Boiler Design Step

The customer’s preliminary specifications usually contain the following items:

1. Steam penetration – Maximum Continuous Rating (MCR)
2. Steam pressure
3. Steam temperature
4. Load range (Boiler turndown)
5. Fuel

1. Calculation of boiler Heat Duty

- Using desired steam parameters, calculate the enthalpy of steam to be generated
- Multiplying enthalpy with the rated steam generation, obtain the total heat value of steam at
rated steaming (boiler heat duty)
- Boiler heat duty is expressed as MKCal/hr or MW or HP
2. Calculation of Burner Heat Duty and fuel firing rate
- Actually, burner heat duty is defined by the rated steam enthalpy at MCR divided by boiler
efficiency
- With an assumed boiler efficiency number, calculate the heat duty of burner
- Knowing the NCV of fuel, calculate MCR rate fuel firing at MCR
3. Fixing furnace geometry
- Select the burner(s) suitable for the calculated fuel firing rate
- From burner size and flame clearance requirements, configure front wall geometry
4. Calculation of furnace volume required
- Using guideline/ limit for VHRR (Volumetric Heat Release Rate)
5. Calculation of required FEGT
- FEGT (Furnace Exit Gas Temperature) has a direct effect on heat available to the superheater
- The flue gas temperature entering superheater is determined from the desired final steam
temperature, i.e. the degree of superheat
6. Calculation of required EPRS
- EPRS (Effective Projected Radiant Surface) is the radiant surface available to pick up the heat
from flue gas
- This is calculated from the required value of FEGT
- EPRS is the surface of furnace tubes directly exposed to radiation, plus the surface formed by
membrane strips/ fins
- This determines the number of tubes required in the furnace section
7. Freezing furnace configuration
- With EPRS, Burner flame clearance requirement and front wall dimensions. Calculate furnace
depth and configure furnace.
8. Calculation of convection bank surface
- This is done by using FEGT and Heat absorption required for steam generation, then it is
necessary to calculate the heat transfer surface required in boiler bank and subsequently, using
this to calculate the number of tubes required in generating bank
9. Selecting Steam Drum
- Let me explain more about the Steam drum size, which is governed by the following factors:
Boiler steaming capacity at MCR
Circulation ratio
Expected load fluctuations
Steam-water separation equipment (in a steam drum)
 Number of generating bank tubes entering steam drum (for ligament efficiency)
10. Calculating economizer surface
- Calculate the minimum flue gas temperature required to avoid dew point corrosion
- This is grossly affected sulfur content in fuel
- Higher the sulfur content, higher is the required flue gas temperature at the stack
- From economizer inlet flue gas temperature and the desired stack temperature, calculate
economizer surface
11. Calculating FD/ ID fan duty
- From MCR fuel firing rate and excess air requirement of the burner, calculate air flow rate
required
- From burner data sheet and air duct configuration, calculate FD fan head
- From flue gas side pressure drop, gas temperature and total gas weight, calculate ID fan duty
and size the fan
12. Calculation of stack height
- Stack height is calculated based on the following criteria:
- Weight SO2 emitted from a stack at 6MCR operation
- Natural draft considered as available while calculating ID fan duty
- The regulation governing dispersal of pollutants (population around the boiler plant)
13. Workout boiler mountings and fittings
- Decide the numbers, location, and capacities of safety relief valves on steam and water circuits
(follow applicable regulation)
- Work out the sizing of direct water level gauges (follow applicable regulation)
- From MCR fuel firing rate and excess air requirement of burner calculate air flow rate required
- Calculate expected thermal expansions at various locations and develop a thermal expansion
drawing
14. Carrying out stress analysis calculations for the configured boiler
- Stress analysis calculation brings out the stress pattern for each pressure part
- It is mandatory to prepare a complete stress analysis calculation underrated temperature and
pressure and obtain approval from statutory authority, before commencing manufacturing/
assembly of the boiler
15. Developing a safety protection system (PLC) and control system (DCS)for the configured boiler
- Follow NFPA-85 guidelines for BMS
- Follow designer standard for control loops