Boiler Design Procedure

Boiler Design

STEP-1
Received data from customer
Steam output, feedwater inlet
Fuel analysis, boiler type
Power plant heat balance

STEP-2
Boiler Thermal Sizing:
Combustion, efficiency, steam output calculation,
Furnace, Back pass & Cyclone sizing,
Metal temperature calculation,
Emission calculation, Air Heater Calculation, etc.
Iteration with customer/steam turbine back to STEP-1

STEP-3
Pressure part material selection and ASME calculation & Pipe Stress Analysis:
Tubing, pipe manifold, drum and internal piping & external piping
Furnace Sizing, Boiler Circulation

STEP-4
Non Pressure Part selection and calculation/Simulation
Structural steel Design calculation
Pressure part hanger calculation, etc.
Iteration to STEP-3 for pressure part weight and arrangement

STEP-5
From step-2, perform external piping selection:
Material selection, ASME calculation, Pipe Stress Analysis
Pressure Drop Calculation

STEP-6
Create Pressure Part Arrangement
Iteration with Step-3/4/5

STEP-7
Create General Arrangement & Layout
Iteration with Step-3/4/5/6

STEP-8
Create P&ID Drawing
Steam/Water Diagran, Flue Gas Diagram,
Fuel Diagram, Limestone Diagram, Inert Injection Diagram

STEP-9
Create Bill of Material of Structural & Support (Non Pressure Part)

STEP-10
Create Bill of Material of Tubing, Piping (Pressure Part)

STEP-11
Create Drum Arrangement Drawing,
Drum Internal Drawing, Welding Detail

STEP-12
Create Pressure Part Drawing & Welding Detail:
Evaporator, Furnace wall, superheater section

STEP-13
Create Non Pressure Part Drawing & Welding Detail:
Structural Steel, Casing, Ducting, Cyclone, Stack,
Air Heater

STEP-14
Sizing & Create Coal Silo, Inert, Limestone
Create drawing, specification of silo system

STEP-15
Create Specification & Sizing of Coal Crusher & System
Create emission equipment, baghouse, dust collector (if required)

STEP-16
Create Equipment List & Data Sheet:
Primary Air Fans, Secondary Air Fans, Blower,
Feed Pump, Start-up burner, Damper,
Ash Screw Cooler,
Soot blower, Chemical Injection System, etc.

STEP-17
Create Valve List & Valve Data Sheet:
Manual valve, pneumatic block valve, MOV,
Control Valve, Blowdown valve, desuperheater system, etc.

STEP-18
Create Instrument List & Instrument Data Sheet:
Flow/pressure/temperature transmitter/gauge
Flue gas analyzer & sampling system
Water/steam sampling and analyzer
Create Bill of material of instrument tube & fitting
Create drawing & bill of material cabling system

STEP-19
Boiler Operation and Control Concept
Create functional control diagram
Create logic diagram
Verify/Iterate with P&ID and Selected Equipment

STEP-20
Electrical System
Create bill of material of electrical
Create drawing & bill of material electrical cabling system

STEP-21
Pipe routing for external piping & 3-D Drawing, Pipe Stress Analysis
Feedwater piping system, steam piping system,
fuel/inert/limestone piping system, ducting for flue gas
Iteration with selected equipment

STEP-22
External piping: Pipe Stress Analysis & Pipe Support Drawing
Pipe Insulation System, Ducting & Casing Insulation System

STEP-23
Refractory Lining System
Anchoring System, Material Selection, Testing and Installation Procedures

STEP-24
Iteration to previous STEP, to verify selected equipment
with design data.

Note:
In general, as one system of boiler, each of process and step need to be verified and iteration with other process or system.
Drawing output, data sheet, etc. will be submitted to sub-vendor for fabrication, manufacturing or equipment supply.
Selected equipment shall be verified with the design data, iteration process is required to verify the design data compare to manufacturer data.

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