Operating Plant Solutions

Operators of power plants today face increasing technical and commercial risks. POWER Engineers has extensive experience in power facilities operations and maintenance. We understand the full range of issues and can help you optimize your plant’s performance and investment value, and mitigate risks.

From assessing your operations and maintenance to providing balance-of-plant, boiler and engineering solutions, POWER can support your coal, oil and natural gas facilities needs during commercial operations.

Operations Assessments

POWER combines technical expertise with financial insight to review and assess your power plant operations and provide support where you need it.

Key Services

  • Process performance
  • Energy efficiency
  • Training
  • Staffing effectiveness
  • Life-cycle costs
  • Cyber security
  • SOP review and development
  • Safety plans and procedures
  • Operability and maintainability reviews

Equipment Analysis and Review

We review your technical and operational data and provide/verify appropriate equipment sizing for optimal operation and efficiency of your generation and balance-of-plant assets.

Startup QA and QC

We provide technical oversight during outages to ensure your milestones and critical-to-quality parameters are met.

Plant Performance Software Modeling

Using advanced modeling software, we develop process models based on plant-specific historical data to improve the design, analysis and optimization of your thermal power plants.

Performance Testing Support

We oversee plant acceptance tests and pre- and post-component upgrade tests—including review of performance test procedures and reports, reviewing and analyzing test data, and witnessing on-site tests.

Component-Based Performance Analysis

We generate custom spreadsheet tools that help your staff track overall plant and component performance trends. Or we can retain the spreadsheet tools and provide periodic reports as part of a remote monitoring service.

Performance Training

We train your staff on performance of gas and steam turbines, HRSGs, condensers, cooling towers, boilers, feedwater heaters, pumps, instrumentation, performance monitoring and startup/shutdown.

Maintenance Assessments

POWER creates comprehensive maintenance management plans for routine and non-routine maintenance processes that can help you maximize your plant’s availability.

Routine Maintenance Plans

These plans identify and prioritize all of the unique actions to be taken at your facility on a daily, weekly and annual basis to address outage schedules, workloads, warranty requirements and equipment health.

Our proven approach:

  1. Establish plant equipment databases.
  2. Research and define maintenance requirements based on OEM guidance.
  3. Develop procedures to align maintenance requirements with plant in-house capabilities.
  4. Integrate the maintenance plan into your facility’s Computerized Maintenance Management System (CMMS).

Major Maintenance Processes

We also generate customized work standards that document highly complex, non-routine maintenance tasks. By evaluating historical plant records, conducting staff interviews, observing maintenance evolutions and incorporating OEM information, we develop detailed processes that improve efficiency and cost effectiveness saving you time and money.

Maintenance Management Services

  • CMMS
    • Optimization
    • Data population
    • Training
  • Work order process
  • Spare parts (inventory, procurement, use)
  • Personnel qualification
  • 3rd party contracting
  • Predictive maintenance
  • Preventative maintenance
  • Outage readiness
  • Outage planning
  • Root cause analysis
  • Procurement support

Balance of Plant

POWER provides balance-of-plant services for existing power plants, including coal, oil and natural gas facilities.

Typical Systems

  • Breechings
  • Ductwork and expansion joints
  • Material handling systems
  • Condensate pumps
  • Condensers
  • Service water pumps
  • Fire loop and systems
  • Feedwater pumps
  • Feedwater heaters
  • Heat exchangers
  • Deaerators
  • Valves and piping systems
  • Cooling towers
  • Process valves and piping systems
  • Baghouse and precipitator maintenance and repair
  • Auxiliary and emergency diesel generators
  • Buildings structural integrity
  • Compressed air systems
  • Water processing chemistry and treatment
  • Electrical systems

Boiler Equipment

POWER provides boiler engineering services for existing coal, oil and gas-powered generating facilities, including circulating fluidized bed, pulverized coal and heat recovery steam generators.

