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BCON > SEC Filings for BCON > Form 10-Q on 4-Nov-2009All Recent SEC Filings

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Form 10-Q for BEACON POWER CORP


4-Nov-2009

Quarterly Report


Item 2. Management's Discussion and Analysis of Financial Condition and Results of Operations

Note Regarding Forward Looking Statements

This Quarterly Report on Form 10-Q contains forward-looking statements concerning, among other things, our expected future revenues, operations and expenditures, sources and uses of capital and estimates of the potential markets for our products and services. Such statements made may fall within the meaning of the Private Securities Litigation Reform Act of 1995, as amended. All such forward-looking statements are necessarily only estimates of future results and the actual results we achieve may differ materially from these projections due to a number of factors as discussed in the section entitled "Risk Factors" of this Form 10-Q. New risks can arise and it is not possible for management to predict all such risks, nor can management assess the impact of all such risks on our business or the extent to which any factor, or combination of factors, may cause actual results to differ materially from those contained in any forward-looking statement. Given these risks and uncertainties, investors should not place undue reliance on forward-looking statements as a prediction of actual results. All forward-looking statements speak only as of the date of this Quarterly Report on Form 10-Q. We undertake no obligation to revise or update publicly any forward-looking statement in order to reflect any event or circumstance that may arise after the date of this Quarterly Report on Form 10-Q, other than as required by law.

Critical Accounting Policies and Estimates

The preparation of financial statements requires management to make estimates and judgments that may significantly affect the reported amounts of assets, liabilities, revenues, expenses and related disclosures. On an ongoing basis, management evaluates our estimates and assumptions including, but not limited to, those related to revenue recognition, asset impairments, inventory valuation, warranty reserves and other assets and liabilities. Management bases its estimates on historical experience and various other assumptions that it believes to be reasonable under the circumstances, the results of which form the basis for making judgments about the carrying values of assets and liabilities that are not readily apparent from other sources. Actual results may differ from these estimates under different assumptions or conditions.

Loss on Research and Development Contract Commitments

We establish reserves for anticipated losses on contract commitments if, based on our cost estimates to complete the commitment, we determine that the cost to complete the contract will exceed the total expected contract revenue. Most of our contracts have been granted on a cost-share basis, for which the expected cost-share is recorded as a contract loss. The U.S. Naval Sea Systems Command (NAVSEA) contract, however, has been granted on a cost-plus-fixed-fee basis. Each quarter, we perform an evaluation of expected costs to complete our in-progress contracts and adjust the contract loss reserve accordingly.

Our engineering and manufacturing overhead rates are based upon direct labor hours, and thus are sensitive to changes in capacity or headcount. Cost estimates for our contracts are also subject to change based upon the number of hours required to complete the project as well as the cost of direct materials, contract-related travel and outside services such as consultants.

Our contracts historically have been completed over multiple fiscal periods, and a reserve for contract losses is recorded at the point when we estimate that such a loss may occur. Although the allocation of overhead to a fixed-price contract does not impact the Company's total costs or loss from operations, it may result in such costs being recognized in an earlier period than when the costs are actually incurred. Moreover, since our current production levels are significantly lower than those used in our "full-capacity" overhead rate, our forecasted costs are based upon subjective estimates and management judgment, and actual results may differ significantly. However, the two fixed price contracts that we are currently working on are relatively small, and the impact of our estimates and assumptions relative to these contracts are not expected to have a material impact on our financial condition or operating performance.

Fixed Assets

Property and equipment in service is stated at cost and depreciated using the straight-line method over the estimated useful lives of the assets. Property and equipment are defined as tangible items with unit costs exceeding our capitalization threshold that are used in the operation of the business, are not intended for resale and which have a useful life of one year or more. The cost of fixed assets is defined as the purchase price of the item, as well as all of the costs necessary to bring it to the condition and location necessary for its intended use. These costs include material, labor, overhead, capitalized interest and, if applicable, exit costs. Exit costs for which we are obligated are accounted for in accordance with ASC 410, "Asset Retirement and Environmental


Obligations." No overhead is generally applied for internally-constructed projects not directly related to our core business (e.g., leasehold improvements). Repair and maintenance costs are expensed as incurred. Materials used in our development efforts are considered research and development materials, and are expensed as incurred in accordance with ASC 730, "Research and Development."

