99.60 % — 6,000 → 24 mg/Nm³ @ 6 % O₂ dry
Design-basis train performance (Electrocyclone + ESP)
Services · EPC delivery
Turnkey emission control projects: single-point responsibility from survey to guarantee test
A turnkey emission control project puts survey, design, fabrication, erection and commissioning under one contract and one measurement basis. Arrow Energy Co., Ltd. carries the train from customer documents to a performance test in mg/Nm³ at stated O₂ — with fabrication at our Samut Sakhon factory and pre-assembly planned to cut outage days.
Samut Sakhon factory & R&D, pressure parts to ASME/JIS practice
Fabrication
ITP hold and witness points per fabrication stage
Quality gates
Bagasse boilers 60–250 t/h (Thailand, Colombia)
Reference classes
01 — Why single-point responsibility
The interface problem a turnkey emission control project removes
Retrofit schedules die at vendor boundaries, not inside anyone's scope.
A typical multi-vendor retrofit has a precipitator supplier, a ducting fabricator, a structural contractor, an electrical contractor and the plant's own maintenance team — five parties and at least ten interfaces. Every interface is a place where a flange pattern, a steel elevation, a cable schedule or a delivery date can disagree, and the disagreement surfaces at the worst possible moment: during a fixed outage, with the boiler down and every idle day costing generation or crushing throughput. When performance then falls short, each guarantee carefully excludes the others' scope, and the plant owns the gap.
Arrow Energy Co., Ltd. delivers emission control and boiler plant turnkey precisely to remove those boundaries. Design, fabrication, erection and commissioning sit under one contract inside our boiler and emission-control services group, so a duct that must meet a casing meets it — the same document register governs both drawings — and one party signs the guarantee test at the stack. The train is designed as a system: pre-collector, precipitator, fan, ash handling and controls sized together, the way our published design basis treats a 60 t/h bagasse boiler (Electrocyclone at 88 % ahead of a four-field electrostatic precipitator: 6,000 → 24 mg/Nm³ @ 6 % O₂ dry — design basis, illustrative calculation, not a guarantee).
02 — Project flow
How an Arrow turnkey project actually runs
Twelve steps, in the order they happen.
The sequence below is how our projects are executed, not an idealised diagram. Each step produces a document the next step consumes.
- Customer documents. Fuel analysis, boiler data, existing drawings, the permit limit with its basis (mg/Nm³ at which O₂), and the outage calendar.
- Preliminary engineering review. First-pass sizing and technology selection — precipitator only, staged Electrocyclone + ESP, or bag filter — with the trade-offs stated in numbers.
- Site survey. Plot constraints, duct routing, foundation conditions, tie-in points, crane access measured on the ground.
- Design development. Process design frozen: gas flow, temperature, dust load, collection stages, fan margin, ash-handling capacity.
- Engineering + commercial review. The customer's engineers challenge the basis before anyone signs; scope split and guarantee basis are fixed here.
- Award.
- Detailed survey. Laser/dimensional verification of every tie-in the detailed design will trust.
- Execution plan. Level-3 schedule, outage plan, lift plans, ITPs, document register issued.
- Fabrication — Samut Sakhon. Casings, internals, ducting and pressure parts at our factory, with customer inspection at defined hold points.
- Installation. Pre-assembly beside the running plant; tie-ins executed in the outage window.
- Commissioning. Cold and hot commissioning through to the guarantee test, per our ESP and boiler commissioning protocol.
- Lifecycle support. Spares, inspection and performance follow-up after handover.
How long does a turnkey emission control project take?
Indicatively: preliminary engineering and proposal 4–8 weeks from complete customer documents; detailed engineering 2–4 months; fabrication 4–6 months overlapping engineering; site pre-assembly 1–3 months while the plant runs; the tie-in outage itself 2–6 weeks; commissioning through the guarantee test 2–4 weeks. Overall, 9–15 months award-to-handover for a full train retrofit.
03 — Scope split
Scope of a turnkey project: what Arrow carries, what the plant keeps
Every interface gets exactly one written owner — before award.
| Scope item | Included — Arrow | Excluded — customer / by others |
|---|---|---|
| Process design, guarantee basis, equipment engineering | Included — one design authority end to end | — |
| Fabrication: casings, internals, ducting, pressure parts | Included — Samut Sakhon factory, ITP-controlled | — |
| Civil works: piling, foundations, paving | Loading data, anchor-bolt plans, supervision | Civil execution by customer's contractor |
| Structural steel and equipment erection | Included — with engineered lift plans | — |
| Electrical: TR sets, controls, field cabling | Included to the agreed terminal point | Incoming MV supply and plant switchgear upstream of that point |
| Water and compressed air for construction/commissioning | Distribution from battery limit | Supply to battery limit |
| Ash handling | Included to silo / truck-loading point | Ash transport and disposal beyond it |
| Commissioning and guarantee test | Included — EPA M5 / ISO 9096 on the stated basis | Operating crew (plant provides, Arrow directs); fuel, water, power for test runs |
04 — Method & project controls
Method, standards and the controls that keep a fixed outage fixed
A retrofit schedule is protected on paper months before it is protected on site.
Document control. A single numbered document register covers every drawing, calculation, ITP and certificate, with revision status visible to the customer. On a retrofit, the drawing that matters most is the one showing what is actually there — existing plants rarely match their thirty-year-old drawings — which is why the detailed survey (step 7) is a separate, post-award activity with its own deliverable, not a footnote to the sales visit. Every tie-in dimension the fabrication shop trusts traces to a measurement taken after award, on the actual steel.
