Steam Boiler House, Bavaria
Our engineering office planned a steam boiler house for an industrial site in Bavaria, with a capacity of 16 tons of steam per hour per boiler. The three boilers operate at 1.3 MPa and 195°C, tailored to the site’s energy requirements. As part of the project, the old economisers were replaced and extended with a flue gas condenser section, cooling exhaust gases to 35–40°C. This improved energy recovery. In addition, all feed pumps were renewed, and a separate condensation circuit was implemented to preheat cold process water. The entire gas piping system was also recalculated and redesigned. In addition to surveying and modeling, all structural calculations as well as workshop and construction plans were prepared.
Challenges
The main challenge was integrating the new components into the existing structural and technical environment. The expansion of the economisers and flue gas condensers required precise adjustments to the thermal and piping systems to connect the new circuits to the process water system. This necessitated a thorough recalculation of structural loads and close coordination with all technical disciplines to ensure efficient integration of the new pumps and pipelines.
01.06.2022 - 01.10.2022
| Tonnage | 5.4 | tons |
| Planning hours | 260 | hours |
| Total area | 396 | m² |
| Length | 16.4 | m |
| Width | 15 | m |
| Height | 5.5 | m |
Adress:
Bavaria, Germany
Project phases
Requirements Analysis
In this phase, the project-specific requirements were comprehensively identified. These included the operating conditions of the steam boiler house with a steam output of 16 t/h, the steam parameters (1.3 MPa, 195 °C), as well as efficiency goals through the replacement of the economisers and the integration of new flue gas condensers. Requirements for the feed pumps and the separate condensation circuit were also defined.
Surveying with 3D Laser Scanning
A detailed 3D laser scan precisely recorded the existing structures and site conditions. This enabled the capture of all relevant structures and connection points, providing a reliable foundation for planning and subsequent modeling.
Remodeling of the Existing Structure
Based on the 3D scan data, the existing setup including all relevant plant components was modeled. This allowed for the smooth integration of new technology into the existing infrastructure and prevented collisions during the construction process.
Design Phase LPH 3 and Concept
According to service phase 3, an initial design was created to represent the concept of the new boiler house. It included all technical requirements such as economisers, flue gas condensers, the revised piping system, as well as pumps and new circuits.
Approval Planning LPH 4
The approval planning (LPH 4) ensured that all legal and technical requirements were met. Plans and calculations were submitted for coordination and approval to enable the implementation.
Execution Planning LPH 5
In service phase 5, precise workshop and construction plans were developed for on-site implementation. All components and connection points were exactly matched to the new technology to ensure efficient and trouble-free assembly and operation.
Galery
