Power Plant Engineering —
Thermoflow Heat Balance, Piping Stress & MEP India
Specialist engineering for gas turbine, combined cycle, coal, biomass, CHP, and renewable power plants. Heat balance and cycle analysis using Thermoflow GT PRO, STEAM PRO, and THERMOFLEX. Piping stress analysis using Caesar II (ASME B31.1). Hydraulic analysis using AFT Fathom and PIPENET. HRSG design, BOP MEP engineering, and PMC. Serving power generation projects across India and internationally from New Delhi and Navi Mumbai.
Power Generation Engineering Expertise
Every deliverable is simulation-validated — from Thermoflow GT PRO heat balance diagrams to Caesar II ASME B31.1 stress isometrics. No assumption-driven design.
Thermoflow Suite — GT PRO / STEAM PRO / THERMOFLEX
The Thermoflow suite is the global industry standard for power plant performance analysis — used by EPC contractors, OEMs (GE, Siemens, Mitsubishi), independent power producers, and lenders worldwide. KVRM is proficient across all three Thermoflow modules, selecting the appropriate tool for each project type.
GT PRO — Gas turbine and combined cycle design-point modelling. We size the gas turbine, configure the HRSG (single/dual/triple pressure), select the steam turbine extraction points, and optimise the overall heat rate. Compressor inlet conditioning, air quality analysis for tropical and high-altitude sites, and performance guarantee documentation.
STEAM PRO — Coal, biomass, and waste-to-energy steam plant modelling. Feedwater heating train design, condenser sizing, back-pressure turbine analysis for industrial steam users.
THERMOFLEX — Custom cycle modelling for CHP, district heating, geothermal, and non-standard configurations where GT PRO or STEAM PRO cannot represent the cycle fully.
What We Deliver
Heat balance and thermodynamic cycle modelling for all power plant types — from open-cycle gas turbines to triple-pressure combined cycle, coal steam plants, and CHP facilities. GT PRO for gas turbine and combined cycle. STEAM PRO for steam and coal plants. THERMOFLEX for custom configurations.
- GT PRO — gas turbine & combined cycle design-point heat balance
- Compressor inlet conditioning — fogging, evaporative cooling, chilling
- HRSG configuration — single, dual, triple pressure with reheat
- Steam turbine selection — extraction points, back-pressure vs condensing
- STEAM PRO — coal, biomass, and waste-to-energy steam cycle modelling
- Feedwater heating train design and condenser sizing
- THERMOFLEX — CHP, district heating, geothermal, custom cycles
- Back-pressure turbine analysis for industrial steam offtakers
Caesar II stress and flexibility analysis for high-temperature, high-pressure power plant piping — main steam, hot reheat, cold reheat, feedwater, condensate, and auxiliary steam lines to ASME B31.1 Power Piping code.
- Main steam line stress — sustained, thermal, and occasional load cases
- Hot reheat and cold reheat piping flexibility analysis
- Feedwater and condensate system stress analysis
- Turbine nozzle load evaluation and OEM allowable verification
- Boiler drum nozzle and heat exchanger nozzle load assessment
- Seismic analysis per IBC / IS 1893 for power plant piping
- Spring hanger selection and sizing for high-temperature pipe runs
- IBR (Indian Boilers Regulation) compliance documentation
Heat recovery steam generator (HRSG) configuration and piping design for combined cycle power plants — integrating Thermoflow GT PRO heat balance outputs with Caesar II piping stress analysis for the steam and feedwater circuits.
- HRSG configuration — single, dual, and triple pressure with reheat
- HP, IP, and LP steam system piping design and stress analysis
- HRSG bypass and steam bypass system design
- HP and LP bypass valve sizing and transient analysis
- Steam drum and feedwater drum nozzle load assessment
- HRSG structural interface — pipe rack and support coordination
- Duct burner integration and supplementary firing assessment
- IBR documentation for HRSG and all pressure parts
Steady-state and transient hydraulic analysis for power plant cooling water systems, condenser circuits, boiler feedwater systems, and fire water networks using AFT Fathom and PIPENET.
