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Workshop on Workforce Needs for Large-Scale Solar Projects

September 15, 2010

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Company Overview

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Strong Track Record Developing Renewable Energy Businesses

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Technology Overview

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SunCatcher™ Technology Overview

25 kW solar power system Dish concentrator tracks, collects, and focuses the Sun’s energy

Stirling engine converts thermal energy to grid quality electricity. 

Highest efficiency among peers (avg. ~25%, record at 31%)

Minimal water requirement (~12 acre‐ft/yr for 500 MW)

Dish systems both modular & scalable Terrain flexible (<5% grade)

High Efficiency, Low Water Use, And Modular Design Provide Competitive Advantage

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SunCatcherTM Technology

A generator is connected to the Solar Stirling Engine; and produces the grid‐quality electrical output of the SunCatcher™. 

The PCU solar receiver absorbs the incoming solar thermal energy, which in turn heats and pressurizes the gas in the heat exchanger tubing.  This gas in turn powers the Solar Stirling Engine.

The Solar Stirling Engine operates with heat input from the sun that is focused by the SunCatcher’s™ mirrors onto the PCU's solar receiver tubes.

The conversion process in the PCU involves a closed‐cycle, high‐efficiency four‐cylinder, reciprocating Solar StirlingEngine utilizing an internal working fluid that is recycled through the engine.

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Scaleable and ModularThree Basic Building Blocks

Dish Semi‐autonomous 

control Self‐contained except 

for:• Hydrogen supply• Back‐feed Electric• AC collection

Remote SCADA Fails independently XN / UPS @ 12 dishes

1.5 MW / 60 Dishes Common 34.5 KV 

step‐up 600 V 

Switchboard Dish Group 

Server

9 MW / 360 Dishes Common H2

compressor (cross –feed)

Overhead riser Site supply for:

• H2 to tanks• Interruptible AC• Water treatment• Sub‐station• SCADA1.5 MW / 60 Dishes 

9 MW / 360 Dishes 

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Calico Solar and Imperial Valley Solar

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Imperial Valley Solar (formerly Solar Two)

Site Size – up to 709 MW Land – BLM lease 6,251 acres, 320 private acres Location – Imperial County, CA; 100 miles E 

of San Diego & 14 miles W of El Centro DNI – 7.2 annual – 54,146 kWh/yr/SunCatcher 

Transmission Interconnection to SDG&E Imperial Valley 

substation – Phase I access to existing Southwest  Power Link and Phase II access to future Sunrise PowerLink

Phase I – 300 MW (Large Generator Interconnection Agreement (“LGIA”) in place) Phase II – 450 MW (LGIA in place for 600 MW total, thereby allowing for future expansion)

Permitting Permitting completed; BLM grant and CEC certification expected September 2010

EPC Phase I – Mobilization for construction Q4 2010, Final Operation Date Q1 2012 – Q2 2012 Phase II – Mobilization for construction Q3 2012, Final Operation Date Q4 2013 – Q2 2014

PPA  Power Purchase Agreement signed with San Diego Gas &Electric

Advantageous site High insolation (7.23 kWh/m2/day),  Relatively flat and large contiguous area Low wind speed Proximity to transmission infrastructure 

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Imperial Valley Solar

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Imperial Valley Solar Workforce

Construction The size of the on‐site workforce will range from 101 to 731 employees depending 

on the phase of construction. Operations

In full commercial operation, the project will staff approximately 164 full time employees.

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Calico Solar (formerly Solar One)

Site Size – up to 850 MW Land – 6,215 acres (originally 8,230) acres 

BLM lease   Location – San Bernardino County, CA; 35 

miles east of  Barstow DNI – 7.5 annual – 56,542 kWh/yr/SunCatcher 

Transmission   Interconnection to SCE Pisgah Substation Phase I – 275 MW Phase II – 575 MW

Permitting Permitting completed; BLM grant and CEC certification

expected October 2010 EPC

Phase 1a – Mobilization for construction Q4 2010  Phase 1b – Mobilization for construction Q2 2011 Phase 2 – Mobilization for construction Q4 2013(Occurs with expansion of Pisgah Substation), 

PPA  Signed PPA with Southern California Edison for full 850 MW

Advantageous site High insolation (7.5 kWh/m2/day),  Relatively flat and large contiguous area Low wind speed Proximity to transmission infrastructure.  Adjacent to the SCE Pisgah Substation.

