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1 5 B A S I C ST E P S I N B O I L E R D E S I G N

(https://www.meee-services.com/15-basic-steps-boiler-design/)

15 BASIC STEPS IN BOILER DESIGN (HTTPS://WWW.MEEE-SERVICES.COM/15-BASIC-STEPS-BOILER-

12 DESIGN/)
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By : Mosay Jala (https://www.meee-services.com/author/jala-mosay/)

Boiler design is the process of designing boilers used for various purposes. The main function of a boiler is to heat water for

steam generation. Steam produced can be used for a variety of purposes including space heating, sterilization
(https://en.wikipedia.org/wiki/Soil_steam_sterilization), drying, humidi cation (https://en.wikipedia.org/wiki/Humidi er) and

power generation. The temperature or condition of steam required for these applications is di erent, so how to design a

boiler varies accordingly.

Of ine
Accessories and mountings are devices, which form an integral part of a boiler but are not mounted on it. They include

economizers, super-heaters, feed pumps, and air pre-heaters. Accessories help in controlling and running the boiler

e ciently. Certain common mountings include:

Feed check valve – regulates the ow of water into the boiler and prevents the back ow of water in case of failure of

the feed pump.

Steam stop valve – regulates the ow of steam that is produced in the boiler to the steam pipe, and may also be used

to stop the supply of steam from the boiler

Fusible plug – placed at the lowest level of water and above the combustion chamber, its function is to extinguish the

re as soon as the water level in the shell of the boiler falls below a certain marked level.

Blow-o cock – removes water from the shell at regular intervals to remove the various impurities that may be settled

at the bottom of the shell.

Safety valves – automatically prevent the steam pressure from exceeding safe levels

Water-level indicators – indicate the level of water in the shell

What are the basic steps in Boiler Design

Based on the abovementioned de nition of a boiler and de ning the accessories and mountings of a boiler system, we can

now discuss the physical and mechanical principles that a boiler compiles with during its functioning process.
Normally a boiler is designed to suit the user’s requirements. Therefore, the boiler design starts with the basic speci cations

stated by the user or customer.

The customer’s preliminary speci cations usually contain the following items:

1. Steam penetration – Maximum Continuous Rating (MCR (https://www.google.al/search?

q=mcr+maximum+continuous+rating+de nition&oq=mcr+maximum+continuous+rating+defe&gs_l=psy-
ab.1.0.0i22i30k1.22721.25470.0.27488.5.5.0.0.0.0.189.900.0j5.5.0.foo%2Ccfro%3D1%2Cnso-ehuqi%3D1%2Cnso-

ehuui%3D1%2Cewh%3D0%2Cnso-mplt%3D2%2Cnso-enksa%3D0%2Cnso-enfk%3D1%2Cnso-usnt%3D1%2Cnso-qnt-
npqp%3D0-1701%2Cnso-qnt-npdq%3D0-54%2Cnso-qnt-npt%3D0-1%2Cnso-qnt-ndc%3D300%2Ccspa-dspm-nm-
mnp%3D0-05%2Ccspa-dspm-nm-mxp%3D0-125%2Cnso-unt-npqp%3D0-17%2Cnso-unt-npdq%3D0-54%2Cnso-unt-

npt%3D0-0602%2Cnso-unt-ndc%3D300%2Ccspa-uipm-nm-mnp%3D0-007525%2Ccspa-uipm-nm-mxp%3D0-
052675...0...1.1.64.psy-ab..0.5.898.YG84ZRs9yis))

2. Steam pressure
3. Steam temperature

4. Load range (Boiler turndown)

5. Fuel

The basic design often begins with just these four or ve parameters, and continues to diversify into ner details along the
way, as further details of operation; site-speci c requirements get discussed and determined. For the optimum design of a
boiler system, it is recommended to take the following steps to ful ll a reliable and durable design of a boiler.

Here are the basic steps in how to design a boiler:

1. Calculation of boiler Heat Duty (https://www.google.al/search?

q=heat+duty+de nition&oq=heat+duty+de&aqs=chrome.0.0j69i57j0l4.11295j0j7&sourceid=chrome&ie=UTF

8)
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 ring rate

actually, Burner heat duty is de ned by the rated steam enthalpy at MCR divided by boiler e ciency
(https://meee-services.com/how-can-we-increase-the-e ciency-of-the-boiler-in-rankine-cycle/) 

With an assumed boiler e ciency number, calculate the heat duty of burner
Knowing the NCV of fuel, calculate MCR rate fuel ring at MCR