Typical Systems

  • Pulverizers and coal-feed systems
  • Burners systems
  • Indicators attachment
  • Internal and external appurtenances
  • Fuel-handling systems
  • Coal bins and ash hoppers
  • Forced-draft fans
  • Induced-draft fans
  • Breechings
  • Ductwork and expansion joints
  • Combustion furnaces
  • Soot blowers
  • Air heaters
  • Scrubber piping and liners
  • Catalyst upgrade and replacement
  • Chimneys and stacks

Engineering Services

POWER provides a full complement of engineering services for your power plant projects—big and small. From new power plants to renovating existing facilities, we offer complete life-cycle solutions from conceptual engineering through operations support.

We also understand our clients have smaller needs as well. Whether it’s solving an existing problem or supplementing owner’s engineering staff, we’re organized to deliver single and multidiscipline services without the resources typically required by larger, full-service projects.

The result: cost-effective, high value solutions for your plant. And all engineering services are provided under the direct supervision of licensed professional engineers who maintain responsible charge of the work.

Typical Services:

  • Feasibility studies and site selection
  • Permitting support
  • Technology selection
  • Front end engineering and design (FEED)
  • Conceptual and preliminary engineering and design
  • Detailed engineering and design
  • Owner’s Engineering
  • Procurement and construction support
  • Plant outage or betterment support
  • Problems analysis and solutions
  • Plant due diligence
  • Plant retrofit assessment and design
  • Cost estimating
  • Construction or O&M field support
  • Staff augmentation
  • Plant walkdowns and inspections
  • Work package development

For additional details, open the respective discipline tab below:

  • Mechanical Engineering (including Process, Piping, HVAC, Fire Protection, Water Quality)
  • Structural Engineering
  • Civil Engineering
  • Electrical Engineering
  • Instrumentation and Control Engineering
  • Computer Aided Engineering

Mechanical Engineering

POWER’s seasoned mechanical engineers and designers have 30 years of experience designing new plants and working in existing facilities.

We can help you review available options and match vendor requirements, project budget and lifecycle costs to a specific technology and design. Then we deliver the complete work package to facilitate successful execution of each project, big or small. 

Typical Services:

  • Plant (Process) systems design
  • Equipment sizing, specification and selection
  • Piping engineering including:
    • Pipe specifications
    • Pipe routing
    • Pipe stress analysis
    • Pipe support design
  • Water/Wastewater supply and treatment
  • Building services including:
    • Heating, Ventilation, and Air Conditioning (HVAC)
    • Fire protection
    • Plumbing
  • Corrosion analysis
  • Plant operating problem analysis and solutions
  • Equipment inspection at shop or at site
  • High energy piping walkdowns and inspections
  • Piping replacement and upgrades
  • Energy efficiency upgrades

Typical Work Products:

  • Design criteria and system descriptions
  • Equipment & construction specification
  • Process flow diagrams
  • Heat balance diagrams
  • Water balance diagrams
  • Piping and instrument diagrams
  • 3D design model
  • Plot plan
  • Equipment arrangement drawings
  • Equipment, pipeline, valve and specialty lists
  • Piping plans and isometrics
  • Stress analysis (calculations)
  • Pipe support design
  • Welded pipe attachment analysis
  • ASME pressure vessel analysis
  • High energy piping and pipe support assessments
  • Evaluation of P91 alloy piping fabrication and installation issues
  • Vendor selection and submittal reviews
  • Demolition and tie-in plans
  • Bill of material
  • Building HVAC engineering
  • Studies and reports
  • Process hazard and safety review reports
  • Record drawings

Key Software and Tools:

  • Thermoflow – Cycle analysis
  • Hysys – Process modeling
  • Pipe-Flo – System analysis
  • Caesar II – Stress analysis
  • FEpipe – Finite element
  • Risa 3D – Frame analysis
  • GT Pro/GT Master- Plant performance analysis
  • Steam Pro- Plant performance analysis
  • SmartPlant – P&ID and 3D design
  • PDS – Plant design system
  • PDMS – 3D design
  • CADWorx – P&ID and 3D design
  • MicroStation & AutoCAD

Structural Engineering

From new construction to renovations, POWER’s structural engineers provide safe, code compliant and economical designs within established budget and schedule parameters.

