Clear Process Engineering & Technology

Industrial energy audits that quantify losses, identify likely root causes, and prioritize corrective actions for maintenance and capital planning.

• Boiler Efficiency Evaluation

  Boiler and combustion system review using operating data, field measurements, and performance benchmarks.

• Loss and Opportunity Ranking

  Quantified findings that rank corrective actions by likely savings, implementation cost, risk, and payback.

• Steam and Condensate Review

  Assessment of steam, condensate, blowdown, heat recovery, and process heat integration opportunities.

Technical and economic studies that compare paths forward before committing capital.

• Fuel Conversion and Switching

  Combustion modeling, fuel handling requirements, emissions impacts, and capital estimates for fuel-switching decisions.

• CHP and Power Generation Studies

  Gas turbine, steam turbine, ORC, HRSG, and engine-generator configurations evaluated against site-specific steam and electrical loads.

• Debottlenecking and Capacity Studies

  Identification of equipment and system constraints, with retrofit or rerate options modeled at target capacity.

• Technology Comparison

  Vendor-neutral comparison of competing technologies on performance, cost, risk, and operational fit.

• Emissions and Permitting Pathway

  Emissions control technology selection, regulatory threshold comparison, and permitting timeline analysis.

Construction-ready multi-discipline engineering packages for boiler systems, process plants, and industrial infrastructure.

• Process Engineering

  Heat and mass balance, P&IDs, process flow diagrams, boiler performance, fluid dynamics, circulation, emissions calculations, PHA, and HAZOP support.

• Mechanical and Piping

  Rotating equipment sizing, boiler sizing, piping arrangements, isometrics, pipe stress analysis, refractory, and anchor design.

• Structural and Civil

  Structural steel, foundations, rebar, site grading, drainage, and subsurface utility design for industrial projects.

• Electrical Engineering

  One-line diagrams, cable schedules, MCC layouts, VFD specifications, power distribution, arc flash, short-circuit analysis, and motor protection settings.

• Instrumentation and Controls

  PLC programming, HMI development, SAMA logic diagrams, I/O lists, instrument specifications, panel layouts, BMS design, and combustion logic.

• 3D Modeling and Reality Capture Integration

  AutoCAD Plant 3D modeling, Navisworks visualization, terrestrial laser scanning, and drone LiDAR or photogrammetry integrated into design workflows.

Engineering-led EPCm, owner representation, procurement coordination, construction management, commissioning, and project controls for industrial installations.

• EPCm Delivery

  Engineering, procurement, construction management, and commissioning under single-source accountability.

• Procurement and Vendor Coordination

  Bid packages, technical evaluations, bid comparisons, expediting, logistics, shop inspections, and factory acceptance tests.

• Construction Oversight

  On-site supervision, safety coordination, quality control, contractor coordination, shop drawing review, and change order evaluation.

• Commissioning and Startup

  Commissioning procedures, system checkout, hydrostatic tests, refractory cure, steam blows, and performance or emissions guarantee testing.

• Owner Representative Services

  Representation of the owner's interests with contractors, vendors, and suppliers during engineering, procurement, fabrication, and installation.

On-site engineering for boilers, combustion systems, thermal equipment, emissions testing, commissioning, and condition assessment.

• Combustion Tuning

  Air-fuel ratio adjustment, OFA tuning, grate speed optimization, and performance benchmarking against design conditions.

• Boiler Inspections

  Internal and external assessment of pressure parts, refractory, grates, and convection pass components with photographic documentation.

• Emissions Testing

  Stack testing, O2/CO/NOx measurement, opacity assessment, and compliance reporting for federal and state requirements.

• Startup Support

  First-fire supervision, safety interlock verification, control loop tuning, and operator training during initial operation.

• UT Thickness Surveys

  Ultrasonic thickness measurement of tubes, drums, headers, and pressure vessels for remaining-wall assessment and replacement planning.

• Root Cause Failure Analysis

  Field investigation of tube failures, superheater damage, grate issues, refractory degradation, and other equipment failures.

