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Education: B.S. – Mechanical Engineering (1973) - General Motors Institute, Flint Michigan
Registration: Michigan #28044 (1981), Oklahoma #15010 (1986) - Ontario Canada #100057385-01 (2002)

Mr. Cousino has a thirty five year background in multi-disciplined engineering, operational consulting, project management and project development practice. Previous assignments have encompassed initial economic feasibility studies, project conceptual and detail system design, financial pro forma, energy purchase and sale contract development, utility rate impact analysis, and interface with project financiers.

A seasoned engineer, experienced in mechanical, power electrical, controls, and structural disciplines, Mr. Cousino has the technical competence to provide a wide range of professional services to small or large projects. This ability, with peer review, helps to keep projects on time and costs minimized. As a construction manager, he can interface directly with various trade contractors for quick resolution of field problems.

Mr. Cousino has twenty-four years of management level experience directly supervising staffs in power plant operations, waste treatment plant operation, mechanical and electrical engineers, contractors and in-plant maintenance crews. He brings this experience to use in his problem solving ability, and his proposals always consider the human – system interaction so necessary for successful projects. Beyond the normal Microsoft Office software, Mr. Cousino is proficient in AutoCAD, CEASAR (pipe stress), PEPSE (thermal performance modeling), Primavera (scheduling).

PREVIOUS WORK EXPERIENCE:

President (2002 – Present) - Wellhead Energy Services, Inc.

Project Manager (1998 – 2002) - Atkins Benham, Inc.

President (1996 – 1998) - The Stranded Gas Association, Inc

Partner (1995 – 1997) - Turbine Systems Engineering, Inc.

Independent Power Project Consultant (1991 –1995)

President (1985 – 1991) - Applied Energy Systems, Inc.

Chief Powerhouse Engineer (1968 – 1985) - Detroit Diesel Allison Div. GMC

BOILER RELATED EXPERIENCE:

Diagnosis of Boiler Operational Problems:

- Analysis of historical data related to tube failures in 5 HRSG's used in a chemical plant. The combination of gas side tube erosion, water side deposits and poor tube layout in the original design caused the Client to experience repetitive re-tubing of the units and excessive process downtime. The report was used to help the Client make the decision to either re-tube the boilers, for the fourth time, or replace them with a more appropriate design.

- Identification of chelant attack on two 65,000 lb./hr package boilers. These units, less than five years old, had experienced a 50% loss in tube metal thickness in selected areas. The operational patterns of the facility were not compatible with the vendor recommended chemical program. A change in the chemicals, and supplier, was initiated and he supervised the transition and performance of the new program.

- Optimization of the heat transfer of a waste heat recovery boiler on a GE Frame 6 gas turbine, by controlling the chemicals, based on the thermal performance of the unit. The resultant 50 deg. decrease in stack temperatures represented a significant increase in thermal efficiency, resulting in significantly less supplemental fuel use. The system was also easier to operate and chemical costs were reduced.

- Working with a number of industrial plants in Mexico to evaluate the water pretreatment systems and boiler water chemistry programs, as they prepared to install cogeneration systems within their facilities. This work involved physical inspections of the equipment, suggested repair procedures, system testing and implementation of operational procedures to optimize the performance of the systems.

- Development of specifications covering the supply of boiler treatment chemicals and monitoring services, which have been used to gain tighter control, and lower operating costs, for industrial power plants. These specs outline a minimum level of service from suppliers to a plant.

Boiler Design:

- Complete boiler design, fabrication support, and commissioning support for three 600 psi specialty heat recovery boilers on an activated carbon process.

- Modification of the steam drum internals in a pair of boilers that were originally designed to operate at 900 psi, and were being used in 600 psi service. The changes reduced steam carryover from levels of 150 ppb, to less than 10 ppb. The feed water distribution piping, continuous blow down piping and steam separation system were redesigned and changed,.

- Re-design of the steam superheaters on the same 900-psi boilers to accommodate a lower temperature requirement, by re-circuiting the existing system. The supply and outlet headers were changed to convert the superheat section from a four-pass to a two-pass configuration.

