Energy & Industrial

From planning through design and construction management/commissioning to plant operation, we’ll help you achieve your project objectives.

Services Designed Around Your Needs

Our staff provide comprehensive engineering, design, analysis, and consulting services for energy and industrial markets worldwide. We work with a variety of clients, including investor-owned utilities, independent power producers/developers, and municipal/government agencies. Along with an unmatched commitment to quality and constructability, we use value engineering in design to optimize capital and operating costs. Our team has the know-how to take on scope-intensive, complex projects that meet our clients’ needs.

Spotlight Technologies and Services

Environmental Services and Compliance

In today’s complex regulatory environment, Sargent & Lundy can guide you to optimal compliance solutions and then execute those solutions on schedule and within budget. Sargent & Lundy is an industry leader in all types of environmental retrofit projects, including flue gas desulfurization (FGD), selective catalytic reduction (SCR), selective non-catalytic reduction (SNCR), fabric filters and precipitators, mercury and air toxic controls, dry sorbent injection, and advanced technologies, such as carbon capture.

Sargent & Lundy draws on extensive experience to assist our clients with difficult decisions balancing technology performance, capital and operating costs, and overall asset and fleet management considerations. We have completed environmental retrofit projects at over 350 units. Our experience working with all major environmental control suppliers can help guide you to informed decisions. We will apply our extensive plant retrofit experience to minimize the impact of your environmental projects on existing plant operations and develop effective designs that can be constructed within limited outage-time windows.

Read more about Zero Liquid Discharge Effluent Guidelines Compliance Strategies for Coal-Fired Power Plants’ FGD Wastewater

Learn more about our Compliance Planning services

Combustion Turbine and Combined-Cycle

In 1957, Sargent & Lundy designed the first utility combined-cycle application in the U.S. at the Rio Pecos Power Plant in Texas. Since then, we’ve designed over 150 combustion turbine, combined cycle, and cogeneration units.

Our expertise encompasses a broad range of cycles and fuels and spans virtually every technology including today’s most advanced machines. Project developers around the globe rely on our proven experience to deliver quality, low-cost, reliable designs and to meet our commitments to tight schedules and budgets. Our services include engineering and design, construction management and commissioning, or full EPC execution.

View our Experience List

Gas Compression and Pipelines

  • Natural gas compression station design
  • Natural gas flow studies
  • Gas conditioning
  • Gas pipeline planning & design
  • Metering & regulation stations
  • Outside battery limit (OSBL) detailed design
  • Fuel gas & process gas delivery system design
  • Pig launcher / receiver design
  • Process hazards analysis (PHA)
  • Gas buffer storage systems

Read about our Gas Compressor Station Project

Sargent & Lundy has designed numerous gas compression stations for gas transmission systems and to support specific plant demands. Our experience and expertise cover reciprocating and rotary compression technologies. Recent projects include a multi-unit reciprocating compression station with a total station horsepower of over 18,000 hp.

Coal Plant Design

Sargent & Lundy is unique in the industry for our continuous involvement with coal plant designs around the world for the past 125+ years. In fact, we have engineered more coal-fired units than any other engineering firm in the United States: 523 coal-fired units world-wide representing over 58,942 MW.

We use our extensive expertise to design coal units around the world with advanced environmental controls while maintaining efficiency and quality. The constructability, operability, and maintainability of our designs reflect this industry-leading know-how, which we apply to supercritical, subcritical, and advanced cycle technologies of all types. Our wealth of experience can help you minimize risk, maximize performance, and minimize capital and operating cost for coal units of all types.

Gas Conversion

Since 2009, Sargent & Lundy has studied more than 50 utility and industrial coal to natural gas conversion scenarios and has been engaged in the physical conversion of approximately 20 projects that include stoker, cyclone, wall-fired, tangential, and turbo firing configurations along with a wide range in firing configurations, boiler designs, and fuels. Our in-house boiler and combustion specialists can assess the impacts relative to heat rate, predicted emissions levels, boiler capacity, changes in pressure excursion, and hazardous area considerations per current National Fire Protection Association (NFPA) code requirements.

Sargent & Lundy’s environmental and permitting professionals will help your organization through the regulatory compliance decision-making process utilizing the gamut of Sargent & Lundy’s project execution expertise to develop a reliable and cost-effective plan going forward. Sargent & Lundy has provided a combination of feasibility studies, detailed engineering, procurement, construction management, and commissioning services for these 20 projects. This recent and diverse experience uniquely enables us to present reliable assessments for a successful gas conversion project.

Our expertise and wide-ranging capabilities make Sargent & Lundy the logical choice to help your organization navigate critical natural gas conversion success factors. Contact Sargent & Lundy now to help determine what is best for your particular needs.

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Before boiler conversion

Sargent & Lundy banner
After boiler conversion

Plant Betterment and Retrofit

Sargent & Lundy is the only industry-leading engineering firm that has consistently emphasized fossil plant betterment as a core part of our business throughout our history. We can respond quickly and efficiently to plan, estimate, and execute all types of maintenance and performance improvement modifications, whether a single unit improvement or a more comprehensive facilitywide assessment.