Using client and local building department input/review, we develop structural requirements and design criteria to be used throughout the design of the project.

During construction, we provide engineering support, review and approve shop drawings and material submittals, provide clarifications and resolve field problems.

Typical Services:

  • Foundation systems with spread footings, deep foundations, retaining structures, tunnels and underpinning
  • Superstructure systems comprised of structural steel, reinforced concrete, timber and masonry construction
  • Steel connection design
  • Shop drawing approval per code requirements
  • Lateral load resisting systems for wind and seismic loads, consisting of rigid frames, braced frames, shear walls and diaphragms
  • Condition surveys and code upgrades including seismic rehabilitation
  • Site inspections
  • Vibration analysis

Typical Work Products:

  • Specifications for geotechnical investigation work
  • Analysis of geotechnical data and topography to establish design parameters for the foundations work
  • Design criteria (or Basis) document
  • Bill of quantities for structural materialsStructural engineering and design of the foundations for equipment and structures including turbine generator foundations, building foundations, cooling tower and tank foundations, electrical equipment foundations
  • Dynamic analysis of equipment foundations
  • Structural engineering and design of the power plant buildings including the structural steel roof and floor systems
  • Engineering and design of steel structures including pipe racks, platforms, stairways, and handrails, including conventional and modular design.
  • Finite Element Analysis of foundations and structural systems
  • Seismic analysis and design of buildings and structures, including soil-structure interaction
  • Feasibility studies and analyses in support of overall plant design
  • Specifications for civil, structural, and architectural materials
  • Peer reviews and Owner’s Engineer technical reviews
  • Analysis and design of existing buildings and structures for renovation and rehabilitation projects
  • 3D modeling of structures and foundations

Key Software and Tools:

  • SmartPlant – 3D modeling
  • MicroStation & AutoCAD
  • STAAD.Pro – Structural analysis and design
  • GTSTRUDL– Structural, finite element and dynamic analyses
  • SAP2000–Structural, finite element and dynamic analyses
  • RISA 3D – Structural analysis and design
  • SP Mats – Foundation design
  • SP Column–Concrete column design
  • L-Pile – Foundation design
  • Enercalc – Structural analysis and design
  • TEDDS – Structural analysis and design
  • SASSY2000-Soil-structure interaction analysis

Civil Engineering

POWER Engineers performs civil engineering functions as part of a larger design project as well as stand-alone engineering activity.  Our staff of civil engineers and designers provides the complete civil work package from conception to completion. 

Typical Services:

  • Land-use planning and permitting
  • Site grading and drainage
  • Underground utility design
  • Cut and fill calculations
  • Roadway and surfacing design
  • Hydrology and storm water pollution plans
  • Fencing
  • Permitting process assistance

Typical Work Products:

  • Building code, zoning and EPA compliance report
  • Feasibility studies and site selection
  • Analysis of geotechnical data and topography to establish design parameters for the site work
  • Land-use planning and permitting documents
  • Site development and utilities plans
  • Design of site grading and paving
  • Site access and roadway design
  • Site safety and security design for new plants and upgrades
  • Hydrology and storm water pollution plans
  • Storm water management and drainage systems

Software and Tools:

  • AutoCAD Civil 3D – 3D modeling and design
  • MicroStation InRoads – 3D modeling and design
  • MicroStation and AutoCAD
  • SmartPlant – 3D modeling
  • HydroCAD – Storm drainage
  • AutoTurn

Electrical Engineering

POWER’s electrical staff consists of engineers and designers capable of undertaking and successfully completing large and small projects, both new and retrofit/expansions.