- Design review of a small HRSG which was to be used in over 250 installations, and made changes which improved the heat transfer, increased circulation, reduced the cost to manufacture and made the unit easier to service.

- Modification the furnace section of a 150,000 lb./hr spreader stoker, coal fired unit to improve combustion and reduce combustibles in the fly ash. The refractory configuration was changed to allow more radiant heat at the grate level.

- Design changes to three field erected coal/gas fired 600-psi boilers that were placed in stand-by service. These units were kept hot; ready to supply superheated steam within ten minutes. The changes involved the superheater drainage system, modification of the four burners, and changes to the fan drives and controls.

- Video boroscope inspections of several heat recovery boilers, of a common design, which were being chemically attacked. I outlined the corrosion mechanisms that were occurring, and pointed out design flaws, which hampered circulation, and contributed to the deterioration, so that the owner could make claim for damages on the boiler designer/manufacturer.

Boiler Installations:

- Specification, purchase support, Engineer-of-Record for the installation, and construction support, for the addition of three, 25,000 #/hr, 600 psi HRSG's at a chemical plant. Boilers operated on a dirty gas stream that included high particulate loading and tar. Total project cost $4,500,000.

- Specification, purchase support, Engineer-of-Record for the installation, and construction support, for the addition of two, 250,000 #/hr, 600 psi/800 F package boilers at a major refinery. Boilers operated on refinery gas, included 9 ppm low-NOx burners, and steam-turbine driven FD fans. Total project cost $27,000,000.

- Project Engineer and Project Manager on the relocation of three 135,000 #/hr 900 psi/750 F heat recovery boilers from a project on the Gulf Coast to an industrial park in Oklahoma. Total project cost $33,000,000.

- Owners Engineer and Project Manager for the installation of a 150,000 #/hr stoker fired, field erected boiler and auxiliaries, including water pretreatment system, coal handling system, ash disposal system and associated piping and electrical distribution. Total project cost $10,000,000.

GAS TURBINE RELATED EXPERIENCE:

- Mr. Cousino worked for the Detroit Diesel Allison division of General Motors, which produced air craft and industrial gas turbine engines, for 17 years. He became very familiar with the packaging and operational requirements of the engines, and attended the factory maintenance training classes. He engineered, and supervised the packaging and installation of a dual gas turbine, single steam turbine, skid mounted, 10 MW, combined cycle system, which was installed in the power plant he supervised.

- Removal of three Pratt Whitney GG4-A7 engines, Worthington power turbines, and 20 MW Electric Machinery generators from an abandoned plant, and repackaging the equipment on skids. The units were re-controlled with a Tri-Sen turbine control package and new field devices. The fuel, synthetic oil and mineral lubricating oil systems were redesigned, and the units were commissioned as peakers under his direction. Combustion system modifications and inlet fogging, which he designed in 1991, were effective in reducing the NOx emissions to below the permitted 75-ppmv level, and boosting high temperature performance by 10%.

- Design the foundations, mechanical field connections, exhaust duct, and supervision of the installation of a GE frame 6, as the Owner's engineer. The unit made commercial power 91 days after it arrived by rail at the site, a record for the GE Dallas region. This machine was the first 25-ppm NOx, steam-injected engine produced, and demonstrated significant operation problems which were related to improper engine/package design on the part of GE. I supervised the fieldwork necessary to correct the problems, and was involved in relaying these problems to GE and representing the Owner in recovery of the cost of repairs.

- Origination of the design of a 1 MW, gas turbine based, mobile cogeneration package which can be quickly installed in facilities, on a lease/shared savings basis.

STEAM TURBINE RELATED EXPERIENCE:

- Purchase support, equipment modifications, installation engineering, and commissioning support for two 1,500 kW, back-pressure steam turbine generators, purchased used and modified to operate at a higher pressure. Modifications included hydro testing the exhaust cases and adding additional external stiffening. Terry Steam Turbine had told the Client that this modification could not be done.

