TBWES' plant improvement project offerings are aimed at enhancing overall plant performance, efficiency, and reliability through a range of specialised engineering interventions.
These projects typically begin with detailed engineering and efficiency improvement studies, followed by the identification and resolution of operational bottlenecks.
Our expertise spans fuel conversion, firing system retrofits, and emission control upgrades to meet evolving regulatory and sustainability demands. We implement advanced technology upgrades, plant automation, and instrumentation enhancements to modernise systems and improve operational precision.
Our services also include plant decommissioning, relocation, replacement-in-kind, and refurbishment of ageing assets. We support utility boiler revamps and reformer upgrades to align existing infrastructure with current performance standards, ensuring extended service life and optimal energy utilisation.
Features / Capabilities
Fuel Conversion & Firing System Upgrades
TBWES offerings include:
- Conducting performance evaluations and implementing modifications for seamless fuel adaptability
- Executing fuel conversions between oil and gas, as well as enabling dual-firing systems
- Designing systems for firing byproducts such as process gas, BFG (blast furnace gas), biogas, and COG (coke oven gas)
- Facilitating conversions for opportunity fuels like biomass, petcoke, dolachar, and washery rejects
- Reviewing original boiler designs to determine suitability for new fuel applications
- Performing thermal design evaluations to ensure compatibility with alternative fuels
- Recommending modifications to boiler pressure parts for new fuel requirements
- Design, engineering and supply of a new fuel firing system and BMS (burner management system) upgrades
- Converting solid fuel firing systems from travelling grate to fluidised bed technology
Performance, Reliability & Efficiency Enhancements
TBWES offerings include:
- De-bottlenecking of boiler operation / performance
- Identification and analysis of limiting factors
- Root cause study of operational limitations
- Assessment of design inadequacies (e.g., heat transfer areas, auxiliaries, instrumentation)
- Development of customised de-bottlenecking solutions
- Redesign of heat transfer areas
- Refurbishment or redesign of auxiliaries and instrumentation
- Enhancing steam generation by upgrading boilers for higher output
- Improving efficiency through optimisation and by enhancing heat transfer and maximising recovery
- Minimising aux. power consumption through operational fine tuning and by redesigning the auxiliaries and their drives
- Engineering services including feasibility studies, performance assessments, GAP analysis, and reliability improvement studies, aimed at evaluating current systems, identifying areas for enhancement, and developing strategies to improve overall efficiency and reliability
- Customised solutions for efficiency improvement
- Modifying / redesigning of combustion system
- Addition of new / modified heating surface area
- Performance testing and fine tuning of boiler operation
- Addition of new / modified heating surface area
- Performance testing and fine tuning of boiler operation
- Reliability improvement
- Root cause analysis for frequent failures of pressure parts, operational issues in auxiliaries, failure in firing system
- Customised solutions through redesigning of pressure parts and finetuning, testing and revamping of auxiliaries
Asset Re-Energisation: Relocation, Revival & Retrofit
TBWES offerings include:
- Extending the operational life and improving performance of boilers from TBWES and other OEMs through targeted upgrades and maintenance
- Modifying key performance components, relocating boiler assets, and recommissioning them efficiently at new user locations
- Modernising boilers of any make by engineering changes in pressure, temperature, and fuel compatibility
- Offering complete re-engineering, reverse engineering, performance simulation, and turnkey relocation, including dismantling, transport, and reinstallation
- Maximising reuse of existing materials based on thorough condition and performance assessments to reduce cost and waste
- Delivering combined benefits of life extension, performance upgrades, fuel conversion, and efficiency improvement
- Servicing and refurbishing salvaged boiler equipment to restore operational reliability and extend service life
Emission Control & Reduction Solutions
TBWES offerings include:
- Modifying the combustion system to meet required emission levels
- Providing solutions to reduce NOx emissions - FGR (flue gas recirculation) system, steam injection, SCR (selective catalytic reduction), and SNCR (selective non-catalytic reduction) systems
- Accessing the effect on boiler performance and modification
Digitalisation & Automation Upgrades
TBWES offerings include:
- Integration of advanced control systems for improved boiler performance
- Automation of startup, shutdown, and load management processes
- Remote operation and performance monitoring capabilities
- Optimisation of fuel usage and combustion efficiency via digital controls
Replacement in Kind (RIK) / Refurbishment
TBWES offerings include:
- Turnkey solutions for meeting turnaround timelines including detail engineering, manufacturing, transportation and site modification work
- Replacing aging components (tubes, headers, drums) with identical parts while ensuring compliance to improve reliability and extending life
- Re-engineering of obsolete & extinct designs with guaranteed performance
- Reverse engineering and delivering parts for replacement
Engineering Design & Feasibility Studies
TBWES offerings include:
- Detailed assessment of the project's technical and economic viability
- Preparation of basic and detailed engineering design packages
- Boiler capacity evaluation and performance optimisation studies
- Layout planning and space utilisation for new or retrofit installations
- Fuel compatibility analysis and combustion system design
- Feasibility of equipment upgrades or replacements
- Structural and thermal analysis of pressure parts and support systems
- Cost estimation and project scheduling for informed decision-making
- Compliance review with regulatory and environmental standards
