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For utilities, IPPs, and their OEMs: heat exchangers and pressure parts
Find the next failure before the outage. Free assessment and roadmap.
The challenge
Fouling, poor flow, and aging tubes cut exchanger duty and plant output year after year.
Review: Performance test
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What changes
Our power generation engineering consultants find where duty is lost and which fixes bring it back.
The challenge
Poor flow in piping, ducts, and intakes causes erosion, vibration, and lost pumping power.
Review: Inspection
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What changes
Fluid flow simulation reshapes piping, ducts, and intakes for less loss and less wear.
The challenge
Start-stop cycles and temperature swings crack headers, casings, and piping over time.
Review: Outage plan
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What changes
Thermal FEA and turbine component stress analysis find the stresses each cycle creates, so fixes target the real cause.
The challenge
Older plants run on parts with no drawings and no supplier, and each failure means delay.
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What changes
Legacy parts are measured, modeled, and improved, so any qualified shop can make them.
Turbine, boiler, HRSG, and heat exchanger OEMs: we act as your engineering team on pressure parts and more.
Your extra design team.
Get Your Free RoadmapUtilities and power producers: we define and design the equipment your plant needs, then work with your OEM.
Your plant, our design.
Get Your Free RoadmapPlant and OEM in one design loop, so thermal performance, pressure integrity, and life extension line up.
One loop, both sides.
Get Your Free RoadmapBring your own manufacturer, or work with our partner network. We take the designs we engineer as far as you need. We don't manufacture, so we never compete with the OEMs we partner with.
Facts about how we work, not project results. One team engineers your product from analysis to delivery, and calculations carry a PE stamp where required.
01
An equipment design or fix with thermal and pressure data behind it, PE-stamped where required.
02
Heat, flow, and FEA results you review and approve at each gate, before anything changes in the plant.
03
You own the IP by default. When an OEM or partner manufacturer is involved, the contract spells out who owns what.
04
If we missed it in our QC, we fix it. If your supplier can't make the part within three years, or supply dries up, we fix that too.
You send
What we need to start
Drawings or CAD for the equipment
Operating data: temperatures, flows, and cycles
Failure and inspection history
Outage windows and plant constraints
Targets: output, life, or outage date
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You get
What you hold at the end
Design or fix: PE-stamped drawings where required
Heat, flow, and FEA results you approved
A fix list ranked by value and risk
Fabrication package, ready to quote
Support through the outage and start-up
We price to the value we deliver, not the hours we log. If the value isn't there for you, we'll say so in the assessment.
Find lost duty in heat exchangers, condensers, and boilers, and design the fixes that bring it back.
Get the lost duty back.
Used For
Exchangers
Condensers
Boilers
Model flow in piping, ducts, and cooling water intakes, so erosion, vibration, and pumping losses drop.
Less loss, less wear.
Used For
Piping
Ducts
Intakes
Find the thermal stresses that start-stop cycles create in headers, casings, and piping before they crack.
Survive every cycle.
Used For
Headers
Casings
Cycling
Design handling gear, skids, and plant equipment, with the build managed through our partner network.
We manage the build.
Used For
Skids
Handling
Equipment
Public benchmark
CFD-backed tuning and new nozzles cut full-load NOx by over half on 575 MW coal boilers (ASME, 2006)
What it means for you
Validated CFD models guided the tuning and the new nozzles on full-size boilers. We use the same kind of models on your heat exchangers and pressure parts, checked against your plant data.
The public record shows what the method can do. What it does for your equipment depends on your constraints, and the free assessment tells you.
Utility, OEM, or both: we set the model, the builder, and the hand-off.
Scope, priorities, outage dates, and approval gates.
Heat, flow, and FEA on the equipment, checked in our QC.
Drawings and a package ready for your outage.
Start-up support, plant data, and later changes.
You approve the design at every gate, so nothing that affects function surprises you. If we missed something in our QC, we fix it. If a supplier can’t make a part within three years, we fix that too.
Outage coming up? Send the drawings and plant data. Free roadmap.
Scrubbers, ducts, and fans designed to your permit limits, without oversizing the system or the fans.
Right-size your controls.
Applications
Scrubbers
Ducts
Fans
Airflow and cooling for data halls modeled in CFD, so hot spots are found before the racks ever go live.
No hot spots at launch.
Applications
Airflow
Cooling
Racks
Aerospace to data centers: see how one engineering team solves hard constraints across ten industries.
Find the one like yours.
Industries
Aerospace
Mining
Data Centers
Fixed scope for one project. A lower-risk place to start when you want to see our work on your data.
Start with one project.
Fits When
One Project
Fixed Scope
From $35K
Scheduled monthly engineering for recurring needs: drawing updates, ASME calcs, or FEA for each sale.
Work on a set schedule.
Fits When
Monthly
Recurring
From $15K/mo
A dedicated PPS team working your program daily, built for long, multi-year development and testing.
Your program, every day.
Fits When
Daily Work
Multi-Year
From $800K/yr
Gold · One project: an exchanger, pump, or part that keeps failing or losing duty.
Platinum · Ongoing work: engineering support across outages and upgrades.
Diamond · A long program: a dedicated team for a plant upgrade or life extension.
FEA, CFD, CAD, DFMA, and testing under one roof. Engineering is a team sport, and you get the whole team.
One team, every skill.
Under One Roof
FEA
CFD
CAD
DFMA
Testing
Veteran-owned SDVOSB status gives defense and federal buyers a set-aside path to proven engineering.
Verify our SDVOSB status.
Credentials
SDVOSB
VOSB
CAGE 8ZK73
NAICS 541330
Missed something in our QC? We fix it. Supplier can't make the part within three years? We fix that too.
Support for the long run.