- Packaging a steam turbine driven, centrifugal water chiller for the power plant he supervised at General Motors. This unit was purchased without a driver, and a used Terry, back pressure steam turbine was installed in place of an electric motor. The system included an integrated turbine/chiller control, matching the steam demands of two absorption chillers, so that the system operated on a demand following schedule. The centrifugal compressor utilized variable driver speed and optimized the thermal performance of the chiller.

- Directed the modification of two 1942 vintage GE 5 MW back pressure turbines to allow the exhaust steam pressure to be increased from 50 psig to 200 psig. The modifications involved removing stages from the machine, turbine shell strengthening, adding additional labyrinth seals at the exhaust-end, rebalance of the rotor, and installation of electronic controls. General Electric had told the owner that such modifications were not possible.

- Supervised the modifications to a 1956 Westinghouse, 400 psig/700 F, extraction, condensing turbine, which convert the unit to a straight back pressure machine. A change in the operations and utility prices at this Mexican paper plant had made the unit uneconomical to operate. These changes provided cost effective performance from an otherwise useless piece of equipment.

RECIPROCATING ENGINE GENERATOR EXPERIENCE:

- Designed and supervised the installation and commissioning of a 650 kW, used Caterpillar natural gas generator set at the City of Claremore Water Treatment Plant. This generator was used as a stand-by source and for peak shaving duty. The installation included step-up transformation and interconnection to the 15 kV municipal distribution system

- Designed, built and commissioned multiple 100 kW, natural gas generator sets for converting waste natural gas into electrical power, for sale to Public Service Co. of Oklahoma. These installations ran un-attended, internet dispatched, and included step-up transformers and 15 kV, utility grade interconnection protective devices.

- Design and supervised the installation of six 500 kW Caterpillar generator sets fueled by low Btu gas from a landfill. Installation engineering included well drilling, collection piping, and compression, plus utility interconnection switchgear and step-up transformation.

COMPRESSION EXPERIENCE

- Specification, installation engineering and startup support of two 3,500 HP Dresser/Clark centrifugal compressors at an automotive manufacturing plant. Installation included adding a refrigerated dryer, enlarging a 13.8 kV/5 kV substation and a cooling tower expansion.

- Installation and commissioning support for a compressor station supplying an air separation plant for heat treatment and process air to a machining operation. The system consisted of a 600 HP IR XLE reciprocating compressor and two IR Centac centrifugal machines, 600 HP and 1,000 HP, along with refrigerated air dryers, carbon filter and cooling tower.

- Design of the surface facilities for a 30,000 HP, salt dome natural gas storage facility, including engine driven reciprocating compressor skids, engine driven salt water injection pumps, a cavern mining water debris filtration plant, gas de-hydration skids, pressure control, metering and interconnection to pipelines.

HIGH VOLTAGE ELECTRIC LINE EXPERIENCE:

- Designed and managed the modification of a 161 kV, double circuit power line for Grand River Dam Authority. The line modification was required to make way for a turnpike extension, and included relocation of the right-of-way, re-use and modification of the support towers to increase clearances, and additional dead-end structures.

- Preliminary design and managed the construction of a 138 kV, substation tied into Public Service Co. of Oklahoma. The ring bus design, with a breaker and a half scheme, took power from a 150 MW IPP plant and fed a looped PSO circuit.

REFRIGERATION & HEATING SYSTEM EXPERIENCE:

- Directed the modification of a 600 ton rated York open centrifugal chiller, originally designed for electric motor drive, to operate with a back pressure steam turbine. This modification included variable speed and inlet vane control for capacity, automation of the steam turbine part load nozzles to optimize lbs/ton-hr, and integration with two 1,400 ton low pressure steam absorption chillers for overall system load tracking.

- Developed, built and patented a pump drive used on steam absorption chillers, that replaces the "canned motor" found on these units with a conventional electric motor. This device extends the time between failures, and reduces the cost of repair.
- Integrated a second economizer, on a heat recovery boiler, of a 10 MW combined cycle cogeneration system, into a closed loop, low temperature building heating system. The system conversion efficiency was significantly improved, and with instrumentation, the heat transfer surface was protected from degradation.

