IBR Design Calculation

Design Data
Design Pressure for Internal Pressure Pd = 48 kg/cm2
= 682.72 psi
Design Temperature for Internal Pressure Td = 485 °C
Corrosion Allowance C.A. = 0 mm
= 0 inch
Material of Construction = Low Alloy Steel
Shell = SA-387 Gr.11 Cl.2
Head = SA-387 Gr.11 Cl.2
Nozzle neck = SA-182 F11 Cl.2
Flange = SA-182 F11 Cl.2
Tubesheet = SA-336 F11 Cl.2
Tube = SA-213 T11
Design Code = IBR 1950 + Latest Amendments and ASME
Section VIII Div.1
Allowable stresses as per IBR at design temperature = min(Et/1.5 , SR/1.5, Sc)
(for Td > 454 ° C) or
Regulation : IBR 271 min(Et/1.5 , S)

where,
Yield point (% proof stress) at design temperature = Et
Yiels Stress at ambient temperature = Ea
The average stress to produce rupture in 100,000
= SR
hours at the design temperature
The average stress to produce an elongation of 1%
= Sc
(creep) in 100,000 hours at the design temperature
The allowable stress as per ASME Section II Part D,
= Sd
Edition 2015 at Design Temperature
The allowable stress as per ASME Section II Part D,
= Sa
Edition 2015 at Ambient Temperature
The allowable stress as per IBR = f

Material Properties
Sr. No. Parts Et Ea Sd Sa f

Mpa Mpa Mpa Mpa Mpa psi

1 Bonnet shell 210.2 310 93.4 148 93.4 13546.53
2 Bonnet head 210.2 310 93.4 148 93.4 13546.53
3 Nozzle neck 186.6 275 92.3 138 92.3 13386.98
4 Nozzle flange 186.6 275 92.3 138 92.3 13386.98
5 Tubesheet 186.6 275 92.3 138 92.3 13386.98
6 Tube 140 205 87.5 118 87.5 17114.45
 Calculation for Shell
Regulation : IBR 366
Maximum working pressure W.P. = 2 x f x E (tc- 0.03)
Dc + tc - 0.03
where,

The allowable stress for component f = 13546.53 psi

Corrosion Allowance C.A. = 0 inch

Efficiency E = 1

Internal Diameter of component D = 450 mm

= 17.71654 inch

Corroded internal diameter of component Dc = D-(2*C.A.)

17.71654 inch

Thickness of component t = 14 mm
= 0.551181 inch

Corroded Thickness of component tc = t-C.A. inch

= 0.551181 inch

Maximum working pressure W.P. = 2 x f x E (tc - 0.03)

Dc + tc - 0.03
= 774.24 psi

Design pressure Pd = 682.72 psi

Since W.P. > Pd, the component design is safe

Hydrotest pressure for component Pt = 1.5 x Pd

= 1024.08 psi
= 72 kg/cm2

Requirement of Compensation for Opening in Bonnet Shell

Regulation: IBR 571

Maximum diameter of uncompensated opening = 2.5 x tc + 2.75

= 4.127953 inch
= 104.85 mm

Size of largest opening in the component = 92.04 mm

Since the size of the largest opening is smaller than the minimum size required for compensating the opening,
the component design is safe and no compensation required.
 Calculation for Head
Regulation : IBR 277
Maximum working pressure W.P. = 2 x f x ( tc - C )
Do x K
where,

The allowable stress for component f = 13546.53 psi

Corrosion Allowance C.A. = 0 inch

Internal Diameter of component D = 450 mm

Outer Diameter of component Do = 478 mm

= 18.8189 inch

Thickness of component t = 14 mm
= 0.551181 inch

Corroded Thickness of component tc = t-C.A. inch

= 0.551181 inch

Head Shape Factor K = 1

Additive thickness C = 0.75 mm

= 0.03 inch

Maximum working pressure W.P. = 2 x f x ( tc - C )

Do x K
= 750.3304 psi

Design pressure Pd = 682.72 psi

Since W.P. > Pd, the component design is safe

Hydrotest pressure for component Pt = 1.5 x Pd

= 1024.08 psi
= 72 kg/cm2
 Calculation for Nozzles Thickness
Regulation : I.B.R 350 (a) Eqn.91

Nozzle Mark N3 N4 N7
Nozzle size inch 4 2 1.5
Schedule 120 N.A. N.A.
Nozzle material SA-182 F11 Cl.2 SA-182 F11 Cl.2 SA-182 F11 Cl.2
Design pressure ( Pd ) psi 682.72 682.72 682.72
Allowable Stress ( f ) psi 13386.98 13386.98 13386.98
Efficiency ( e ) 1 1 1
Thickness of pipe ( tn ) mm 11.13 16.6 15.95
inch 0.44 0.65 0.63
Corrosion Allowance (C.A) inch 0 0 0
Corroded thickness ( tnc ) inch 0.44 0.65 0.63
Nozzle neck outside diameter mm 114.3 84 70
( dn ) inch 4.5 3.31 2.76
Constant ( C ) inch 0.03 0.03 0.03

Permissible working pressure 2 x f x e ( tnc - c )

(W.P.) dn - tnc+ c

psi 2683.94 6170.95 7437.21

Design Pressure ( Pd ) psi 682.72 682.72 682.72

Since W.P. > Pd, the Since W.P. > Pd, the Since W.P. > Pd, the
component design is component design is component design is
safe safe safe

1.5 x Pd
Hydrotest pressure for
psi 1024.08 1024.08 1024.08
component (Pt)
kg/cm2 72 72 72
 Calculation for Tube Thickness
Regulation: IBR 579 (b)

Minimum thickness due to internal e1 = Pd x dt .+ C.A.

pressure as per Eqn. XII / 15 Pd + 2 x f
= 0.02 inch
= 0.508 mm

where,
Design pressure Pd = 682.72 psi

Tube external diameter dt = 20 mm

= 0.787402 inch

The allowable stress for component f = 17114.45 psi

Minimum tube thickness as per code e2 = 1.75 mm

for tubes subjected to internal pressure
Regulation : IBR 579 d

Minimum tube thickness as per code e3 = 2.1 mm

for tubes subjected to external pressure
Regulation : IBR 579 d

Minimum thickness of tubes e = max.(e1, e2, e3)

= 2.1 mm

Actual thickness provided as per MDS ea = 2.1 mm

The component thickness selected is safe as per design and as per IBR requirements
 Calculation for Tubesheet
(A) Check for Ligament between the Tube Holes
Regulation: IBR 580

Tube external diameter dt = 20 mm

= 0.787 inch

Tube pitch p = 26 mm
= 1.023622 inch

Actual thickness of tubesheet Ta = 120 mm

Minimum Ligament between tube holes Li = dt /8 + 0.5

= 0.6 inch
= 15.24 mm

Provided Ligament La = 5.6 mm

Alternatively

Minimum Tubesheet Thickness T = 0.125 x dt + 0.2

= 0.3
= 7.62 mm

Minimum cross-sectional area Am = 0.17 D + 0.025

= 0.15879 inch2
= 102.445 mm2

Provided cross-sectional area Aa = La x Ta

= 672 mm2

Minimum required thickness of tubesheet Tr = 0.5 inch

( for dt < 2 inches ) = 12.7 mm

The component thickness is acceptable as per IBR requirements