Capital assets are classified as "Construction in Progress" when initially acquired, and reclassified to the appropriate asset account when placed into service, with the exception of land, which is capitalized upon purchase. Depreciation expense is not recorded on assets not yet placed into service.

Materials purchased to build flywheels, power electronics and other components used in our frequency regulation installations are classified as CIP, along with the related labor and overhead costs. Some components of the Smart Energy Matrix™, such as the flywheels and power electronics, are considered "fungible" in that they can be moved and redeployed at a different location. Non-fungible costs are costs which would not be recovered if we redeployed the matrix or portions thereof. In some cases, we may elect to deploy a Smart Energy Matrix™ system at a location for the purpose of demonstrating our technology or gaining experience operating in that particular market. In these instances, the costs of the fungible components are capitalized, and the remaining costs, which may include such costs as site preparation, interconnection costs, capitalized interest and estimated exit costs, are expensed.

Impairment of Long-Lived Assets

In accordance with ASC 360, "Property, Plant and Equipment" long-lived assets we hold and use are reviewed to determine whether any events or changes in circumstances indicate that the carrying value of the asset may not be recoverable. The conditions to be considered include whether or not the asset is in service, has become obsolete, is damaged, or whether external market circumstances indicate that the carrying amount may not be recoverable. When appropriate we recognize a loss for the difference between the estimated fair value of the asset and the carrying amount. The fair value of the asset is measured using either available market prices or estimated discounted cash flows.

In certain instances, we may determine that it is in the best interest of the Company to re-deploy all or part of a Smart Energy Matrix™ system installed at a given location. When such a determination has been made, we will determine which costs are associated with the movable (fungible) components, and which costs are non-fungible. We will record a period expense for the net book value associated with the non-fungible components.

As of September 30, 2009, in order to determine whether or not the current inventory of flywheels and related equipment on hand is impaired, we reviewed the current status of our Stephentown project, and noted the following:

† The first 20 MW installation, planned for Stephentown, NY, is expected to cost approximately $69 million, which includes substantial contingency, legal, consulting and administrative costs. Some of these costs are either unique to the DOE loan guarantee process, or are greater than we expect to apply to subsequent similar facilities. All of these costs are eligible project expenses under the loan program rules.

† The second 20 MW installation is expected to cost approximately 35% less than the first 20 MW plant. Cost reductions for the second plant are expected to occur due to savings from

†          Reduced legal, consulting and administrative costs

†          Volume supplier agreements, and

†          Production and construction optimization.

† The location for the first 20 MW installation will be in the NYISO region. This is currently the most attractive market for regulation services. Historically, it has offered attractive frequency regulation clearing prices and is expected to provide us with a control signal that is well-suited to our type of energy storage-based regulation resource.

† We performed cash flow testing based upon a variety of scenarios, using historical 24-month average day-ahead and real-time clearing prices for regulation in NYISO. Our analysis included the potential impact of various "worst case" scenarios based upon potential negative factors, individually and in combination, such as a reduction in the frequency regulation clearing price of up to 20%; increases in energy costs of up to 20%; higher construction costs of up to 30%; or certain


changes in control signals. The clearing prices during recent months have been dropping. We believe this primarily due to the overall economic climate, and we expect the clearing prices to increase as the economy strengthens. However, if the current trend towards lower prices is sustained for an extended period, it would make meeting our debt service requirements difficult for that period of time.

† Our forecast and models indicate that we can expect positive cash flows from a 20 MW frequency regulation installation in Stephentown, New York, and that consequently, as of September 30, 2009; no impairment reserve is required for our current supply of flywheels and related fungible Smart Energy Matrix™ components.

Overview

We design, manufacture and operate flywheel-based energy storage systems that provide frequency regulation and other highly reliable energy solutions for the worldwide electricity grid at competitive costs. We also plan to sell individual and large-scale systems outright or on a fractional basis. As we expand our flywheel production and continue to lower system costs, we believe we will be able to market other cost-effective applications for our flywheel systems that will further expand our revenues.