POWERPLANT EXPERT SYSTEM DEVELOPMENT:

- Development and implementation of on-line expert systems to monitor powerplant performance and optimize cogeneration plant profitability, through control of the gas turbine load, back pressure steam turbine load, drum pressure, supplemental firing, and boiler chemistry. This system was constructed within a Foxboro I/A, DCS system. The steam distribution system had six customers, all with different purchase rates. The power was purchased under a single, three component, power purchase contract.

- Development of preliminary control configurations for an expert system to control boiler chemistry in industrial facilities. This system integrated on-line monitoring with manual chemical tests to optimize chemical usage and protect the system during various component outages, such as dosage pump failures, tanks running dry, valves sticking, plugged strainers and orifices, inadequate solution strength, etc., items which happen with regularity within an industrial plant. On-line operator instruction and automated process control could be included within this system.

- Development of an expert system gas turbine and boiler performance monitoring program that is interactive in the turbine control system of a major supplier of aftermarket controls. This program is used to assist the operators in evaluating turbine condition and heat recovery boiler performance, and will include on-line help libraries statistically suggesting corrective actions, and affecting hardware through a DCS system.

POWERPLANT OPERATIONS STAFF DEVELOPMENT:

- Functioned as the General Motors Corp. representative for the Joint UAW/GM Employee Training Task Force, charged with developing programs to improve the technical understanding and performance level of stationary engineers. He was deeply involved in self-study curriculum selection, testing procedures and follow-up skills assessment.

- Direct hired the operations and maintenance staff and directed the training on a 150 MW combined cycle cogeneration power project, including the Chief Engineer. The project commissioning and compliance testing was performed by this staff, and first year plant availability was in excess of 96.5%, with only 7% employee turnover.

- Development Standard Operating Procedures for an 85 MW, heat recovered gas turbine project. The procedures included plant startup, shutdown, and preventive maintenance inspections, and were written before the facility was initially commissioned. The 230 kV, interconnecting, "ring bus" substation was included in the SOP's, integrated with the safety and isolation requirements of the serving utility.

RELIABILITY CENTERED MAINTENANCE STUDIES:

- Developed the evaluation criteria, supervised the data collection and entry, performed the analysis and presented the findings on a RCM Study, encompassing over four years of operating history, for a 500,000 lb/hr, coal fired power plant. The Study identified primary failure modes, cause-and-effect relationships, and suggested modifications to the coal handling and water pre-treatment systems, along with changes to the Standard Operating Procedures for the plant staff. The Study resulted in a 12% improvement in steam availability for the plant.

CRUDE OIL PIPELINE STATION & TERMINAL DESIGN:

- Multiple projects designing pumping stations for crude oil pipelines. Scope included design and specification of pumps, drivers, instrumentation, electrical power supply components and pipeline interconnections. Individual pump sizes range to 5,000 HP, with total station HP to 15,000 HP.

- Multiple projects re-designing tank farm manifolds to bring the piping above ground for easier inspection and corrosion evaluations. Projects included the installation of "canned" type booster pumps at the individual tanks, new metering, proving, and connections to interstate pipelines.

- Multiple station evaluations to allow transport of heavy, viscous Canadian and Western US tar sands crude oils in systems designed for light/intermediate crude. Projects involved pump testing and new line hydraulics to determine the new operating conditions, and evaluation of the ability of the existing power systems to deliver the product.

MISCELLANEOUS PROJECTS:

- Re-engineering the renovation of the ventilation system on the Detroit Canada Tunnel, including replacement of the exhaust blowers, rebuilding and re-powering of the 1928 vintage supply fans, integration of a new SCADA system and air distribution system changes to minimize CO concentrations within the tunnel. The initial design was performed by a large engineering firm, and resulted in higher than expected bids to complete the project. Mr. Cousino reviewed the scope of the project, revised the design to meet the needs of the Client and reduced the cost of the project by 60% from the original bid. The project involved working with engineers from the City of Windsor Ontario, extensive performance testing following completion. Installation engineering, commissioning and training were included.

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