Steps in 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 Diagram, 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 the previous STEP, to verify selected equipment
with design data.

Note:
In general, as one system of the 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, the iteration process is required to verify the design data compare to manufacturer data.