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Engineering the reliability of critical thermal assets.

From detailed engineering and plant modelling to pipe stress, FEA and remaining-life assessment — ProSIM brings analysis-led engineering to the systems that keep thermal power plants operating.

Thermal Power Experience

Engineering experience that connects directly to plant realities.

ProSIM’s thermal-power work includes structural integrity, remaining-life assessment and fitness-for-service studies for critical piping and turbine components. Its documented work covers main steam, hot reheat, cold reheat, HP bypass and LP bypass piping systems, combining inspection data, pipe flexibility, FEA and code assessment.

NTPC Units35+ in a documented RLA / RLE work order
Plant Capacities120 / 210 / 500 MW
FFS FrameworkAPI 579
Codes ReferencedASME B31.1 / B31.3
Built Around Engineering Depth

More than design support. Engineering insight for complex energy assets.

ProSIM supports thermal power owners, EPCs and equipment stakeholders across design, modification, operation and life extension.

Our multidisciplinary capability connects detailed engineering with computational analysis, piping expertise, materials knowledge and structural integrity assessment — helping teams make better engineering decisions before problems become outages.

Thermal power plant engineering and analysis
Core Capabilities

One engineering partner. Multiple layers of technical depth.

A capability stack designed for high-temperature, high-pressure and safety-critical thermal assets.

01
Detailed EngineeringMultidisciplinary engineering for new systems, modifications and plant upgrades — mechanical, civil & structural, electrical & instrumentation and equipment engineering.
02
Piping & 3D Plant ModellingAccurate routing, modelling and as-built digital representation of complex facilities — 3D plant modelling, piping layouts & isometrics, re-routing & optimisation and laser-scan integration.
03
Pipe Stress & FlexibilityEngineering evaluation of piping under thermal, sustained, occasional and dynamic loads — support & hanger design, nozzle loads, dynamic analysis and optimisation.
04
FEA & MultiphysicsSimulation-led insight for components and systems exposed to complex mechanical and thermal loading — linear / nonlinear FEA, thermo-mechanical analysis, fatigue & creep and fluid-structure interaction.
05
CFD & Thermal AnalysisNumerical evaluation of flow, heat transfer and coupled physical phenomena — flow analysis, heat transfer, thermal fields and multiphysics studies.
06
Decision SupportTranslate analysis results into practical engineering recommendations for repair, reuse, redesign or life extension — failure analysis, design optimisation, engineering judgement and owner's advisory.
Thermal Plant Systems

Focused on the systems where engineering decisions matter most.

01
Main Steam & Hot ReheatStress, flexibility, support and integrity assessment of critical high-temperature piping.
02
Cold Reheat & Bypass SystemsEngineering evaluation of CRH, HP bypass and LP bypass systems under operating and occasional conditions.
03
Boiler & Pressure ComponentsStructural and thermo-mechanical assessment of pressure-retaining and high-temperature components.
04
Turbines & Hot PartsAnalysis and remaining-life assessment of critical turbine components and ageing assets.
05
Supports, Hangers & AnchorsDesign, evaluation and optimisation to improve load paths and piping-system behaviour.
06
Plant ModificationsEngineering for rerouting, replacement, upgrades and brownfield modifications.
Advanced Analysis

See the failure mode. Understand the mechanism. Engineer the solution.

ProSIM combines FEA, materials and damage modelling with engineering codes and judgement to move beyond a pass / fail answer — thermo-mechanical stress, fatigue and creep, damage modelling, code assessment, failure analysis and design optimisation.

Thermo-mechanicalFatigue & CreepDamage ModellingCode AssessmentFailure AnalysisDesign Optimisation
Asset Integrity · RLA / RLE · FFS

From inspection data to an engineering decision.

For ageing thermal assets, the question is not simply whether a component has degraded — it is what that degradation means for safe operation and how its useful life can be managed.

Asset integrity and remaining-life assessment of thermal power components
01
Understand the assetReview design basis, operating history, materials and inspection information.
02
Model the conditionAccount for as-is conditions — defects, corrosion and relevant damage mechanisms.
03
Analyse & assessApply FEA, damage mechanics and applicable fitness-for-service requirements.
04
Recommend the actionSupport repair, reuse, replacement or life-extension decisions with engineering evidence.