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.

Decommissioning

With the increase of environmental regulatory challenges and advancements in fuel burning options, many coal-fired power plants are facing retirement. It may no longer be feasible to operate and renovate many power plants. Therefore, decommissioning and dismantling becomes part of these facilities’ lifecycles.

Building on our extensive power generation experience, POWER provides solutions to those who have made the decision to retire a plant and now face a series of complex choices. Decommissioning often presents clients with many new challenges, so it is extremely important that someone with expertise and experience is involved during the dismantle process.

Engineering Services

  • Plant decommissioning
  • Engineers probable cost estimates
  • Life cycle cost estimates
  • Feasibility studies
  • Feasibility consultation and alternative technology review
  • Project feasibility and sizing studies and estimating
  • Detailed design
  • Construction services
  • Due diligence
  • Environmental permitting
  • Permitting definition and support
  • On-site retirement support

Critical Piping Assessment

With a dedicated team, we can manage the overall critical piping assessment program for you including the scheduling/planning of future inspections and monitoring activities at your plants.

Multi-Phased Approach

We employ a multi-phased approach that can be tailored specifically to you and the needs of your plant(s). This approach results in 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.

  • Phase I: Perform Validation Walkdown
  • Phase 2: Confirm the Position of the As-Found High Energy piping
  • Phase 3: Create Piping Stress Analysis Computer Models
  • Phase 4: Manage Non-destructive Examinations
  • Phase 5: Perform Walkdown/Assessment of High Energy Piping
  • Phase 6: Perform As-Found Piping Stress Analysis
  • Phase 7: Perform Updated Piping Stress Analysis
  • Phase 8: Prepare Engineering Report

3-D/LIDAR Scanning

LIDAR Scanning

POWER incorporates the latest 3-D or Light Detection and Ranging (LIDAR) scanning into our engineering and design. LIDAR produces an accurate geometric model, in the form of a point cloud, from an existing site or plant.

This powerful model can be used in multiple design situations before, during and after engineering activities. The point cloud saves clients time and money by limiting manual measurements and costly repeat site visits.

Typical Uses

  • Site/Plant Verification. In the absence of, or in comparison to, existing drawings of a site or plant, the point cloud obtains or verifies dimensional information for equipment, structures, piping or field aspects.
  • Conditional Dimensions. Scans taken during different conditions (e.g. hot/cold, active/inactive, load/no load) are used to create an accurate side-by-side geometric comparison of pipe, ducting, structural members or equipment.
  • Before/After Illustrations. The point cloud can create an accurate and realistic comparison model of a project before construction and after the project is complete. It can also illustrate multiple options/iterations.
  • As-built/As-constructed Documentation. The point cloud of a completed can assist with the creation or modification of as-built documentation.
  • Safety. Objects and features at dangerous heights or difficult-to-reach locations can often be measured in a point cloud without endangering field personnel.

Boiler Equipment

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

Typical Systems

  • Pulverizers and coal-feed systems
  • Burner 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
  • AQCS systems – scrubbers, SNCR, ESP

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

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
  • 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
  • Plant safety

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
  • Visual inspections of structural systems, specifying and coordinating testing, providing repair and replacement recommendations, producing bid packages to perform the work and overseeing repairs

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

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
  • AutoPipe – Stress analysis
  • FEpipe – Finite element
  • Risa 3D – Frame analysis
  • GT Pro/GT Master – Plant performance analysis
  • Steam Pro/Steam Master – Plant performance analysis
  • SmartPlant – P&ID and 3D design
  • Plant 3D – P&ID and 3D design
  • PDS – Plant design system
  • PDMS – 3D design
  • CADWorx – P&ID and 3D design
  • MicroStation and AutoCAD
  • LIDAR 3D – Laser scanning

 

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:

  • Feasibility studies and site selection
  • Land use planning and permitting
  • Interface and coordination with federal, state, county or local permitting agencies
  • Site development and utility systems
  • Identification of geotechnical investigation requirements
  • Detailed site development engineering design
  • Storm water management and drainage facility design
  • Building code compliance
  • Animation, photo simulations and 3-D design
  • Owner’s engineering
  • Construction laydown, parking and traffic management
  • Vehicular access roads to and around the development

Typical Work Products:

  • Design criteria
  • Procurement of boundary, topographic and aerial surveys
  • Geotechnical investigation specification and foundation design criteria evaluation
  • Storm Water Pollution Prevention Plan (SWPPP)
  • Bulk material estimates
  • Erosion control plan
  • Rough grading plan and earthwork calculations
  • Site grading and drainage plan
  • Storm water calculations: hydrology, hydraulics, quantity control and quality control
  • Wastewater calculations: gravity or force-main
  • Underground utility plan
  • Public improvement plans for wastewater or gas line extensions to development
  • Site security plan
  • SmartPlant 3D underground utilities model
  • 3D site surface model
  • Civil construction specifications
  • Permit packages
  • Heavy-haul routing
  • Pavement layout and design
  • Site screening with berms, landscaping or fencing plans
  • Construction cost estimates
  • Spill Prevention Control and Countermeasures (SPCC) plans
  • Retaining wall plans and calculations

Construction Observation/Resident Engineer Services:

  • Scheduling
  • Coordination of inspections
  • Coordination of earthwork operations and testing
  • Interface with permitting agencies
  • Daily, weekly and monthly reports
  • Contract administration and pay application review
  • Coordination of concrete placements and testing
  • Interface with Contractor and subcontractor

Software and Tools:

  • AutoCAD Civil 3D – 3D modeling and design
  • Bentley InRoads – 3D modeling and design
  • MicroStation and AutoCAD – 2D design
  • Bentley CivilStorm – storm water system analysis and design
  • TR-55 and Bentley PondPack – basin design
  • Transoft AutoTURN – vehicle access design

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.

We have secured controls labs in our offices to use for system logic and graphic configuration and testing. POWER also performs field upgrades and integration of control systems, start-up and commissioning, control loop tuning as well as panel testing and checkout.

Typical Services:

  • Control system design, assembly and testing
  • Control system upgrade studies, justification and implementation
  • Instrumentation and control valve selection and specification
  • Plant interlock and process control design
  • 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
  • Burner Management System NFPA compliance 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 and control valve 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
  • Siemens T3000 DCS
  • Emerson Ovation DCS Platform
  • GE Cimplicity HMI
  • ABB SymphonyPlus and Harmony DCS Platforms
  • Extensive experience with legacy systems

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.

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)
  • AutoDesk AutoCAD
  •  AutoDesk Plant3D
  • Autodesk Inventor
  • AutoDesk Revit Structural
  • CADWORX (Intergraph)

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

POWER has experience with and is capable of performing on-site 3d scans and generating accurate point clouds for design purposes and as-built documentation. FARO scanning technology is utilized for the 3d scanning process and the resulting point clouds can be utilized in the software packages listed above.  Point clouds are created using:

  • AutoDesk Recap
  • FARO Scene