An industrial power plant at sunset

Technology Transfer Services

Operational Manual Design & Technology Transfer Services

FCS specializes in the seamless integration of new technologies, so your organization and facilities will maximize the return on investment.

FCS designs fully custom training manuals around a plant’s specific equipment and team needs. Our services ensure that a plant’s team has standardized and easy-to-follow guidelines in place to ensure the plant runs at peak efficiency.

FCS also aids in knowledge transfer through training simulators. Training simulators have gained wide acceptance as an effective way to improve power plant availability and performance. Simulators allow operator trainees to gain practical experience in the shortest possible time. They can also be used to meet other objectives including training other personnel as part of a multi-skilling effort, validating plant procedures, and in evaluating control system and plant design modifications.

Often times, purchased simulators do not meet these objectives because they were not properly specified, did not undergo detailed enough validation during the design and testing phase, and/or did not have adequately designed training programs. FCS has extensive experience developing simulator specifications, and conducting design reviews, model validation, and acceptance testing to ensure the simulator meets the utility’s requirements.

The best engineered simulators have limited value unless they are implemented in a well-planned, comprehensive training program designed to meet the specific objectives of the plant and personnel expected to be trained. FCS has extensive experience designing and developing power plant simulator training programs for control room operators and other plant staff.

Contact Us

The FCS Solution

FCS provides support to utility and other power generation clients involved in procuring a power plant simulator, including:

Simulator Feasibility Study

Justifies simulator purchase and associated investment.

Specification Development

Identifies training requirements.

Vendor (Bidder) Evaluation

Includes objective evaluation approach designed to quantify each Bidder’s response to the bid specification.

Simulator Design Review

Ensures simulator project remains on track and meets objectives.

Acceptance Testing Assistance

Acceptance Testing Assistance, including:

  • Procedure Development
  • Testing Personnel

Simulator Training Program Development

Ensures investment in simulator is maximized.

Environmental Services

A primary concern for operators of today’s new or existing power plants – whether coal, oil or gas fired – is the control of environmental air emissions. Air control systems designed to remove NOx, sulfur, carbon monoxide, mercury, dust and other pollutants have been mandated by the EPA. FCS will ensure the operators of these new systems are trained in proper operation and control under normal and abnormal conditions.

Operators are expected to learn a new system and controls with no previous experience. That is where FCS comes in. We can provide that experience, having produced training courses and materials for many plants including those designed by Hitachi Power Systems America, Shaw, Black and Veatch, Wheelabrator, Babcock And Wilcox, URS Washington Group, and Alstom. 

  • Wet Flue Gas Desulfurization Systems (FGD)
  • Dry Flue Gas Desulfurization Systems (DFGD)
  • Selective Catalytic Reduction Systems (SCR)
  • Selective Non-Catalytic Reduction Systems (SNCR)
  • Activated Carbon Injection System (ACI)
  • Dry Sorbent Injection Systems (DSI)
  • Carbon Monoxide Catalytic Converters
  • Oxidation Catalyst Systems (Diesels and Gas Turbines)
  • Particulate Removal Systems (Baghouses, Wet and Dry Electrostatic Precipitators (WESP/DESP)
  • Low NOx Burners and Dry Low NOx Systems
Technology Transfer Services

Seamlessly Integrate New Technologies

We can develop training and documentation that will help you and your plant seamlessly integrate new technologies into your workforce. We are eager to pass that experience on to you and your operators!

FCS also has extensive experience providing a range of operational excellence or readiness services in support of coal power plant conversions to natural gas firing.

In addition to supporting projects with air quality control systems, FCS has extensive experience supporting Industrial Water Systems and water treatment systems designed to treat runoff from coal piles, ash ponds, gypsum piles and so on around industrial facilities.

Get Started
Technology Transfer Services

Coal Combustible Residual (CCR) Projects

FCS has also recently been supporting Coal Combustible Residual (CCR) projects designed to support the environmentally sound recycling of coal ash and safe disposal of coal ash in landfills and surface impoundments. In support of the CCR projects FCS has worked on the following systems:

  • Submerged Chain Conveyor Systems (Replacing Sluiced Bottom Ash Systems)
  • Dry Vacuum-Type Dry Ash Conveying Systems
  • Dense Phase Ash Conveyor (DEPAC) Systems
  • Fly Ash Handling Pressure Systems
  • Gypsum Dewatering Systems
  • Coal Combustible Residual Transport Systems
  • Coal Combustible Residual Electrical Distribution Systems

Maintenance Management Support

FCS has assisted with the development and installation computerized Maintenance Management Systems at numerous utility and manufacturing plants.

These systems provide a “state-of-the-art” solution to the automation of maintenance management functions. The systems allow for easy customization, and the data collected is available to users in the most flexible format possible. It assists maintenance personnel with their basic activities:

  1. Maintenance planning, scheduling, and record keeping
  2. Spare parts control
  3. Purchasing
  4. Storage and retrieval of equipment data
  5. Preventive, Predictive and Corrective Maintenance activities
Contact Us
Technology Transfer Services

Ensure Reliable Equipment Operations

Although not specially part of an MMS implementation, Facility Lockout-Tagout (LOTO) Procedures are an important part of an effective maintenance management as they ensure the maintenance work is done safely. FCS can provide comprehensive and site specific LOTO as required.

A key component of reliable service, managed through a computerized MMS, is having the following elements to ensure reliable equipment operations:

Asset Identification System

The Asset Identification System is an important resource for compiling, organizing, and managing the equipment installed at your facility. Once loaded into the MMS database, it allows maintenance tasks to be identified and scheduled, and for spare parts to be identified and tracked to specific equipment.

Predictive and Preventive Maintenance Plans

The maintenance plans identify those pieces of equipment that require periodic maintenance to ensure facility reliability. They provide the scheduling data for the MMS-generated maintenance orders to ensure reliable equipment operations and reduced equipment life-cycle costs.

Spare Parts

An effective spare parts program is needed to minimize downtime of the equipment, systems and facilities. The spare parts programs are based on the maintenance required for the facility components and must be reasonably available during both planned and unplanned maintenance activities.

Maintenance Task Lists and Schedules

Maintenance Tasks Lists ensure maintenance is performed in accordance with manufacturer recommendations and industry accepted practices. The task lists provide man-power, material, and tracking data for MMS-generated maintenance.

Maintenance Lubrication Schedules

Lubrication schedules detail the type of lubricant required, the points to be lubricated and the frequency of lubrication again ensuring reliable equipment operations.

Technology Transfer Services