production line investigation that focuses
• on identifying conditions which are
• detrimental to, or opportunities to improve,
• profitable operation.
• For each of the opportunities identified, the
• cost of the improvement is estimated and a
• simple ROI analysis is performed.

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Process Line Profitability Audits

• The results of this first analysis are
• discussed with plant and/or corporate
• management and a priority list is produced
• of those items which are preferred.
• Preference may be for those opportunities
• which give the greatest returns, or those
• which can be achieved quickly and
• economically.
• The preferred opportunities are now
• studied in more detail and a more thorough
• cost and ROI analysis is performed.

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Process Line Profitability Audits

• The results of this second analysis are
• discussed again with plant and/or
• corporate management to decide which
• projects should be submitted for approval
• and allocation of funds.
• An appropriation grade estimate and ROI
• determination is produced for each
• selected project for submittal.

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Process Line Profitability Audits

• The approved projects are executed.
• Project cost and schedule are reduced
• because of the preparation work already
• carried out, which enables each bidder for
• the project to bid with confidence on a well-
• defined project scope.
• When each project is complete, the line
• investigation is repeated to measure the
• results and ensure that the returns are in
• fact being realized.

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Plant Inventories and Updated Drawings
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Plant Inventories and Updated Drawings

• Many plants do not have an accurate and
• detailed inventory of the process and
• support equipment in the plant.
• This makes preventive maintenance,
• correct stocking of spares and planning of
• improvement work difficult, finally
• reducing uptime and efficiency.
• A small Baisch team can quickly carry out
• a physical inspection of the plant and
• produce an accurate inventory with all
• necessary details of the plant total
• equipment.

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Plant Inventories and Updated Drawings

• Few plants have process drawings that are
• current in the information contained. Many
• plants have some or none, others have
• drawings only on paper.
• This makes planning of improvements and
• even maintenance work difficult, since the
• process line has to be physically checked
• each time work is needed.

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Plant Inventories and Updated Drawings
A small Baisch team can quickly carry out a
physical inspection of the plant and produce
general arrangement drawings, PIDs, balanced
flow diagrams and other drawings (in a level of
detail to be decided in advance by the client)
in an electronic form to fit the clients
standards.
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Plant Inventories and Updated Drawings
Some examples of inventory/ drawings

• Inventory/
• Equipment
• Equipment List
• Motor List
• Instrument Index
• Spare Parts List /
• Inventory
• Equipment
• Numbering
• Scheme /
• Implementation

• Drawings - updated
• or generated new
• PI Diagrams
• Site Plan
• General Arrangement
• Machine Elevation
• MCC Face Layouts
• Electrical One-Line
• Mass Balance
• Drawing Index
• Drawing Numbering
• Scheme /
• Implementation

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Plant Inventories and Updated Drawings

• One of the main reasons for the lack of
• updated inventory and drawings in plants
• today is that cost cutting has left plants
• without enough people to enable
• continuous updating of drawings and
• inventories.
• Baisch will if desired maintain in the
• Baisch office the drawing and inventory
• records for any plant, updating these at a
• frequency to be determined by the client.

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Plant Inventories and Updated Drawings
The confidentiality of the data will be
protected. All data will be organized so as to
be immediately and securely available
electronically to the client in a form
convenient to his standards. This service
removes the necessity for someone at the plant
to continually update the records.

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Steam System Modeling
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Steam System Modeling

• Steam and condensate systems and other
• systems containing fluid flowing at high
• temperatures or pressures are potential
• safety hazards.
• When such systems are modified, or even
• when ambient conditions in the plant or part
• of the plant change, stresses in the piping
• and vessels can become unacceptable.
• Baisch specialists can audit the whole
• system, model the system, define areas
• where an unsafe condition exists and
• recommend the action necessary to make
• the system safe.

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Power Systems Analysis
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Power Systems Analysis

• Baisch electrical specialists are thoroughly
• experienced at performing for clients the
• following
• Arc-Flash Hazard Analysis
• Short Circuit Analysis
• Protective Device Coordination Analysis
• Load Flow Analysis
• Motor Starting Analysis
• A Baisch team will visit the plant to gather
• data. This information will allow the building
• of a computer model of the power
• distribution system.

