Thermal Design Consultancy for Boilers, HRSGs and Steam Systems
ThermoExpert provides thermal design, heat recovery and steam system engineering for refinery, petrochemical, power and process industries. We size, verify and troubleshoot boilers, HRSGs and utility systems for new, retrofit and brown field projects.
- Boiler and HRSG thermal design, from furnace sizing to off-design performance
- Waste heat recovery: thermal oil heaters, ORC systems and economizers
- Steam, feedwater and condensate system design with full hydraulic calculations
- Independent design verification, performance checks and commissioning support
Industries We Serve
ThermoExpert works with plants where steam, heat recovery and utility systems decide production, fuel cost and availability.
Refineries and Petrochemicals
Steam generation and utility systems for continuous process plants where availability drives everything.
Power Plants
Combined cycle and cogeneration plants, including HRSGs behind gas turbines and engine based captive power.
Sugar, Paper and Biomass
Solid fuel fired boilers burning bagasse, rice husk, wheat straw and corn cob, where fuel quality varies through the season.
Textile and Process Heating
Thermal oil systems, process steam and condensate recovery for plants that heat, dry and cure.
Captive and Standby Utilities
Auxiliary and standby boilers that have to start reliably and hold load when the main plant cannot.
EPC Contractors and OEMs
Design support, independent verification and technical bid evaluation for project and procurement teams.
Thermal Design and Engineering Services
Eighteen consultancy services across five areas, from boiler and HRSG thermal design to independent verification, commissioning and engineering documentation. Every scope is calculated for your operating cases and developed to the applicable international codes.
Boiler and Steam Generator Thermal Design
6 services, including auxiliary water tube boilers.
See details →Waste Heat Recovery and Power Generation
3 services, including heat recovery thermal oil heaters.
See details →Steam, Feedwater and Utility System Design
5 services, including deaerator design, spray type and tray type.
See details →Performance, Verification and Commissioning
3 services, including steam system performance check and improvement.
See details →Engineering Documentation and Procurement Support
4 services, including operation and maintenance manuals.
See details →Boiler and Steam Generator Thermal Design
Thermal design for auxiliary, solid fuel fired and heat recovery steam generators. Each design is built around the project steam demand, the fuel, and the operating cases the plant will actually see, and is developed to meet the applicable international codes.
Auxiliary Water Tube Boilers
High performance thermal design consultancy for auxiliary water tube boilers that support demanding industrial operations. The design is developed around your steam demand, fuel characteristics and the applicable international codes, so the boiler holds pressure and temperature through load swings rather than only at the rating point. Typical applications are refinery, petrochemical and power plant utility systems where the auxiliary boiler has to carry the plant during start up, upset and turnaround.
What we cover
- Optimal furnace sizing for the fired duty
- Efficient heat transfer surface arrangement
- Circulation adequacy verified at all loads
- Faster load response
- Long term operational reliability
- Provision for real time efficiency monitoring
Auxiliary Fire Tube Boilers
Cost effective, dependable and energy efficient steam solutions for utility and standby applications. We optimise furnace configuration, gas flow paths and heat transfer surfaces to deliver stable performance, lower fuel consumption and safe operation. The result is a package boiler design that balances efficiency, simplicity and ease of maintenance across its service life, tailored to utility, standby and small process duties.
What we cover
- Furnace configuration and gas flow path optimisation
- Heat transfer surface design for stable performance
- Reduced fuel consumption
- Safe operation and operator friendly layout
- Ease of maintenance through the service life
- Lifecycle cost considered alongside thermal performance
Solid Fuel Fired Boilers, Water Tube Type
Water tube solid fuel fired designs for high pressure, high capacity steam generation, where efficiency, safety and long term operability depend on getting the combustion side right. We focus on precise heat balance calculations, furnace loading, combustion optimisation and heat recovery, so operation stays stable across varying fuel qualities. Designs are optimised for a wide range of solid fuels, including bagasse, rice husk, wheat straw and corn cob.
What we cover
- Optimized furnace and combustion chamber design for complete fuel burnout
- Advanced heat transfer surface arrangement for maximum efficiency
- Low flue gas losses and reduced auxiliary power consumption
- Design compliance with international codes and environmental norms
- Improved reliability under load fluctuation and fuel variability
- Suitable for bagasse, rice husk, wheat straw and corn cob
Hybrid Solid Fuel Fired Boilers
Hybrid designs combine the robustness of conventional boiler technology with heat recovery and combustion strategies that add flexibility. They suit plants where fuel availability changes through the year, where load varies widely, or where emission control is a decision factor. The arrangement is selected so the plant can move between fuels without giving up efficiency or stable steam conditions.
