Construction of boiler houses

Professional design, supply, installation and commissioning of individual solutions for heat supply, steam and hot-water boiler houses of any complexity.

A reliable and economical source of thermal energy or process steam — is the basis for the uninterrupted operation of industrial enterprises, agricultural complexes, residential areas and social infrastructure facilities. LLC «Dalgakiran Compressor Ukraine» performs a full range of works on the construction, reconstruction and modernization of steam and hot-water boiler houses «turnkey».

We offer individual solutions adapted to the specific needs of your technological process and available types of fuel (natural gas, liquefied gas, diesel, biomass/pellets or combined burner systems).

Why is it worth ordering the construction of a «turnkey» boiler house?

• Comprehensive approach: A full cycle of works from one contractor — from heat balance calculation to commissioning and obtaining permitting documentation.
• Maximum efficiency and fuel savings: The use of modern high-efficiency boilers, burner devices with smooth two-stage or modulating control and economizers (efficiency up to 95–98%).
• Automation without the constant presence of personnel: Implementation of modern automation and dispatching systems for safe and autonomous operation of the boiler house.
• Industrial safety: All solutions comply with the current construction, environmental and fire safety standards of Ukraine (DBN, safety rules for gas supply systems and equipment operating under pressure).

Stages of construction of «turnkey» boiler stations

1. Heat audit and calculation of heat / steam requirements

The first stage of project implementation is determining the actual or calculated consumption of thermal energy and heat carrier parameters.

• For hot-water boiler houses (heating, DHW, ventilation): The total heat load of the facility, the network temperature schedule (for example, 95/70 °C or 110/70 °C) and the heat carrier flow rate are calculated.
• For steam boiler houses (technological needs): The required hourly steam consumption (tons/hour), operating pressure, temperature and steam quality (saturated or superheated) are determined in accordance with the requirements of technological equipment.
• For operating facilities (modernization): An audit of the existing boiler equipment is carried out, heat losses, the condition of water treatment and excessive fuel consumption are analyzed.

Stage result: Technical specifications with clearly defined thermal capacity, fuel type, type and number of boilers and water treatment scheme.

2. Feasibility study (FS) and selection of fuel type

At this stage, a comparative analysis of fuel supply options and technical solutions is carried out to achieve the lowest cost of heat or steam production.

We evaluate and calculate:

• Comparison of fuel options (natural gas, diesel, fuel oil, pellets/wood chips, combined fuel);
• Feasibility of installing heat recovery units (economizers) for heating feed water or air;
• Calculation of costs for chemical water treatment (CWT) and deaeration to protect boilers from scale and corrosion;
• Payback period for the implementation of new boiler equipment (ROI).

Stage result: A substantiated feasibility study with calculation of capital and operating costs and the investment payback period.

3. Development of project documentation

The third stage covers the development of a complete set of design and estimate documentation and its approval in accordance with the legislation of Ukraine.

The project covers the following sections:

• TM (Thermomechanical solutions): Boilers, burners, pumping equipment, heat exchangers, deaerators, storage tanks;
• GSV / TS: Internal gas supply, fuel supply, fuel pipelines and gas regulating stations (GRP/GRU);
• CWT (Chemical water treatment): Iron removal, softening, reverse osmosis and water deaeration units;
• EO, ATM: Power supply, automation, emergency protection systems, gas contamination alarms and dispatching;
• OV, VK, AB: Ventilation, water supply, sewerage, architectural and construction solutions, chimneys and silencers.

Stage result: An approved project that has passed the necessary examinations, a completed equipment specification and work estimate.

4. Construction works and preparation of premises

The fourth stage provides for construction and installation preparation of the site or building for the installation of boiler equipment.

• Capital construction or reconstruction of premises: Arrangement of foundations for boilers, pumps and chimneys; preparation of industrial flooring; arrangement of channels for utilities; installation of ventilation systems and air intakes.
• Block-modular construction (BMK): Construction of a special foundation site, connection of external utility networks (gas, water, electricity, sewerage) for quick installation of the factory module.

Stage result: A prepared building or site that complies with all construction and fire safety standards for the installation of pressure equipment.

5. Supply, installation and engineering piping

The fifth stage includes delivery of hot-water or steam boilers, auxiliary equipment, their installation and assembly.

Our specialists perform:

• Installation of steam/hot-water boilers, burners and chimneys;
• Assembly and installation of water treatment units (demineralization, softening) and deaeration;
• Laying and piping of steam, hot water, fuel and condensate pipelines;
• Installation of circulation, network and feed pumps, shut-off and control and safety valves;
• Installation of power distribution boards, automation cabinets, pressure, temperature and level sensors.

Stage result: A fully installed boiler station, tested for hydraulic strength, tightness and compliance with the project.

6. Commissioning works, operational adjustment tests and training

The final stage — comprehensive testing and commissioning of the boiler station.

Engineers of «Dalgakiran Compressor Ukraine» carry out:

• Flushing and chemical cleaning of the boiler circuit;
• Adjustment of water treatment systems and analysis of the quality of boiler/feed water;
• Initial start-up of burners, adjustment of combustion processes and flue gas analysis;
• Operational adjustment tests: Preparation of operating charts for boiler operation at different load levels to ensure maximum efficiency;
• Checking the operation of automatic protection and interlock systems (in case of deviations in pressure, gas, water or power outage).

Personnel training: We provide instruction and training for the customer’s operators and technical personnel on the rules of safe operation of boiler equipment, working with automation and actions in case of emergency situations.

Stage result: A boiler house ready for operation, signed commissioning certificates, issued operating charts and a complete set of as-built documentation for submission to regulatory authorities.

Additional solutions from «Dalgakiran Compressor Ukraine»

• Block-modular boiler houses (BMK): Fully ready factory complexes in containers that do not require capital construction and are easily transported to the facility.
• High-pressure steam boiler houses: Specialized solutions for the food, chemical, pharmaceutical and woodworking industries.
• Heat recovery and deaeration systems: Installation of economizers, steam deaerators and condensate return systems to significantly reduce fuel consumption.
• Service support: Maintenance of boilers, burners, automation, cleaning of heat exchangers and regular performance of operational adjustment works.

Need to calculate the boiler house capacity or order an audit of the heat supply system?

Contact our engineers from the heat and power equipment department to receive professional consultation and arrange a specialist’s visit to your facility.