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Power Systems Analysis

• Arc-Flash Hazard Analysis
• From the computer model the following will be
  generated to allow compliance with NFPA 70E
• The flash hazard boundary
• How much energy a worker will be
• exposed to in the event of an arc
• The hazard class for the piece of
• equipment
• Recommended PPE (personal protective
• equipment) for working on the equipment
• Warning labels for the equipment
• containing the above information
• The data needed for the client to establish
• and implement a safety program and train
• employees to follow the program

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Power Systems Analysis

• Short Circuit Analysis
• Determines the required interrupting
• ratings and setting for the system
• protective devices
• Identifies areas of concern where the
• available faults exceed the fault duty
• ratings of the system busses and
• devices
• Enables the development of a plan to
• decrease the available fault currents in
• these areas to an acceptable level

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Power Systems Analysis

• Protective Device Coordination Analysis
• Verifies that the power distribution
• system protective devices are selected
• and set to ensure that the system is
• properly protected
• Verifies that if a fault or overload
• condition occurs, the protective device
• closest to the fault or overload will
• open quickly enough to protect the
• equipment and minimize the disruption
• to the rest of the system

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Power Systems Analysis

• Load Flow Analysis
• Calculates the voltages, currents and phase
• angles for each bus of the distribution
• system
• Verifies that equipment is not overloaded
• Verifies that cables/conductors are properly
• sized
• Verifies that voltage levels are acceptable
• Enables a plan to shed load from overloaded
• equipment and reduce unacceptable voltage
• drop throughout the system
• Determines if the overall power factor of the
• system can be improved with the addition of
• capacitors
• The above will lead to longer equipment life,
  safer working conditions and energy savings

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Power Systems Analysis

• Motor Starting Analysis
• Calculates the voltages, currents and
• starting times required when starting
• large motors
• Provides verification that the power
• distribution system is capable of
• starting any additional large motors to
• be added to the system in future

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Power Systems Analysis

• The overall study will provide the following
• Safer working conditions for plant
• personnel
• Information necessary for a
• comprehensive safety program
• Compliance with NFPA 70E, soon to be
• a requirement for OSHA compliance
• Longer equipment life
• Energy savings
• A computer model of the complete
• power distribution system, allowing the
• impact of future power system
• modifications to be entered and
• evaluated quickly and conveniently.

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Energy Audits
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Energy Audits

• Why?
• Energy prices are increasing at a rate
• much higher than inflation.
• Accounting practices no longer use
• average costs for steam and electricity.
• Energy saved is the highest cost energy
• purchased fossil fuels, purchased power.
• Cost reduction has replaced production
• increase as the main reason for projects,
• especially in the Pulp and Paper industry.
• For most plants, the possible savings are
• great.
• ROI in most case studies is 40-150.

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Energy Audits

• What will the study determine?
• Current energy use for each process step
• and piece of equipment in a facility.
• Minimum possible energy use for the facility.
• Capital projects or process changes required
• to reduce the difference between current and
• minimum consumption
• ROI for each project or process change.

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Energy Audits

• How will the study be done?
• Review energy records (at least one year).
• Assemble equipment and process details,
• flow rates, temperatures, water use.
• Construct a computer process simulation of
• the entire facility, carefully calibrated.
• Analyze in detail the energy use of each
• piece of equipment and process step.
• Compare these with calculated minimums.

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Energy Audits

• How to decide priorities?
• Concentrate first on 20 of items that use
• 80 of energy.
• Calculate value of energy reduction for each.
• Determine total cost of achieving this.
• Determine acceptable ROI and hurdle rate.
• Eliminate those in which the reduction cannot
• practically be realized and those with
• insufficient ROI.
• The remaining items are priorities.

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Energy Audits

• What next?
• Enter the priority projects in the facility
• process simulation, to verify the
  interactions.
• Complete review of the final list of projects
  to
• remove those that are not acceptable
• because of production, maintenance or
• environmental concerns.
• Produce appropriation grade estimate for
• each remaining project, correct ROI
• accordingly.
• Prioritize and schedule project execution.

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Energy Audits

• Funding assistance.
• Wisconsin Focus on Energy - is a public/private
• partnership offering energy information and
  services to
• residential, business and industrial customers
• throughout Wisconsin. The goals of the program
  are to
• encourage energy efficiency and use of
  renewable
• energy, enhance the environment and ensure the
  future
• supply of energy for Wisconsin.
• The partnership can provide funding for energy
  studies
• and for the implementation of energy
  efficiency
• improvement projects to qualified residents
  and
• businesses in Wisconsin.
• Qualification for this funding is according to
  location and
• the suppliers of energy (gas and electricity)
  to the
• residence or business. Most (gt85) of
  Wisconsin
• business and residents qualify for the
  funding. Checking
• on qualification is simple and rapid.

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Energy Audits

• Wisconsin Focus on Energy Funding assistance.
• Financial help is provided for energy studies
  to identify
• ways of reducing energy consumption.
• Financial help is also provided for the
  implementation
• of an energy consumption reduction project.
• Funds are awarded based on kWh and Therms
  saved,
• up to 7,500 for studies and 40,000 for
  projects. Up to
• 100,000 may be awarded for a single facility.
• Application for funding may be made direct to
• Wisconsin Focus on Energy or through a Program
  Ally.
• Baisch Engineering is a Program Ally and will
  gladly
• take care of your application for funding.

