Reconstruction of boiler house in Tashkent

Design of a hot-water boiler plan for energy-efficient generation of thermal and electrical energy. The facility is based on hot-water boilers, a gas piston unit, and an absorption heat pump with auxiliary equipment located in Uzbekistan.

Scope of Work Within Process Engineering and Piping:

ENECA specialists developed comprehensive process piping solutions incorporating safety and reliability requirements, economic feasibility, and lifecycle cost optimization for the facility.

The scope of piping design includes: heat network pipings (supply and return boiler loop, low-temperature loop, internal loop heating water, make-up water supply), softened water pipings, gravity drain lines, and flue gas condensate pipings. Backup fuel (diesel) supply and return lines were developed as a separate system.

Total pipe run length: 3770 m.

Design Features and Key Challenges:

• Climatic conditions: arid climate, dust storms, and seismic activity;

• High density of utility networks within the building, equipment congestion, and limited space for pipe fixing;

• Thermal expansion compensation requirements;

• Gravity-flow pipings and strict slope compliance requirements

• Combined routing of pipings with different media parameters, temperatures, and pressures

The following engineering calculations performed:

Hydraulic analysis: pipe diameter sizing, flow capacity, media velocity, and pressure drop along the piping route;

Stress analysis: strength and stiffness calculations considering thermal expansion, concentrated and distributed loads, support displacement, internal pressure thrust forces, wind and snow loads, and seismic effects.  Calculation of the optimal pipe wall thickness determined taking into account the media corrosivity and pipeline wall thinning rate.

Calculation of supports and structural loads: piping dead load, medium load, and thermal insulation load; thermal deformation loads; positioning of fixed and sliding supports (checking for pipe sag and  lift-off of pipe supports from metal structures); analysis of the loads transmitted to fixed supports and supporting metal structures.

Calculation and selection of anti-corrosion protection means for pipings and their supports: Determination of a protective coating system type and scope of anticorrosion coatings for process equipment and pipelines based on operating conditions, medium corrosivity category, surface thickness loss rate, design durability, operating temperature, thermal insulation availability, UV exposure, and environmental factors.  The surface preparation requirements were established prior to coating application.

Thermal insulation calculation: calculation of the minimum required insulation thickness; selection of  standard product sizes for insulation taking into account energy and cost efficiency; selection of vapour barrier and cladding materials.  Preparation of a piping insulation data sheet .