What we cover
- Integrated design combining water tube, fire tube or auxiliary heat recovery concepts
- Enhanced thermal efficiency with reduced capital and operating costs
- Flexible operation for multi fuel firing and load variation
- Optimized flue gas heat utilisation to minimise fuel consumption
- Future ready design allowing emission control upgrades
HRSG Thermal Design, Behind Gas Turbines
Specialised thermal design for heat recovery steam generators installed behind gas turbines in combined cycle and cogeneration plants. The work covers the full pressure arrangement, from single pressure units to dual and triple pressure designs with supplementary firing, and the performance is evaluated at part load and off-design, not only at the guarantee point.
What we cover
- Detailed thermal and heat balance calculations
- Single, dual and triple pressure HRSG design
- Supplementary firing evaluation
- Steam generation optimisation
- Tube sizing and thermal performance analysis
- Pinch point and approach temperature optimisation
- Off-design and part load performance evaluation
- Compliance with international design standards
- Technical support for new and retrofit projects
HRSG and Waste Heat Recovery, Behind Engines
Thermal design for waste heat recovery systems installed behind gas and diesel engines in industrial and captive power plants. Engine exhaust is a smaller and more variable heat source than a turbine, so the design has to earn its fuel savings at the loads the engines really run. We evaluate the recovery potential, then size the unit for steam or hot water accordingly.
What we cover
- Exhaust heat recovery system thermal design
- Detailed heat balance calculations
- Steam and hot water generation solutions
- Tube sizing and thermal performance evaluation
- Part load performance analysis
- Energy recovery and fuel savings improvement
- Customized solutions for gas and diesel engines
- Technical support for retrofit and brown field projects
Waste Heat Recovery and Power Generation
Heat that leaves the stack is fuel you have already paid for. We evaluate the recoverable duty, then design the equipment that turns it into process heat, steam or electrical power.
Heat Recovery Thermal Oil Heaters
Thermal design for heat recovery thermal oil heaters installed behind gas turbines and gas or diesel engines, for industrial process heating and cogeneration. Thermal oil systems are sensitive to film temperature and pressure drop, so the tube arrangement and oil side hydraulics are designed together with the exhaust gas side rather than after it.
What we cover
- Detailed thermal and heat balance calculations
- Thermal oil heater sizing and performance evaluation
- Exhaust gas heat recovery optimisation
- Thermal oil temperature profile analysis
- Tube sizing and heat transfer calculations
- Pressure drop evaluation for gas and oil side
- Part load and off-design performance analysis
- Fuel savings and energy efficiency improvement studies
- Technical support for new and retrofit installations
Organic Rankine Cycle (ORC) Systems
Thermal design and engineering for Organic Rankine Cycle systems installed behind gas turbines to recover waste heat and generate power. The assessment starts with the available exhaust energy and the temperature profile, then covers working fluid selection, evaporator design and net power output across the operating range, so the cycle is matched to the heat source instead of the other way round.
What we cover
- Waste heat recovery assessment from gas turbine exhaust
- Detailed thermal and heat balance calculations
- ORC cycle performance and efficiency analysis
- Working fluid selection and optimisation
- Evaporator and heat exchanger thermal design
- Exhaust gas temperature profile evaluation
- Net power output optimisation
- Part load and off-design performance analysis
- Energy efficiency and fuel savings studies
Economizer Thermal Design
Economizer design for steam boilers, HRSGs and waste heat recovery systems, to raise feed water temperature and lift overall plant efficiency. The gain has to be balanced against flue gas temperature limits, draft loss and material selection, so the sizing is carried out with the flue gas temperature profile and the water side pressure drop in view together.
What we cover
- Detailed thermal and heat balance calculations
- Economizer sizing and thermal performance evaluation
- Tube sizing and heat transfer calculations
- Feed water temperature optimisation
- Flue gas temperature profile analysis
- Pressure drop calculations for gas and water side
- Heat recovery and boiler efficiency improvement studies
- Material selection support based on operating conditions
- Technical support for new, retrofit and brown field projects
Steam, Feedwater and Utility System Design
The boiler is only part of the plant. Deaeration, condensate recovery, expansion control, piping hydraulics and overpressure protection decide whether the steam system is efficient and safe in daily operation.