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Outsourcing of Plant Engineering Effort
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Outsourcing of Plant Engineering Effort

• Why Outsource?
• The depth and extent of experience of the
  Engineer from
• the Consultant is more than can be expected
  from others.
• The Consultants Engineer has huge resources
  available
• at his office and can access them quickly and
• economically.
• Outsourcing enables the customer to cope with
  peak
• loads without staffing for peaks and paying
  for inactivity.
• Coverage for exceptional loads such as outages
  is
• provided by the Consultant.
• The Consultants discipline specialists can be
• interchanged with no increase in cost. The
  customer
• would need staff engineers for each
  discipline.
• Ramping down from a peak is easy, involves no
• termination of employees with the attendant
  problems.

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ENGINEERING OUTSOURCING STRUCTURE
Customers Engineering Manager Discipline Managers
Resources at Customer
Resources at Kaukauna
Customer Project Manager
Customer Project Manager
Baisch Project Manager
Baisch Project Manager
Baisch Project Manager
Permanent support group sized for minimum work
load
Temporary support group for additional varying
load
Support group resource at Baisch office
Document files and organization at Baisch office
Strategic Assistance
TEMPORARY RESOURCES SUPPLIED AS NEEDED
RESOURCES PERMANENTLY AVAILABLE
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Outsourcing of Plant Engineering Effort

• Financial justification
• Baisch has developed a financial justification
  model that can be customized to provide the
  justification for the clients specific
  situation. In most cases, the following are found
  to be true
• Plants and corporate engineering departments
• staff for average or higher than average
  workloads to
• avoid excessive overtime.
• Engineering effort for exceptional loads such
  as
• outages or major projects is typically
  outsourced to a
• Consultant Engineer.
• The workload of most plant and corporate
• engineering departments varies greatly with
  time.

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Outsourcing of Plant Engineering Effort

• Financial justification (contd.)
• The distribution of disciplines within the
  workload
• also varies greatly, electrical projects, for
  example,
• tending to occur in clutches.
• It is more economical for the client to staff
  for
• minimum constant workloads and outsource all
• additional engineering
• For most of the cases Baisch has studied,
• covering engineering loads in this way shows
• savings in the clients overall engineering
  cost of
• from 20 to 30.

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Client/OEM Engineering Services
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Client/OEM Engineering Services
Baisch staff engineers can provide the following
services to clients, including equipment
suppliers 1. Civil/Structural/HVAC
Material handling Equipment
layout Document existing
conditions Mechanical drive
integration Machine vibration
studies Pipe hangers supports
Detail component stands
Finite element analysis Tank
detailed design
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Client/OEM Engineering Services

• Baisch staff engineers can provide the following
  services to clients, including equipment
  suppliers
• 2. Process
• Process modeling
• Balanced flowsheets
• Heat balance
• Piping drawings
• Tankage detailing
• Process equipment audits

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Client/OEM Engineering Services

• Baisch staff engineers can provide the following
  services to clients, including equipment
  suppliers
• 3. Electrical Instrumentation
• Drive definition
• Control Instrumentation Project
• Variable speed drive integration
• DCS Configuration
• PLC Programming
• E I project design
• E I panels

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Client/OEM Engineering Services
Baisch staff engineers can provide the following
services to clients, including equipment
suppliers 4. General Basic
engineering data Technical assistance/troublesho
oting Startup assistance Drawing
standard conversion Component
standardization to N.American Conversion to mill
standards Appraisal and valuation of
equipment Minority Content / purchasing
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Facility Master Plans
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Facility Master Plan

• Provides documentation on an existing facility
• Evaluates the facility infrastructure to match
  with
• current and future production
• Analyses material and personnel flow through
  the
• facility today and in the future
• Defines immediate needs for greater efficiency
• Provides a road map for future capital
  investments
• Develops a capital plan for future expansion or
  
• modification
• Positions buildings and equipment so as not to
• obstruct future anticipated growth
• Defines extent of possible expansion
• Provides information defining a new facility
  once
• limit of existing facility is reached

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Appraisals and Valuations
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APPRAISALS VALUATIONS
A group of Baisch senior people are thoroughly
experienced in appraisal/ valuation of plants and
equipment, as well as due diligence studies.
These services are used for Insurance Refinanci
ng Acquisitions Sale or purchase of used
equipment These appraisals/ valuations and
studies are normally carried out on behalf of
banks, insurance companies or other financial
institutions, but these services are always
available to clients.
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Strategic Planning
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Strategic Planning
Within the Baisch organization there is an
immense amount of experience in project
assessment and selection, project execution
systems and much other expertise which can be
summarized as strategic planning. This
experience and expertise is available to clients.
Involving a senior Baisch expert can bring an
extra dimension of insight and experience to help
with the clients specific strategic planning,
channeling the entire Baisch experience and
knowledge through the participant.
Confidentiality is assured in all cases.