3. Fixing furnace geometry

Select the burner(s) suitable for the calculated fuel ring rate

From burner size and ame clearance requirements, con gure front wall geometry
4. Calculation of furnace volume required

Using guideline/ limit for VHRR (Volumetric Heat Release Rate)

5. Calculation of required FEGT (https://www.acronym nder.com/Furnace-Exit-Gas-Temperature-

(furnaces%2fboilers)-(FEGT).html)
FEGT (Furnace Exit Gas Temperature) has a direct e ect on heat available to the superheater

The ue gas temperature entering superheater is determined from the desired nal steam temperature, i.e.
the degree of superheat

6. Calculation of required EPRS (https://www.acronym nder.com/EPRS.html)

EPRS (E ective Projected Radiant Surface) is the radiant surface available to pick up the heat from ue 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/ ns
This determines the number of tubes required in the furnace section

7. Freezing furnace con guration

With EPRS, Burner ame clearance requirement and front wall dimensions. Calculate furnace depth and

con gure 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 (https://en.wikipedia.org/wiki/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 uctuations
Steam-water separation equipment (in a steam drum)

Number of generating bank tubes entering steam drum (for ligament e ciency)
10. Calculating economizer surface
Calculate the minimum ue gas temperature required to avoid dew point corrosion
This is grossly a ected sulfur content in fuel

Higher the sulfur content, higher is the required ue gas temperature at the stack
 From economizer inlet ue gas temperature and the desired stack temperature, calculate economizer

surface
11. Calculating FD/ ID fan duty
From MCR fuel ring rate and excess air requirement of the burner, calculate air ow rate required
From burner data sheet and air duct con guration, calculate FD fan head

From ue 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 ttings

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 ring rate and excess air requirement of burner calculate air ow rate required

Calculate expected thermal expansions at various locations and develop a thermal expansion drawing
14. Carrying out stress analysis calculations for the con gured 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 con gured boiler
Follow NFPA-85 guidelines for BMS
Follow designer standard for control loops

Modern boiler design bene ts

What are the bene ts of a modern boiler design? To answer this important question we must know that modern boiler
design o ers several bene ts. In the past, improper design of boilers has caused explosions, which led to the loss of life and
property. Modern designs attempt to avoid such mishaps. Further, mathematical modeling can determine how much space
a boiler will need and the type of materials to be used. When the design speci cations of a boiler are determined, design

engineers can estimate a cost and time schedule for the construction.

How to design a boiler? First, we must know that it may be based upon:

Production of a maximum quantity of steam with minimal fuel consumption

Economic feasibility of installation

Minimal operator attention required during operation
Capability for quick starting
Conformity to safety regulations

Quality of raw water: how hard or soft the water is will determine the material of the boiler.
Heat source – the fuel to be burned and its ash properties or the process material from which the heat is to be
recovered.
Capacity/steam output required, usually measured in tonnes per hour or kg/s.
 Steam condition – pressure, temperature, etc.
Safety considerations
Mechanical constraints
Cost restrictions

Monetary cost
The tensile strength of material must be considered while using any joining processes.

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COMMENTS (11)

Ahmed hussien Elsayed ahmed / September 25, 2017 / Reply

send me a copy of report and thanks to you

mustafa emad / January 10, 2018 / Reply

ineed to manual pdf boiler

Kory Gaillard / May 16, 2018 / Reply

Your site is so fantastic. I’m going to come back here again.

Francis Gilpin / June 18, 2018 / Reply

“This is a really useful post, thanks for that!”

Ty Hochstetler / June 24, 2018 / Reply

“Best Blog post! Enjoying the information on this website, you’ve done a _superb job on the content.”
 rushikesh / October 6, 2018 / Reply

I want help to design a boiler

qusay / March 10, 2019 / Reply

can you help me by sending me a handbook on re tube boiler design

deepak verma / May 18, 2019 / Reply

Hi
PLEASE GUIDE US PRESSURE AND TEMP DROP per mater 101 mm ms pipeline from Boiler to process
end. boiler capacity would be 6t/hr and DIESEL re burner.. and also advice for Boq and total
condensate unit please suggest the design Parameter pdf for same…

Dinesh jadhav / June 27, 2019 / Reply

This is most useful for designer, requested to give any book which will cover all aspect of boiler system

design for a new beginner

Mohmmed Khiralla Idris Abdelrahim / November 27, 2019 / Reply

This is very good, I will come back here

Debra Turnbough / February 19, 2020 / Reply

The excellently written article, doubts all bloggers o ered the identical content since you, the internet
has to be far better placed. Please stay the best!

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