Thermal System
We instrument the boiler–turbine–process loop under real load and convert it into a clear heat-and-power picture—where energy is converted, where it is lost, and what to fix first. The output is a prioritized, production-safe plan that lowers fuel cost and stabilizes process steam.
Steam flow measurement
Inline or clamp-on metering with header mass balance and shift profiling to separate base load from variable demand and produce a verified demand curve.
Piping leak test & evaluation
Ultrasound sweep plus valve-tightness and bypass checks. We quantify leakage as mass flow and rank repairs by cost and operational risk.
Absorption chiller performance checking
Heat balance and COP verification using approach temperatures, flows, and solution health (vacuum, purging, fouling). Corrective actions are specified and sequenced.
Energy improvements
Meter-driven changes: set-point reduction after drop fixes, header balancing, PRV→turbine recovery, heat-recovery/economizer, condensate/flash-steam return, and control tuning—with payback and implementation steps.
Steam turbine performance evaluation
Trend inlet/outlet P-T, compute isentropic efficiency, and review governor/PRV interaction to confirm stability margin and recover avoidable throttling losses.
Steam quality checking & evaluation
Dryness fraction/superheat and dew-point verification at points of use; assess separators, drip legs, and filtration to prevent carry-over and water-hammer.
Steam trap checking
Ultrasound and thermal profiling to classify blow-through, cold, and cycling traps. We deliver a tagged register with loss estimates and a prioritized replacement plan.
Measurement Plan
Audit meter map for the boiler–turbine–process loop.
This schematic is the metering plan that turns a steam plant into numbers you can trust. Fuel rate and NCV establish boiler heat input; feedwater mass/enthalpy anchors the inlet state; boiler outlet P/T fixes the steam condition you actually deliver. At the back-pressure turbine, inlet/outlet P/T quantify the thermodynamic drop while generator kW validates conversion and separates mechanical/electrical losses. The process header confirms pressure and steam quality at the lowest safe set-point instead of an inflated “just in case.” Side draws and blowdown are accounted so the mass/energy math closes.
Instrumentation Scope
Defined meter points for P/T/flow/kW (fuel, feedwater, boiler, turbine, header, blowdown) to close the mass/energy balance and anchor all calculations.
Fuel rate & NCV (boiler heat in)
Feedwater flow/enthalpy (inlet state)
Boiler outlet P/T (steam state out)
Turbine P/T in & out + generator kW
Header P/T & quality; blowdown & side draws
Field Results
Readings yield field-verified boiler η, turbine isentropic η, a closed balance, and a quantified loss register under real production load.
Boiler efficiency (field-verified)
Turbine isentropic efficiency
Closed mass & energy balance
Loss register: drops, leaks, blowdown
Baseline captured under real load
Content Creation
Data drives actions: minimum safe set-point, PRV↔turbine recovery, pressure-drop fixes, trap/condensate program, and heat-recovery screens—sequenced by savings/risk.
Trim set-point to the minimum safe
Sequence PRV ↔ turbine to recover throttling
Fix pressure-drop hotspots before adding pressure
Steam-trap program & condensate return
Screen heat-recovery / economizer
Content Creation
Instrumented, time-synced, thermo↔kW cross-checked; auditable under load; delivers a prioritized, verifiable plan that cuts thermal cost without uptime risk.
Instrumented, time-synchronized, thermo ↔ kW cross-check
Reproducible under production; auditable
Prioritized actions with payback & risk
Lower thermal cost without uptime risk