Our experience includes reliability improvement, heat rate/efficiency improvement, controls and electrical system upgrades, O&M cost reduction, system failure response, and rapid emergency response. We have assisted multiple clients with moving their units’ performance to top quartile levels. Our engineers and designers are skilled in seamlessly integrating modifications into existing systems with minimal disruption and cost. We have special expertise in addressing areas with limited space and outages with limited time and can help you successfully meet your unique project challenges.

Advanced Technologies (carbon capture, clean coal, coal gasification)

If you’re seeking help in evaluating and implementing emerging, advanced technologies, such as coal gasification, oxy-fuel combustion, and post-combustion CO2 removal, Sargent & Lundy has proven solutions. We are at the forefront of advanced technologies, including complete design services for pilot projects.

Our advanced technology services include initial feasibility studies, preliminary conceptual designs, formal FEED studies, plant integration planning, detailed design, and project and construction management. We are experienced in collaborating with advanced technology suppliers and operating plant management and staff, helping facilitate seamless integration of process systems with existing plant systems while minimizing outage time and disruption to plant operations.

View our Experience List and read about our Petra Nova Carbon Capture Project

Learn more about our Emission Technology services

Combined Heat and Power

Sargent & Lundy has long applied its engineering and design expertise at industrial complexes, educational, institutional, and other campus environments for projects that generate power and useful energy sources for heating and cooling. We understand the important relationships between power generation, campus utility production, and all forms of onsite energy consumption.

We are adept at evaluating and implementing the options that best suit the goals and requirements of industrial and institutional campus utilities. Power generation and distribution, heating, cooling, and water all present their own unique challenges, and our dedicated specialists make it easy for our clients to navigate complex issues.

Sargent & Lundy combined heat and power project

Our recent experience spans diverse technologies and system designs associated with CHP including:

  • Combined heat and power (CHP) – cogeneration, desalination
  • Chiller and heat pump technologies
  • District heating and cooling
  • Reciprocating internal combustion engines (RICE)
  • Combustion turbines – simple cycle and combined cycle
  • Packaged boilers

Our experience includes extensive retrofit work for conversion, upgrade, and expansion of existing facilities. We can evaluate the existing condition of your campus and provide the right level of service for your project.

Industrial

We provide services to industrial clients for new design of or modifications to industrial utility systems. Our services include planning, feasibility studies, economic analysis, design, equipment procurement, construction management, and startup support to ensure the most cost-effective solutions to their utility problems.

Downstream and Midstream

Our team of engineers and designers use a multidisciplined approach to the oil and gas midstream and downstream industry. We have strong expertise and experience in performing studies and design services for water treatment upgrades, fuel conversions, pollution control improvements, assessment of remaining plant life, controls modernization, steam system modifications, and new generation facilities. Our clients benefit from our depth of expertise, particularly our familiarity with integrating energy needs with process demands.

EPC and EPCM

At Sargent & Lundy, we have a long and proven track record of successfully executing projects in a turnkey/EPC contract arrangement. We regularly execute projects in joint ventures with construction contractors who also have proven records of success.

Our EPC services encompass the full range of project management, engineering, design, procurement, construction, inspection, expediting, startup, and commissioning, with successful training and turnover, for a complete and successful project.

Owners Engineer Services

For those seeking an owner’s engineer partnership, we can provide the specialized technical expertise and due diligence services to meet quality, performance, budgetary, schedule, legal, and other requirements. Activities may include site and technology selection, feasibility studies, EPC specification and bid assistance, environmental reviews, construction monitoring/management, and site surveillance.

 Comprehensive Services

  • Complete Engineering and Detailed Design
  • Comprehensive Project Management
  • Procurement
  • Construction Management and Commissioning
  • Alternative Fuels
  • Project Feasibility and Optimization Evaluations
  • Regulatory Compliance and Permitting
  • Global Experience and Capabilities

Specialized Expertise

Process Hazard Analysis

Sargent & Lundy’s proven track record of successful designs is the foundation on which our engineers and other professionals continually build their expertise in fully understanding power plant and industrial system design and operation. That expertise extends to the vital services of HAZOP, HAZID, and SIL analyses. Our effective and efficient analyses result in safe operating systems and add value to your project. Our comprehensive services include:

Hazard and Operability (HAZOP) Services
  • Planning & Scoping (HAZID)
  • Facilitation
  • Recordkeeping
  • Reporting
  • Follow-up
Safety Integrity Level (SIL) Services
  • Evaluating Hazards and Risks via Layer-of-Protection Analysis
  • Designing Safety Instrumented Systems to Meet Required SIL
  • Analyzing Safety Instrumented Systems to Verify SIL is Achieved

Read More

Analytical Services for Industrial, Commercial, and Institutional Distribution Power Systems and Microgrids

Sargent & Lundy offers a full suite of analytical capabilities and engineering studies for planning, design, and operations of industrial, commercial, and institutional distribution power systems and microgrids.  Read More

Generator Protection Support and Compliance with NERC and IEEE Standards

Sargent & Lundy has been providing services for complying with NERC Protection and Control (PRC) standards since their inception. We support utilities upgrading and maintaining their protection systems with system and documentation review, design & implementation of upgrades, and analyses to meet NERC and IEEE standards. Read More