We Fix
Our QC Misses
Supplier Gaps
Supply Chain
We price to the value we deliver, not hours logged. You buy a design that works, not more iterations.
Pay for the result only.
Collections
Gold
Platinum
Diamond
What do your power generation engineering consultants do?
Our power generation engineering consultants work on the plant equipment that limits output or forces outages: heat exchangers, condensers, boilers, piping, and pressure parts. Most plants feel it as lost duty, worn piping, cracked headers, or a part no supplier still makes. Each of these starts as an engineering problem. Fouling and aging tubes cut exchanger duty year after year. Start-stop cycling cracks headers and casings that were designed for steady load. Boiler pressure parts fall under ASME Section I, so a repair that misses the code holds up the restart. Every forced outage costs output, and the fix often waits for the next planned window.
Heat transfer analysis finds where duty is lost and which fixes bring it back. Fluid flow simulation reshapes piping, ducts, and intakes for less loss and wear. Thermal FEA finds the stresses each cycle creates, so fixes target the real cause. Reverse engineering brings obsolete parts back into supply. Each fix is checked against your plant data and your inspection history before you approve it.
Can you work within our outage schedule?
Yes. Most plants make their biggest fixes during planned outages, and every day offline costs output. Our power generation engineering consultants plan backward from your outage dates. A design that is late waits for the next window, often months away, while the problem keeps costing you every week. The U.S. Energy Information Administration reports planned and forced outages separately, and notes that forced outages can result from equipment failure. A failure between windows takes the unit down on the worst possible day, with no crew or parts ready. Long-lead parts make it worse, because they can't be ordered until the design is set and approved.
The free assessment ranks fixes by value and risk. The roadmap then sets which designs must be ready for which outage. Each fix is checked in analysis first, so the crew installs a design that has already been reviewed. Long-lead parts are flagged early, so they can be ordered in time. If a fix can't make the window, we tell you early and plan it for the next one.
Can PPS work with our OEM or manufacturer?
Yes. Power generation engineering consultants from PPS fit the partnerships that are normal in power plant projects. We work in one of three models. As your OEM partner, we act as your engineering team. Operator-led, we design the equipment and work with the builder you choose.
When design, build, and test sit with different companies, problems pass back and forth. The builder works from an old drawing, and each party defends its own scope. The Department of Defense's IPPD Handbook organizes programs around integrated product teams for this reason. In a joint program, the plant and the OEM work with us in one loop.
We engineer the design and coordinate the builder in one loop. Bring your own manufacturer, or work with our network of fabricators, machine shops, and test labs. You decide how far we take the design, up to the start of production. We never run production, so we never compete with your OEM. NDAs cover every party, and you own the IP by default, set in your contract.
What do you need from us to start?
To start a project with our power generation engineering consulting, send what you have, in any format. That usually means drawings or CAD for the equipment, operating temperatures, flows, and cycles, and the failure and inspection history. Add outage windows, plant constraints, photos, and your targets for output or life. Old inspection reports help too. Missing data is the most common reason engineering projects stall, because a model built on guessed inputs gives a guessed answer. That is why we don't start the work until every data set is in.
Once it is, the first step is a free assessment of your project scope. We confirm what the work can and can't answer, and tell you what is still missing. Then we send a roadmap proposal with scope, targets, and approval gates. Every project is scoped on its own, so the roadmap sets the schedule, not a stock promise. NDAs are available before you share any files. For gaps in material data, NIST material measurement data is a good first stop.
Who owns the design and the models?
You own the design, the drawings, and the models from your power generation engineering consulting project by default, as set in the contract. With an OEM involved, the contract says who owns what. Some firms keep the models, or license them back to you, so every later change sends you back to them. That locks your product to one vendor and makes design reviews harder, because your team can't open the evidence behind the decisions. You receive the native CAD, the drawings, the simulation model files, and the documented results. Your engineers can then check the work, rerun a load case, or hand the package to a supplier or customer.
We sign mutual NDAs before any of your data is shared, and your files stay in our controlled project folders while we work. If your program has export-control or customer data rules, tell us at the start and we will set up the data handling to match them. For defense programs, the State Department ITAR guidance sets the rules we follow.
What happens if a prototype fails in test?
If a prototype fails in test, we find out why and fix the design. Hard engineering carries unknowns on any project: real loads, material lots, and assembly effects never match a model perfectly. With power generation engineering consulting from PPS, you approve the data at each gate. A test result is then checked against predictions you have already seen, not a black box. A failure in test is data. It shows which assumption was wrong: a load, a material property, or a boundary condition. That data improves the model and the design.
When testing is in scope, we plan the test to confirm the margins that matter most. Then we correlate the model to the results, following ASME verification and validation practice. If the miss was ours, because something slipped through our QC review, we fix it. If the test uncovers a condition nobody knew about, we scope the change with you and update the roadmap. Either way, you get a clear answer and a path to a design that holds.
How is power generation engineering consulting priced?
We price power generation engineering consulting to the value it delivers, not the hours we log. Hourly billing rewards extra iterations, so the cheapest quote often becomes the most expensive project once tooling, rework, and field failures show up. Our incentive is to get the design right the first time. We engage by fit, not as a ladder. Gold (from $35K): you have one project and need help with it. Platinum (from $15K/mo): you have recurring work at a steady rhythm. Diamond (from $800K/yr): you have a long development program, often multi-year.
Gold is never required, and some clients start at Platinum or Diamond. These are starting points, not quotes; your roadmap sets the price. We price to the value we deliver, not the hours we log. If the value isn't there for you, we'll say so in the assessment. Our engineering consultant pricing page explains how each collection works in more detail.
Exchangers losing duty or parts cracking early? Send the data.
Send your drawings, plant data, and failure history. We review your project scope in a free assessment and reply within one business day with next steps.
On-site assessments that require travel are quoted separately.