Boiler System Design: Key Considerations

Industrial boiler system design involves a broad spectrum of technical, operational and environmental considerations.

At Integro Design Engineering Associates (IDEA) Ltd., our multidiscipline team of engineers and designers apply these considerations in the overall system design for clients’ projects.

Specification and Design Requirements

1. Boiler Rating and Selection: Optimal boiler capacity and selection to meet steam demands while considering future expansion.
2. Heat Transfer Rate Limitations: Ensuring efficient heat transfer while avoiding thermal stress.
3. Steam Outlet Conditions: Tailoring steam pressure and temperature to process needs.
4. Mechanical Considerations: Designing for durability and operational efficiency under specified conditions.
5. Safety: Incorporating robust safety mechanisms to mitigate operational risks.
6. Skid Mounting and Plot Space: Efficient use of space and modular design for ease of expansion and maintenance.
7. Multiple Boiler Installation: Planning for future expansion.

Water Treatment and Fuels

1. Water Treatment: Measures to treat feedwater to prevent corrosion, scaling, and fouling.
2. Fuels: Optioneering for different fuel/ energy source types (diesel oil, bio-diesel, gas, biogas, electrical) and considerations for fuel combustion efficiency, emissions and client’s sustainability goals.

Auxiliaries

1. Burners and Fans: Selection and integration of accessories for optimal combustion and airflow
2. Stacks, Ducts, Insulation and Boiler Blowdown: Review of exhaust gases, conserving heat (economiser) and controlling water quality
3. Hotwell tanks and deaerators: Design of boiler feedwater system in which make-up water is stored and condensate is returned, is key to maximise the overall system efficiency.
4. Steam Header and off takes: In multiboiler installation, it is essential to carefully design the header and offtakes to ensure steam distribution is optimised.

Utility Calculations and Environmental Considerations

1. Fuel and Boiler Feedwater Requirements: Optimising fuel consumption and water treatment for efficiency and environmental compliance.
2. Emissions and Heat Conservations: Selecting low NOx burners, monitoring emissions, and employing heat recovery systems to minimise environmental impact.

Control and Instrumentation

1. Instrumentation and Burner Management: Advanced controls for monitoring and managing boiler operation.
2. Water level and fuel/ air supply: Precise control of water level and fuel/ air ratio for efficient combustion.
3. Outlet temperature, safeguarding and interlocks: Temperature control and safety interlocks to prevent hazardous conditions

Start-up/ Shutdown/ Maintenance

1. Procedures for Start-up and Shutdown: Standard operating procedures to ensure safety and preserve equipment integrity
2. Testing and Training – Appropriate testing regime along with training for the operators

Compliance with applicable Design Codes and Standards

1. Adherence to Industry Codes: Compliance with relevant industry codes and standards for design, construction and operation including PER and PSSR.

How can we help?

Contact our team today for any support with your boiler system.