Typical Services:

  • Site evaluation for electrical interconnections, with utility interface as required
  • Evaluation of alternative electrical configurations for cost and reliability
  • Electrical hazardous analysis (area classification)
  • Power distribution- high, medium, and low voltage
  • Power utilization to equipment
  • Lighting and small power
  • Instrumentation and control wiring
  • Grounding and lightning protection
  • Fire detection
  • Communication systems

Typical Work Products:

  • Single line diagrams
  • Electrical design criteria and system descriptions
  • Elementary and connection diagrams
  • Phasing diagrams
  • Conduit, cable tray and underground distribution design
  • Cable and conduit schedules
  • Termination schedules
  • Grounding plans and details
  • Lightning protection studies
  • Lighting protection plans and details
  • Illumination calculations and fixture selection
  • Illumination plans and details, including receptacle layouts
  • Panelboard schedules
  • Fault duty calculations
  • Fire alarm system riser, plans and details
  • Load flow analyses
  • Transformer sizing calculations
  • Steady state and motor starting voltage drop analyses
  • Protective relay and circuit breaker settings and time-current coordination
  • Arc flash analyses
  • Ground grid analyses
  • System grounding calculations
  • Cable sizing calculations
  • Electrical heat rejection calculations
  • Hazardous area classification drawings and design basis
  • Equipment procurement specifications
  • Electrical installation and testing specifications
  • Performance specifications for design-build services or systems
  • Electrical material quantity estimates
  • Cost estimates for equipment and installation
  • Engineering reports and assessment studies

Key Software and Tools:

  • CAE design using Microstation and AutoCAD
  • 3-D physical design using Smart Plant 3-D
  • Cablematic software for cable schedule, conduit schedule and termination schedule
  • Electrical analyses, including relay coordination and arc flash, using:
    • ETAP
    • SKM Power Tools
  • Ground grid analysis using SES CDEGS software
  • Lightning protection design using SES Shield software
  • Illumination design using Visual software
  • Underground cable sizing using ETAP and CYMCAP software

Instrumentation and Controls Engineering

POWER designs plant automation systems, security systems, instrumentation, networks, foreign device interfaces, control rooms arrangements, wiring, energy management and control, system integration and Human-Machine Interfaces.

In addition to being a certified Rockwell Solution Partner, we have secured controls labs for use in system configuration testing and FAT witness tests for our clients. POWER also performs field start-up and commissioning of control systems, as well as panel testing and checkout.

Typical Services:

  • Control system design, assembly and testing
  • Instrumentation selection and specification
  • Plant interlock and process control design
  • Plant security system conceptual design and specification
  • Control panel design
  • Logic and HMI design and configuration
  • Foreign device interface (Datalink) design
  • Network and wiring design
  • Instrumentation installation design
  • Vendor evaluation, interface and document review

Typical Work Products:

  • Control system design criteria
  • Control system architecture drawing
  • Control room layout drawing
  • Control panel layout drawing
  • Control analog and digital logic diagrams
  • Control logic narratives
  • Graphic display sketches
  • Piping and instrumentation diagrams
  • Instrument specifications and datasheets
  • Instrument installation details
  • Instrument location plans
  • Instrument index
  • Control system IO list
  • Datalink points lists (for foreign device interfaces)
  • Control philosophy documents

Key Software and Tools:

  • SmartPlant P&ID and SmartPlant Instrumentation
  • SmartPlant Review (Model Review)
  • Rockwell Logix and FactoryTalk Platforms
  • Siemens PCS 7 Control System Platform
  • Emerson Ovation DCS Platform
  • MicroStation, AutoCAD, SmartSketch & Visio
  • GE Proficy Process System
  • GE Cimplicity HMI

Computer Aided Engineering (CAE)

POWER maintains a CAE group charged with supporting our CAE systems. Our plant design software tool is the SmartPlant suite of products by Intergraph, which includes:

  • SmartPlant P&ID (SPID) for producing intelligent piping and instrumentation diagrams
  • SmartPlant Instrumentation (SPI) for all aspects of instrumentation engineering and design
  • Smart 3D for plant 3D modeling including Work Share.
  • SmartPlant Electrical for electrical engineering and design

We also understand that many clients prefer to use other 3D modeling applications. For these clients, we have successfully used the following, either in stand-alone fashion or in conjunction with the above SmartPlant tools:

  • PDMS (Aveva)
  • PDS (Intergraph)
  • 3D Microstation (Bentley)
  • 3D AutoCad (AutoDesk)
  • CADWORX (Intergraph)

POWER can also translate documents from one application to another, and can produce final deliverables in several formats to suit client standards.