- Cooling water system hydraulic analysis — cooling tower, condenser, pump sizing
- Condenser circulating water surge — pump trip transient analysis (AFT Impulse)
- Boiler feed pump sizing and NPSH available vs. required analysis
- Feedwater heater system hydraulic analysis
- Closed cooling water system design and pump selection
- Fire water network design and hydraulic calculation (NFPA 13/20)
- Makeup water system and demineralised water system analysis
- Variable speed drive (VFD) assessment for pump energy savings
Mechanical, Electrical, and Plumbing design for power plant auxiliary systems and buildings — control buildings, switchgear rooms, administration buildings, battery rooms, and turbine hall auxiliary systems.
- HT/LT electrical distribution — SLDs, load flow, short circuit (ETAP)
- MV/LV switchgear sizing and relay coordination studies
- HVAC for control rooms, switchgear rooms, and battery rooms
- Fire protection — turbine hall, transformer bund, cable galleries (NFPA 850)
- Deluge system for transformer protection (NFPA 15)
- CO₂ suppression for battery rooms and cable cellars
- Plumbing and drainage for auxiliary buildings
- Emergency DG and UPS sizing for critical plant loads
Heat rate benchmarking and auxiliary power consumption analysis for operating power plants — identifying the most impactful improvements available at the lowest capital cost, using Thermoflow GT PRO off-design analysis and field measurement data.
- Heat rate benchmarking — gross vs. net heat rate, design vs. actual
- GT PRO off-design analysis — part-load and ambient condition performance
- Compressor inlet air cooling assessment — fogging vs. chilling economics
- Condenser performance — TTD, DCA, cleanliness factor analysis
- Boiler / HRSG efficiency — stack losses, radiation, incomplete combustion
- Auxiliary power reduction — largest consumers, VFD opportunity assessment
- Heat rate improvement roadmap with capital cost and payback estimates
- ISO 50001 energy management system support
Simulation Tools & Codes We Work To
Every power plant deliverable produced using the industry-standard software for that discipline — Thermoflow for heat balance, Caesar II for piping stress, ETAP for electrical studies — and checked against the applicable ASME, IEEE, or NFPA standard.
- Thermoflow GT PRO — Gas Turbine & Combined Cycle Heat Balance
- Thermoflow STEAM PRO — Coal, Biomass & CHP Steam Cycles
- Thermoflow THERMOFLEX — Custom Cycle Configurations
- Caesar II — Piping Stress Analysis (ASME B31.1 Power Piping)
- AFT Fathom — Cooling Water & Feedwater Hydraulic Analysis
- AFT Impulse — Transient Surge (Condenser Pump Trip)
- PIPENET — Fire Water & Auxiliary Network Analysis
- REVIT — BOP MEP BIM Design
- ETAP — Electrical Power System Studies
- HAP — HVAC Load Calculations
- ASME B31.1 — Power Piping (main steam, feedwater, reheat)
- ASME Section I — Power Boilers (HRSG and steam drums)
- ASME Section VIII — Pressure Vessels (feedwater heaters)
- IBR — Indian Boilers Regulation (boilers and pressure parts)
- NFPA 850 — Fire Protection for Electric Generating Plants
- NFPA 15 — Water Spray Systems (transformer deluge)
- NFPA 20 — Fire Pump Installations
- IEEE C57 / IS Standards — Transformer and Switchgear
- IEC 60076 / IS 2026 — Power Transformers
- IS 1893 / IBC — Seismic Design (piping and structures)
- ISO 50001 — Energy Management Systems
Serving power generation projects across India and internationally:
Explore Our Engineering Services
Thermoflow GT PRO heat balance, Caesar II ASME B31.1 piping stress, HRSG design, or BOP MEP — our engineering team in New Delhi and Navi Mumbai responds within 24 hours.