Deaerator Design, Spray Type and Tray Type
Thermal and process design for spray type and tray type deaerators used in boiler feed water systems. The objective is efficient removal of dissolved oxygen and carbon dioxide, because what the deaerator leaves behind ends up as corrosion in the boiler and the feed lines. Sizing covers the deaerating section, the storage volume and the steam and feed water distribution.
What we cover
- Detailed thermal and heat balance calculations
- Spray nozzle sizing and arrangement analysis
- Tray sizing and tray arrangement evaluation
- Deaerator sizing and performance assessment
- Feed water heating and deaeration analysis
- Steam consumption and vent rate calculations
- Operating pressure and temperature optimisation
- Storage tank sizing and residence time evaluation
- Oxygen and dissolved gas removal performance analysis
- Boiler feed water system integration
Condensate System Design
Condensate system design for industrial steam and power plants, so that hot condensate returns to the boiler instead of being dumped. The design covers the recovery and return network, tank sizing, pump selection with NPSH checked against the real condensate temperature, and flash steam recovery where the pressure levels justify it.
What we cover
- Condensate system thermal and hydraulic calculations
- Condensate recovery and return system design
- Condensate tank sizing and capacity evaluation
- Condensate pump sizing and selection support
- Flash steam recovery assessment
- Pipe sizing and pressure drop calculations
- Net Positive Suction Head (NPSH) evaluation
- Steam trap and condensate handling evaluation
- System performance analysis under varying load conditions
Expansion Vessel System Design
Expansion vessel system design for closed loop heating, cooling, thermal oil and hot water systems. The vessel holds system pressure stable while the fluid expands and contracts, which protects pumps and joints and keeps suction pressure above the point where pumps cavitate. Sizing is based on the calculated fluid volume expansion across the full operating range.
What we cover
- Expansion vessel sizing and capacity calculations
- System pressure and thermal expansion analysis
- Cold fill and operating pressure evaluation
- Thermal fluid volume expansion calculations
- Pressurisation system design and optimisation
- Safety valve and system protection assessment
- Pump suction pressure and NPSH considerations
- Integration with hot water and thermal oil systems
- System performance evaluation under varying load conditions
Hydraulic Calculations
Hydraulic calculations for steam, water, thermal oil and process piping systems. Line sizing decides velocity, pressure drop, noise and erosion, and it sets the pump head you will pay for over the life of the plant. We size the network, check the distribution and balance it, and verify NPSH and control valve pressure drop before the equipment is bought.
What we cover
- Flow rate and velocity calculations
- Pipe sizing and hydraulic analysis
- Pressure drop calculations for piping systems
- Pump head and system resistance calculations
- NPSH evaluation for pump systems
- Control valve pressure drop analysis
- Flow distribution and balancing calculations
- Thermal oil, steam and water system hydraulic evaluation
- System optimisation for energy efficient operation
Steam System Pressure Safety Valve Capacity Calculations
Pressure safety valve capacity calculations for steam systems, based on the credible overpressure scenarios for the plant. Each relieving case is evaluated, including fire and blocked outlet, and the required capacity is compared against installed valves so undersized protection is found on paper rather than in service. The work follows ASME and the other applicable international standards.
What we cover
- Pressure safety valve capacity calculations for steam systems
- Evaluation of overpressure and relieving scenarios
- Boiler and steam drum overpressure assessment
- Fire case and blocked outlet scenario analysis
- Steam generation and relieving load calculations
- Set pressure and accumulation evaluation
- Inlet and outlet pressure drop calculations
- Verification of existing PSV adequacy and sizing
- Compliance with ASME and applicable international standards
Performance, Verification and Commissioning
Independent engineering on work that is already designed, installed or running: where the losses are, whether the design holds up, and whether the plant is ready to start.
Steam System Performance Check and Improvement
A structured evaluation of the whole steam system to find operational inefficiency, energy losses and reliability risks. We build the steam and heat balance, review generation, distribution, condensate recovery and utilisation, then return practical recommendations ranked by what they save against what they cost to implement.
What we cover
- Steam system thermal and energy performance evaluation
- Steam balance and heat balance analysis
- Boiler and steam distribution system assessment
- Steam pressure and temperature performance review
- Condensate recovery system evaluation
- Steam trap performance assessment and recommendations
- Identification of steam and energy losses
- Fuel efficiency and energy saving improvement studies
- Practical retrofit and optimisation recommendations
Independent Design Verification
An independent review of boiler, utility system, heat recovery and process plant design, carried out by engineers who did not produce the design. Calculations, datasheets, PFDs and P&IDs are checked against the project requirements and the applicable standards, and inconsistencies and technical risks are listed with the recommendation to close them.