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Calico Solar Project Site

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Calico Solar Workforce

Construction The size of the on‐site workforce will range from 101 to 731 employees depending 

on the phase of construction. Operations

In full commercial operation, the project will staff approximately 136 full time employees.

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Calico Solar as Sample Project forWorkforce Discussion

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Timing

Phase 1a Phase 1b

Dependent on DOE Financing Phase 2

Dependent on SCE

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Balance of Plant

Dan CrossMortenson Construction

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Mortenson’s Scope

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2020

Mortenson’s Scope

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Mortenson’s Scope

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Mortenson’s Scope

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Mortenson’s Scope

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Mortenson’s Scope

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Mortenson’s Scope

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Workforce Projections• Projected Construction Start: 4th Quarter 2010

• Projected Labor Force: Ramping up from 25 to 450 at peak of production

• Skilled Labor Needs: Electricians, Operators, Carpenters, Millwrights, Plumbers, Ironworkers, Cement Finishers, Laborers

• Hiring Projections: Hiring will follow phased deployment, slower start in late 2010 to a peak in late 2011.

• Hiring Methodology: Majority of trades will be engaged via subcontracts. Subcontractors’ sources of labor can vary (e.g., local unions halls, direct hires, current staff, etc.). Local subcontractors will be provided opportunities to compete for the work.

• Notice of Opportunities: For activities that Mortenson will self-perform, we do make use of hiring fairs, which are typically held 4-6 weeks prior to need. Local media will be utilized to publicize these events. First event will likely be in the second quarter of 2011.

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SunCatcher Assembly

& Maintenance

Justin Elliott Stirling Energy Systems

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SES SunCatcher Schematic

SES – TSA Scope Split:

•SES responsible for assembly of all elements shown (except pedestal) and commissioning of units and SCADA system. Maintains SunCatchers

•Tessera Solar installs Pedestals and rest of BoP, transports and erects dishes & PCUs, completes all electrical, controls and hydrogen fit out and provides energized unit block with communications to SCADA. Operates plant

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SunCatcher Assembly Line

•Centralized, multi‐station assembly line will produce 12 complete dish assemblies per 8‐hour shift

•Imperial Valley Solar and Calico Solar will each run 2 lines in parallel, each operating 2 shifts per day for a total output of 48 units per day

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SunCatcher Assembly and Commissioning workforce Requirements

Three phase approach to build out for both projects:

Phase 1 Phase 2 Phase 3 Phase 4

Description Facilities Establishment

Assembly Production

Facilities Demobilization

Ongoing Maintenance

Workforce (ramping to) 35 265 35

IVS timing:

Starting Q2 / 2011 Q3 / 2011 Q4 / 2012 Q3 / 2011

Duration 4 months 15 months 2 months 5 years

Calico timing:

Starting Q3 / 2011 Q4 / 2011 Q1 / 2013 Q4 / 2013

Duration 4 months 15 months 2 months 5 years

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SunCatcher Assembly and Commissioning workforce Requirements

Workforce profile:

Management and Supervision: Typical professional management/supervision type staffing, including:

General management, manufacturing, electrical, systems engineers, EHS, quality, logistics, maintenance supervisors, etc.

Total management team – approx 20 at peak

Assembly line operation Assembly workers – approx 160 at peak Material handlers – approx 35 at peak

Commissioning crew Graduate electrical, systems engineers/technicians – approx 50 at peak

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SunCatcher Maintenance workforce Requirements

Local Project Workforce profile:

Management, Supervision and Administrative: Typical professional management/supervision type staffing, including:

General management, mechanical, electrical, systems engineers, EHS, quality, inventory & logistics, maintenance supervisors, etc.

Total supervisory team at steady state for full build‐out – approx 5

PCU maintenance and troubleshooting operations: SunCatcher PCU technicians* ‐ approx 55 at peak

*These positions will be trained and certified directly by SES

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Operations

Calico Operations staff will total approximately 136 full‐time employees

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Summary

• General overview of what we plan• Timing very much driven by DOE financing