One design authority for the whole train. Because the pre-collector, precipitator, fan, ducting and ash handling are engineered by one team, system-level trades are made deliberately rather than by default. An Electrocyclone first stage at 85–95 % collection changes the ESP inlet load by an order of magnitude, which changes SCA, casing size, TR rating and hopper duty; fan margin is set against the whole train's draught loss, not one vendor's fraction of it; and the temperature window — ≤ 400 °C at the Electrocyclone, ≤ 200 °C at the ESP — is managed as one gas path. In a multi-vendor structure each of these trades is a negotiation; here they are design decisions.
Quality gates. Fabrication proceeds through inspection and test plans: material certificate review, welding to qualified procedures, dimensional and alignment checks, and trial assembly of critical modules, each with hold or witness points the customer's inspector can attend at the factory. Pressure-part fabrication is to ASME/JIS practice; code-stamp scope is stated per project. Our ISO 9001:2015 certification (TÜV Rheinland) covers spare parts, installation and maintenance services.
Erection engineering. Every major lift has an engineered lift plan — crane selection, ground bearing, rigging, exclusion zones — prepared before mobilisation, not improvised under the hook. Casing modules and duct sections are pre-assembled at grade beside the running unit, so the outage consumes tie-ins rather than assembly. On congested bagasse and biomass sites this is routinely the difference between a 3-week and a 6-week shutdown.
What should a plant prepare before requesting a turnkey proposal?
Five documents: a recent fuel analysis (moisture, ash, LHV), boiler rating and flue-gas data at the loads you actually run, the emission limit with its stated O₂ basis, general-arrangement drawings of the gas path and plot, and the outage calendar. With these, preliminary engineering starts immediately; without them, the first weeks are spent reconstructing them.
Reference classes for this delivery model: sugar mill Thailand 170 t/h bagasse · biomass power Thailand 250 t/h · sugar mill Colombia 230 t/h — see project references. Where an existing precipitator can be recovered rather than replaced, the scope shifts to an ESP upgrade instead; we quote the cheaper path when measurement supports it.
05 — Deliverables
What the plant holds at handover
The project is finished when the file is, not when the crane leaves.
- Design dossier: process design basis, equipment sizing calculations, guarantee basis statement (mg/Nm³, reference O₂, dry/wet, load window).
- As-built drawing set and the complete document register.
- Fabrication quality records: material certificates, weld records, ITP sign-offs, factory inspection reports.
- Erection records: alignment protocols, torque records, lift plan close-outs.
- Commissioning dossier: air-load and gas-load V-I curves per field, controller settings, boiler-side records where in scope.
- Performance guarantee test report to EPA Method 5 / ISO 9096 on the stated basis.
- Operating and maintenance manuals, training records, and the recommended two-year spares list.
Method and standards, summarised. Process design uses the same published physics as our equipment pages — Deutsch-Anderson framing corrected by Matts-Öhnfeldt (k ≈ 0.5) for real polydisperse ash — with every concentration stated in mg/Nm³ at its reference O₂, dry or wet declared. Structural design follows the applicable building code of the site country; electrical installation follows IEC practice; welding is to qualified procedures with NDT per the ITP. The guarantee test is run by the commissioning method described on the ESP and boiler commissioning page — one stated basis, isokinetic traverse, corrections shown in the report, not summarised out of it.
Guaranteed figures are stated per project after the technical assessment, on a stated basis (mg/Nm³, reference O₂, dry/wet, load range). What we publish beforehand are design-basis calculations, labelled as such — and a project flow in which the party that wrote the basis is the party that must test against it.
FAQ
Engineering questions, answered
What does turnkey mean in an emission control project?
One contractor answers for the result at the stack. Arrow carries survey, process design, fabrication, erection, electrical integration and commissioning under a single contract, closing with an isokinetic guarantee test in mg/Nm³ at a stated O₂ reference. Interfaces between designer, fabricator and erector become internal to Arrow instead of contractual gaps.
Why do multi-vendor emission control retrofits run over schedule?
Because every vendor boundary is an interface: ducting by one party, ESP by another, electrical tie-ins by a third. A flange mismatch or a late load list stops erection during a fixed outage window, and each party's guarantee excludes the others' scope. Single-point responsibility removes the gaps where those days and disputes accumulate.
How does Arrow control quality during fabrication?
Through inspection and test plans: each fabrication stage in Samut Sakhon carries defined hold and witness points — material certificates, weld and dimensional checks, trial assembly of critical modules — which the customer or their inspector can witness at the factory. Pressure parts are fabricated to ASME/JIS practice; code-stamp scope is stated per project.
What scope does the customer typically keep in a turnkey project?
Commonly: civil foundations and piling built to Arrow's loading data, incoming MV power to an agreed terminal point, water supply, and ash disposal beyond the silo or truck-loading point. The exact split is fixed in a scope matrix in the proposal, so every interface has one written owner before award.
How is outage time minimised on a turnkey retrofit?
By moving work off the critical path: structural steel, casing modules and ductwork are pre-assembled beside the running plant while it operates, lift plans are engineered in advance, and the outage itself is reserved for tie-ins, electrical connection and commissioning. Erection engineering typically converts weeks of in-outage work into pre-outage assembly.
Send us your plant data
Fuel, boiler capacity, gas flow, current emission and the limit you must meet. An Arrow engineer replies with a technical assessment basis — not a brochure.