What we cover
- Independent review of engineering and design documents
- Verification of thermal and hydraulic calculations
- Design compliance assessment with applicable codes and standards
- Review of process datasheets and technical specifications
- Evaluation of equipment sizing and performance parameters
- Assessment of system safety and operational reliability
- Review of process flow diagrams (PFDs) and P&IDs
- Identification of design inconsistencies and technical risks
- Support for project approvals and technical audits
Commissioning Services
Commissioning support for boilers, steam systems, heat recovery equipment, thermal oil systems and utility plants, covering the transition from installation to operational readiness. The scope runs from pre-commissioning checks and functional testing through boiler light up and steam blowing to performance verification and the commissioning report.
What we cover
- Pre-commissioning and commissioning support services
- System inspection and readiness verification
- Start up and shutdown procedure support
- Functional testing of equipment and systems
- Performance verification and operational checks
- Assistance in boiler light up and steam blowing activities
- Instrumentation and control system verification
- Troubleshooting during commissioning activities
- Preparation of commissioning reports and documentation
Engineering Documentation and Procurement Support
The documents that keep a plant operable and the technical work that keeps procurement honest: manuals, narratives, preservation procedures and quotation vetting.
Operation and Maintenance Manuals
Professionally structured operation and maintenance manuals for boilers, utility systems and industrial process plants. The manual is written around your equipment and your operating philosophy, so operators get procedures they can follow at three in the morning rather than a binder of vendor leaflets.
What we cover
- Preparation of customized O&M manuals
- Equipment operation procedures and guidelines
- Start up and shutdown procedures
- Preventive maintenance recommendations
- Safety precautions and operational practices
- Troubleshooting guidelines and fault analysis
- System description and operational philosophy
- Integration of process and equipment data
- Support for commissioning and operator training
Process and Control Narratives
Process and control narratives for industrial utility and process systems, defining the operating philosophy, control logic and system functionality. The narrative is what the control system is configured from and what the operators are trained on, so interlocks, trips and alarm philosophy are written down explicitly instead of living in someone’s head.
What we cover
- Process operation philosophy development
- Control logic and sequence description
- Interlock and protection philosophy documentation
- Start up, shutdown and emergency operation narratives
- Instrumentation and control system description
- Process control strategy development
- Alarm and trip philosophy documentation
- Integration with DCS and PLC systems
- Coordination with process and instrumentation diagrams (P&IDs)
Boiler Preservation Procedures
Preservation procedures that protect boilers during shutdown, storage and extended idle periods. Idle boilers corrode from the inside, and the damage shows up as tube failures after restart. We specify wet or dry lay up to suit the outage length and the site conditions, with the monitoring and start up preparation that goes with it.
What we cover
- Wet and dry boiler preservation procedures
- Short term and long term preservation planning
- Corrosion prevention and protection guidelines
- Chemical preservation recommendations
- Lay up and storage condition assessment
- Preservation monitoring and inspection guidelines
- Boiler water chemistry preservation requirements
- Start up preparation after the preservation period
- Safety and operational precaution guidelines
Vendor Specifications and Quotation Vetting
Technical support through the procurement cycle, from writing the specification to evaluating what comes back. Offers are compared on a like for like technical basis, deviations are identified, and performance and design parameters are verified, so the cheapest quotation is not accepted on the strength of an exclusion buried in the small print.
What we cover
- Preparation of technical specifications for vendor items
- Development of process and performance requirements
- Equipment datasheet preparation and review
- Technical requirement definition for procurement packages
- Technical evaluation of vendor quotations and proposals
- Technical bid comparison and compliance assessment
- Performance and design parameter verification
- Identification and review of technical deviations
- Technical clarification support during bid evaluation
From Enquiry to Commissioning Support
A consultancy scope is only useful if you can check it. Assumptions are written down, calculations are reviewed before issue, and the deliverables are the documents your project, procurement and operations teams actually need.
Thermal design, not drafting
Every deliverable starts from a heat and mass balance. Sizing, surface arrangement and performance are calculated, then checked against the operating cases you actually run.
Design for the real operating range
Plants rarely sit at the design point. Part load, off-design and fuel variation cases are evaluated so the equipment behaves when conditions move.
Code aware engineering
Designs are developed to the applicable international codes and standards for the equipment and the project, including ASME requirements for steam safety valve capacity.
New, retrofit and brown field
Retrofit work carries constraints that greenfield does not: existing headers, footprints, tie-ins and shutdown windows. Our scope is built around them.