Our principal market focus is on the geographic regions of the domestic grid that provide open-bid markets for regulation services. These regions and their Independent System Operator (ISO) or Regional Transmission Operator (RTO) designations are: New England (ISO New England or ISO-NE); California (California ISO or CAISO); New York (New York ISO or NYISO); Mid-Atlantic (PJM Interconnection); and Midwest (Midwest ISO or MISO). Even though the RTO in Texas (Electric Reliability Council of Texas or ERCOT) is an open bid market, it is not regulated by the Federal Energy Regulatory Commission (FERC). Consequently, we are not able to encourage beneficial market rule changes there that are mandated by FERC Order No. 890. This Order was intended to promote greater competition in electricity markets, in part by allowing non-generation resources such as ours to bid and sell into frequency regulation markets and be compensated on equal terms with traditional generation resources. As a result, we are focusing on the FERC-regulated open-bid markets first and will begin to work on entry into ERCOT once we are operating in the other markets.

These regional ISOs/RTOs or grid operators purchase frequency regulation services from independent providers in open-bid markets that they manage and maintain. We are seeking to become one such provider. We believe our technology will offer grid operators the benefits of greater reliability; faster response time; cleaner operation, including zero direct emissions of carbon dioxide (CO2), nitrogen oxide, sulfur dioxide and mercury; and lower maintenance costs compared to conventional power generation facilities that also provide frequency regulation services. We believe that we will have lower operating costs and faster response time than the majority of other entities that provide frequency regulation services, which we believe will allow us to have sufficient margins to make the Company economically viable.

Under the open-bid market like that operated by NYISO, grid operators forecast the need for frequency regulation as a percentage of expected power demand, and approved suppliers submit bids for these services. Bids are stacked from lowest to highest prices until the cumulative amount of bids is sufficient to meet the calculated need. The price submitted by the highest selected bidder determines the price paid to every bidder that has been scheduled to provide service, although each ISO may calculate payments based on formulas that yield different revenue results, even with equivalent frequency regulation clearing prices.

Our Smart Energy Matrix™ recycles excess energy when generated power exceeds load and delivers it when load exceeds generated power. We believe that our low operating costs will allow us to participate with a very favorable profit margin in the open-bid markets. Also, our systems respond up to 100 times faster than fossil fuel generators providing frequency regulation. Certain ISOs have implemented or are considering tariff changes that would provide additional or enhanced payment mechanisms to compensate resources, such as ours, for faster regulation response.

To participate in this regulatory-driven open-bid market, we expect to build, own and operate a number of frequency regulation installations known as Smart Energy Matrix™ systems designed to provide reliable and sustainable frequency regulation services for utility grids. Our primary business model is a sale-of-services model, similar to that of independent power producers who also build, own and operate their own power plants. Under this model, we will be bidding our services into multiple open-bid markets for regulation on a daily basis. Additionally, we may:


† Participate in pilot programs to demonstrate our technology, such as the ISO-NE Alternative Technologies Pilot Program, under rules that may provide alternative bidding and payment plans than those provided by the permanent market rules

† Sell Smart Energy Matrix™ systems on an equipment-sale basis in both the U.S. and overseas markets

† Share ownership of some plants together with investors as a means of accelerating cash flow during the early years of our commercial deployment

† Enter into bilateral contracts with utilities that currently provide or purchase regulation services to satisfy their obligations to pay for or provide regulation services in their respective grid regions.

On November 18, 2008, we connected our first 1 MW Smart Energy Matrix™ to the electric grid in Tyngsboro, Massachusetts. The 1 MW system was installed under the ISO New England Alternative Technologies Pilot Program, which allows us to generate revenue for regulation services while we, and ISO-NE, explore ways to optimize the beneficial impact of the technology and while ISO-NE develops permanent market rules that will govern the application of the technology. A second MW of capacity was connected to the grid in July 2009 and is also earning revenue. We plan to interconnect a third MW of capacity before the end of 2009. We expect to redeploy the second and third megawatts to the Stephentown site as in-kind equity under the terms of the DOE loan guarantee program.

The pilot program and its revenue component will continue until permanent rules are in place. The pilot program was approved by FERC as part of ISO-NE's compliance with FERC Order No. 890, which is intended to promote greater competition in electricity markets, strengthen the reliability of the grid, and allow so-called non-generation resources (which include our flywheel technology), to participate in frequency regulation markets on a non-discriminatory basis.