Industrial 3D laser scanning, drone photogrammetry, and LiDAR for brownfield engineering, clash detection, fabrication drawings, and as-built documentation.

• Terrestrial Laser Scanning

  Trimble X7/X9 scanning for interior and exterior capture of boiler houses, process buildings, pipe racks, and equipment areas.

• Drone Photogrammetry

  DJI Mavic 3E flights for aerial models used in construction planning, project communication, and exterior equipment documentation.

• Drone LiDAR

  Aerial LiDAR capture for large-scale site documentation, exterior piping, and areas not accessible by terrestrial scanners.

• Point Cloud to 3D Model

  Point clouds, 3D models, Navisworks files, and scan-derived 2D drawings for engineering, fabrication, and construction.

• Clash and Interference Reports

  Documented interferences between existing conditions and proposed designs, with photographs and dimensional data for resolution.

Combustion technology selection, design, troubleshooting, tuning, and retrofit engineering for biomass, multi-fuel, and conventional fuels.

• Stoker Systems

  Fixed pinhole, traveling, reciprocating, and vibrating grate combustion system engineering.

• Bubbling Fluidized Bed

  BFB combustor design and troubleshooting for biomass and industrial steam generation.

• Circulating Fluidized Bed

  CFB combustion system evaluation, integration, and design support.

• Fuel Metering and Distribution

  Feed equipment sizing, number of feed points, feed wall configuration, and fuel distribution review.

• Air Systems and OFA

  Combustion air and overfire-air system design, distribution, and tuning.

• Refractory and Thermal Design

  Thermal design of refractory, furnace lining, and high-temperature combustion-zone components.

Boiler engineering from furnace to feedwater for watertube, firetube, HRSG, biomass, natural gas, multi-fuel, and hydrogen-ready applications.

• Stoker-Fired Watertube Boilers

  Boiler designs using solid-fuel grate systems for industrial and biomass steam generation.

• Fluidized Bed Boilers

  Bubbling and circulating fluidized bed boiler applications for biomass, waste-derived fuels, and opportunity fuels.

• Suspension-Fired Watertube Boilers

  Pulverized or finely ground fuel combustion in suspension for industrial and utility-scale applications.

• Package Boilers

  Factory-assembled watertube or firetube units for process heating, auxiliary steam, and industrial service.

• HRSGs

  Heat recovery steam generators for exhaust heat recovery from turbines, engines, and process sources.

• Waste Heat Recovery Boilers

  Boiler systems for process exhaust, kiln, engine, and industrial waste-heat applications.

Air pollution control engineering for combustion systems, fuels, process conditions, and permit requirements.

• Baghouses and Fabric Filters

  Particulate control systems for industrial boilers and process exhaust.

• Electrostatic Precipitators

  ESP evaluation and engineering for high-volume flue gas particulate removal.

• SCR and SNCR Systems

  NOx control system design, reagent handling, integration, and compliance support.

• Dry Sorbent and Activated Carbon Injection

  Acid gas, mercury, and hazardous-pollutant reduction systems integrated with upstream and downstream equipment.

• Wet Scrubbers

  Wet flue-gas treatment systems for industrial air pollution control applications.

• Multi-Pollutant Control Trains

  Integrated systems combining multiple air pollution control technologies in sequence.

Custom heat-transfer equipment and heat-recovery systems engineered to ASME code for fouling, temperature, and corrosion conditions.

• Economizers

  Feedwater economizer design and replacement for boiler flue-gas heat recovery.

• Air Preheaters

  Combustion air preheating equipment for boiler and process heat recovery.

• Superheaters and Reheaters

  Steam temperature control equipment for power generation and high-temperature process applications.

• Shell and Tube Exchangers

  Custom exchanger engineering for industrial process heat transfer.

• Condensers and Flash Steam Systems

  Steam-side recovery, condenser, thermocompressor, and mechanical vapor recompression evaluations.