Our Engagement Process
1. Enquiry
You share the scope, operating data and constraints. We confirm what is needed and what is missing.
2. Data review and confidentiality
Plant data is treated as confidential and can be covered by an NDA before anything is shared.
3. Scoped proposal
A written scope: the calculations, documents and drawings you receive, with the schedule.
4. Thermal design and calculations
Heat and mass balance, sizing, heat transfer and hydraulic calculations, and performance evaluation across the operating cases.
5. Internal check
Calculations and documents are reviewed before issue, and assumptions are listed so you can audit them.
6. Issue and support
Deliverables are issued, then we support review comments, vendor queries, procurement and commissioning.
What You Receive
- Heat and mass balance and thermal design calculation reports
- Equipment sizing and performance evaluation reports
- Process datasheets and technical specifications for enquiry and procurement
- Hydraulic calculations for steam, water, thermal oil and process piping
- Pressure safety valve capacity calculations and relieving case summaries
- Process and control narratives, operation and maintenance manuals
- Technical bid comparison, deviation lists and vendor quotation vetting reports
- Independent design verification and design review reports
Code Aware Engineering, and Your Data Stays Yours
Designs are developed to meet the international codes and standards applicable to the equipment and the project, including ASME requirements for steam safety valve capacity. Plant data, drawings and commercial information are treated as confidential, and a non disclosure agreement can be signed before anything is shared.
Thermal Design Engineering from Lahore, Pakistan
ThermoExpert is a thermal design and engineering consultancy working on boilers, heat recovery steam generators, waste heat recovery equipment and steam utility systems. We support plant owners, EPC contractors and equipment manufacturers on new, retrofit and brown field projects, from the first heat balance through to commissioning.
- Thermal design, heat recovery and steam system engineering
- Independent verification of designs produced elsewhere
- Commissioning, performance checks and engineering documentation
Talk to an engineer
Send your steam capacity, fuel and operating conditions, and you will get a technical reply, not a brochure.
- Phone+92 301 8412030
- WhatsAppMessage us
- OfficeLahore, Pakistan
Frequently Asked Questions
What does a thermal design consultancy actually deliver?
You receive engineering documents, not drawings alone. A typical scope includes the heat and mass balance, sizing and heat transfer calculations, hydraulic calculations, performance evaluation at design and part load, process datasheets for procurement, and a calculation report that lists the assumptions so your team or a third party can audit it.
Do you work on existing plants or only new projects?
Both. A large part of our work is retrofit and brown field: adding heat recovery to an operating plant, verifying whether existing equipment still suits changed conditions, or finding why a steam system no longer performs. Existing plants carry constraints such as tie-in points, footprint and shutdown windows, and the design is built around them.
Which fuels do your solid fuel fired boiler designs cover?
Designs are optimised for a wide range of solid fuels, including bagasse, rice husk, wheat straw and corn cob. Fuel quality varies through the season, so furnace sizing, combustion air arrangement and heat transfer surfaces are checked against that variation rather than a single fuel analysis.
Can you review a thermal design that another company produced?
Yes. Independent design verification is a defined service. We review calculations, datasheets, PFDs and P&IDs against the project requirements and applicable standards, then report design inconsistencies, technical risks and the recommendations to close them. It is also used to support project approvals and technical audits.
What information do you need to start a thermal design?
As a minimum: steam or heat duty and conditions, fuel analysis, feed water and ambient data, the operating cases including part load, and any site constraints. For an existing plant, add the current equipment datasheets and operating logs. If something is missing we will tell you what it is and what assumption we would otherwise make.
Which codes and standards do you design to?
Designs are developed to meet the international codes and standards applicable to the equipment and the project. For steam pressure safety valve capacity calculations this includes ASME and the other applicable international standards. The governing codes for a specific scope are confirmed in the proposal before work starts.
Is our plant data kept confidential?
Yes. Operating data, drawings and commercial information are treated as confidential and are used only for your project. A non disclosure agreement can be signed before any data is shared.
Do you support commissioning and start up?
Yes. Commissioning services cover readiness verification, functional testing, start up and shutdown procedure support, boiler light up and steam blowing assistance, instrumentation and control verification, troubleshooting, and the commissioning report.
Tell Us About Your Plant
Share the scope and the operating data you have. If something is missing we will tell you what is needed before any work is quoted.
Direct contact
- Phone+92 301 8412030
- WhatsAppMessage us
- LocationLahore, Pakistan
Useful to include: steam capacity and conditions, fuel, plant type, and whether the project is new, retrofit or brown field.