As part of the process of modifying its market rules, ISO-NE has been adjusting the control signal it sends to our Smart Energy Matrix™ to help maximize our regulation effectiveness. ISO-NE has a three-part payment model for regulation service:

1. Payment for the resource's MWs of capacity that are scheduled to perform regulation, referred to as "Time-On-Regulation."

2. Payment based on the degree to which a resource changes its output, referred to as "Regulation Service" or "Mileage." Fast-response resources receive higher mileage payments than slower-responding resources.

3. Payment to compensate generators for lost revenue as a consequence of providing frequency regulation rather than conventional power generation, referred to as "Opportunity Cost."

Revenues that we are currently receiving from this pilot program are lower than those that we expect to receive under permanent market rules, principally because under ISO-NE's pilot program market rules, we are not eligible for opportunity cost payments, which represent approximately one-third of the revenue received by conventional regulating generators. We are encouraging ISO-NE to develop permanent market rules that will provide an additional payment component for alternative technologies that would be approximately equal to opportunity cost. The trend at other ISOs has been to incorporate features in their tariffs that intrinsically compensate all resources, including energy storage providers, for opportunity cost.

Electricity costs for operating the 1 MW pilot Smart Energy Matrix™ in Tyngsboro through the end of April 2009 were higher than what we expect our electricity costs to be in the future. Because the 1 MW pilot project is connected to a distribution-level power line, from November 2008 through late April 2009, we paid the retail price for our gross withdrawals from the grid, instead of paying the wholesale price for the net electricity (withdrawals minus injections), plus retail transmission and distribution charges. However, in late April 2009, ISO-NE and our local distribution company implemented a change which reduced our commodity cost of electricity by netting the electricity withdrawn and injected into the grid, and billing for that net usage at the wholesale rate. In addition, a new regulation dispatch signal implemented by ISO-NE in May 2009 has reduced the amount of net electricity we need to purchase. We are still paying retail transmission and distribution charges. These favorable adjustments now enable us to earn positive gross margin for the remainder of the pilot program. The cost of electricity will be even further reduced for our 20 MW facilities, as we plan to be connected to transmission-level (rather than to distribution-level) power lines. We will be charged the lower wholesale commodity price for our net energy usage and will not be subject to transmission and distribution fees, which currently represent approximately 70% of our cost of energy.

In October 2009, we were approved to earn alternative energy credits under the Massachusetts Alternative Energy Portfolio Standard (APS) program. Our flywheel systems were designated as the first resources to qualify under this program by the Massachusetts Department of Energy Resources. Our systems are eligible for this program because they discharge electricity to


provide frequency regulation with zero fuel consumption or emissions. We have begun earning these state-authorized APS credits, or certificates, starting in the second quarter of 2009. The number of certificates we will earn is based on a formula that takes into account the amount of stored energy we inject into the grid in Massachusetts. We plan to sell the credits to utilities or other retail electricity suppliers that need to meet mandated Massachusetts APS requirements, thus creating an additional revenue source. We are currently evaluating how much the APS certificates may be worth and how to sell them in the most effective manner. We do not believe the revenue from these certificates will be material to the financial statements, and therefore, no entry has been recorded to reflect their receipt as of September 30, 2009.

Our Smart Energy 25 flywheel system includes the flywheel and its associated power electronics. A Smart Energy Matrix™ is an array of ten Smart Energy 25 flywheel systems that provides 1 MW of energy storage. A frequency regulation installation includes one or more Smart Energy Matrices™, along with ancillary equipment and site work. A typical full-scale installation would have a capacity of 20 MW.

The location of our regulation installations and the sequence in which they will be constructed depend on a number of factors, including but not limited to:

† Comparative market pricing available for frequency regulation in different markets

† Our ability to receive appropriate revenues and payments according to the market rules of each regional market

† Availability of transmission lines

†          Availability and cost of land



†          Ability to secure all necessary environmental and other permits and
approvals

† Ability to obtain grid interconnection approvals.

On July 17, 2008, we received a land-use permit we had requested from the town of Stephentown, New York. During the third quarter of 2008, we purchased approximately seven acres of land at a site in the town where we plan to build our first 20 MW installation. The site is served by two transmission companies:
National Grid and New York State Electric and Gas (NYSEG). National Grid owns a 115 KVA transmission line that abuts the site, and NYSEG owns a substation that also abuts the site.