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Procurement Services
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Procurement Services

• Baisch has the resources and experience to
  perform the procurement function fully or partly
  on the clients behalf. This could include
• Specification of items or material to
• be purchased
• Obtaining of quotations from client-
• approved vendors
• Analysis and comparison of
• quotations
• Negotiation of price and terms
• Definition of commercial and
• technical guarantees
• Maximizing minority content

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EPC Project Supply
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EPC Project Supply
Baisch is experienced in supplying the
engineering, procurement and construction for
projects, having available partners with whom we
have supplied successful EPC projects in the
recent past. Even for very large projects where
the engineering participation in the scope is
minor, Baisch can put together partnerships which
give the client a full EPC supply.

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Control Panel Supply
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Control Panel Supply
The Baisch standard engineering services for
control systems include providing the design and
installation engineering, DCS configuration, PLC
programming, installation discipline coverage,
checkout and start-up assistance. In addition,
Baisch are able to provide the control panels,
desks and boxes with all controls pre-installed.
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Control Panel Supply
The panels, desks and boxes can be manufactured
to conform with the clients standard form, or to
fit onto existing panels, desks or boxes. This
gives the client a single-source supplier
responsible for the total control project.
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Plant/ Process Troubleshooting
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Plant/ Process Troubleshooting
Many plants nowadays lack the number or
qualification of personnel necessary to
troubleshoot equipment or process problems, so
that these problems persist too long and cause
financial losses. Baisch staff is rich in
knowledge and experience of production equipment
and processes. This knowledge and experience is
available to clients to help determine the causes
of equipment and process problems, as well as to
recommend solutions to fix the problems and
prevent their recurrence.

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Owners Engineer
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Owners Engineer
A senior Baisch engineer can be loaned to
a client for a determined time to act for the
client as, for example, Project Manager or
Construction Manager. During this time the
Baisch engineer works directly for the customer,
supervising, directing and verifying work done by
others for the customer. This can include
engineering done by others.
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Owners Engineer
This enables the customer to have a professional
and highly experienced engineer working for him
and protecting his interests on a project by
project basis without the necessity of hiring
such a person full-time.
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Plant Balanced Process Model
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Plant Balanced Process Model
Baisch uses a specialized program to produce
computer simulation models of a production line
or a complete plant. These models contain a
complete mass and/or energy balance for the
plant. A plant visit is first necessary to walk
the lines and gather the information necessary
to input to the program. One of the necessities
is currently accurate PIDs. If these are not
available, Baisch can produce them. See the
special service Plant Inventories and Updated
Drawings.
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Plant Balanced Process Model
Baisch can then produce a complete computer model
showing the current process with a full mass
and/or energy balance of all lines and loops. The
model can be prepared for an individual
production line, if the line is completely
independent of other lines. This is rarely the
case, as separate production lines usually share
common utilities such as water and steam, and/or
discharge effluent to a common system. In this
case it is more meaningful to model the complete
plant as process changes in one line can affect
other lines.
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Plant Balanced Process Model

• The model can be produced to show
• Mass balance only
• Mass balance plus energy balance
• The whole process in a dynamic
• simulation which can be run in real time
• or accelerated time. It can show, for
• example, tanks filling and emptying,
• pumps going on and off and so on. This
• allows operations and/or engineering
• staff to take action to avoid future
• problems before they happen.

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Plant Balanced Process Model

• Once the model is complete it can be used
  to predict the effect of process changes
  throughout the plant.
• This makes possible process optimization without
  the costly and wasteful necessity of testing each
  step physically one by one in actual production.
• The model also makes possible virtual assessment
  of the effects of new products on the process
  lines and associated systems.
• The energy balance will enable more efficient use
  of available energy and reduction of energy
  losses. The payback from this can be huge.

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Plant Balanced Process Model
Troubleshooting any part of the process is made
much easier since the model indicates what flows
and conditions should be at any point. These can
then be compared with the measured
reality. Baisch will be able to modify the model
to check the effects of process line
modifications or additions, making strategic
planning and project assessments simple and
rapid. The plant will find the model to be a tool
which enables efficient management of the whole
process and pays back the cost very quickly.

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