Our interconnection request for the 20 MW plant includes National Grid as the transmission provider. Before we can enter into an interconnection agreement with NYISO, we were required to perform a System Impact Study, which is now complete. We must now complete a Facilities Study. The purpose of these studies is to confirm that our facility can be safely and reliably interconnected with the grid, and to identify any utility upgrades or other equipment that may be needed before construction can begin. Construction and development of this site is also subject to certain state and local permitting processes. After executing an interconnection agreement, necessary upgrades to grid equipment to permit such interconnection will begin, in a timeline roughly parallel to our construction of the facility.

In October 2009, the New York State Public Service Commission (PSC) granted us a Certificate of Public Convenience and Necessity (CPCN) and approved our petition for lightened regulation for the planned 20 MW flywheel frequency regulation plant in Stephentown, New York. These approvals include the project's overall financing. At its October 15th meeting, the PSC determined that Beacon's proposed flywheel plant in Stephentown is in the public's interest. In September 2009, the PSC affirmed that Beacon's Stephentown plant has met all relevant PSC environmental requirements. With these PSC decisions now in place, the Company is authorized to apply for applicable permits, submit any final plans and drawings to PSC for review, and prepare to construct and operate the plant.

On June 10, 2009, we announced that we and the New York State Energy Research and Development Authority (NYSERDA) are in the process of negotiating a statement of work relating to a grant to pay for a portion of the interconnection and other aspects of the Stephentown facility. The value of the grant, if finalized, is expected to be approximately $2 million.

We may elect to install 1 MW installations in ISOs to provide early insight to operating within each market. The economics of these 1 MW systems may not be representative of expected revenues and costs for a 20 MW plant, and therefore the non-fungible costs may be expensed on our income statement rather than being booked as a fixed asset on our balance sheet. For


example, in the New York market, we are considering whether to deploy a 1 MW resource at the Stephentown site, but initially interconnected to NYSEG (later to be interconnected to National Grid, when such interconnection is approved). Similarly, in Ohio we expect to deploy 1 MW at the AEP facility as described below. The non-fungible costs associated with deploying small installations (such as at the AEP facility) which are not intended to remain in service for terms exceeding two years will be expensed.

On February 23, 2009, we announced that we had signed a contract with American Electric Power (AEP), one of the largest generators of electricity in the U.S., and one of its operating subsidiaries, Columbus Southern Power Company. The contract will entail building a 1 MW Smart Energy Matrix™ regulation facility at an AEP site in Groveport, Ohio. The system, which will be connected to the grid within the operating region of the PJM Interconnection (PJM), will provide flywheel-based frequency regulation services. Installation of this Smart Energy Matrix™ is expected to begin in 2010. The 1 MW system will provide valuable insight into the operation of our technology on PJM's grid and make us better prepared to deploy and profitably operate full scale 20 MW plants in PJM's coverage area.

On July 2, 2009, we announced that we received a conditional commitment from the DOE for a loan guarantee of approximately $43 million. The loan, which would be funded by the U.S. Treasury's Federal Financing Bank, is expected to provide debt financing for approximately 62.5%, of the estimated $69 million total project cost of our planned 20-megawatt (MW) flywheel-based energy storage installation to be located in Stephentown, New York. Of the $26 million not financed by the loan, we have already incurred approximately $13 million in eligible project expenditures, which will be considered part of our equity contribution to the project. A significant portion of this in-kind contribution will come from the redeployment of 2 MW or more of energy storage from Tyngsboro to the Stephentown site. We are exploring funding alternatives for the remaining $13 million, including a direct equity investment in the project by one or more third parties and/or the sale of our stock. In addition, we are in the process of negotiating a statement of work relating to a grant from NYSERDA to pay for a portion of the interconnection and other aspects of the Stephentown facility. The value of the grant, if finalized, is expected to be approximately $2 million.

We plan to have an aggregate of up to 3 MW of flywheel energy storage capacity produced and installed in Tyngsboro before year-end. In addition to our Stephentown, New York, site, our Glenville, New York, site and an identified site within AEP, we are also identifying and developing additional sites in our target markets.

In volume production, our goal is to complete 20 MW facilities at a cost of approximately $25 to $30 million each, though the first 20 MW plant will cost approximately $69 million, of which approximately $50 million is direct . . .

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