Boiler Calucation Sheet

DOC. No.
HIL-DTL-17-019-CAL-IBR-102 IBR CALCULATIONS 1 OF 51
IBR CALCULATIONS FOR 10TPH COMBI BOILER
MODEL NO : HIL-100-MP-5
DOC. No.HIL-DTL-17-019-CAL-IBR-102 IBR CALCULATIONS 1 OF 51
REV.NO. REVISION NOTE PREPARED CHECKED APPROVED DATE

TABLE OF CONTENTS
S. No. DESCRIPTION PAGE No.
1 DESIGN DATA 3
2 MAXIMUM METAL WORKING TEMPERATURE 4
3 NOZZLE CONNECTION DATA 5
4 HEAT TRANSFER AREA 6
5 TUBE THICKNESS CALCULATION - MEMBRANE WATER WALL 7
6 WW BOTTOM HEADER THICKNESS CALCULATION 8
7 WW LHS/RHS TOP HEADER THICKNESS CALCULATION 9-10
8 WW TOP FRONT HEADER THICKNESS CALCULATION 11
9 WW TOP REAR HEADER THICKNESS CALCULATION 12
10 REAR WALL INTERMITTENT HEADER THICKNESS CALCULATION 13-14
11 RISER STUB THICKNESS CALCULATION - R1 TO R4 15
12 DC LINK STUB THICKNESS CALCULATION - L1 TO L12 16
13 I1 TO I4 NOZZLE THICKNESS CALCULATION - INTERNAL PRESSURE 17
14 I5 TO I8 NOZZLE THICKNESS CALCULATION - INTERNAL PRESSURE 18
15 D1 TO D4 NOZZLE THICKNESS CALCULATION - INTERNAL PRESSURE 19
16 RISER PIPE THICKNESS CALCULATION 20
17 DC PIPE THICKNESS CALCULATION 21
18 DC LINK PIPE THICKNESS CALCULATION 22
19 SHELL THICKNESS CALCULATION - INTERNAL PRESSURE 23
20 TUBE SHEET THICKNESS CALCULATION 24
21 PITCH OF TUBES CALCULATION 25
26-27
1 STAY TUBES THICKNESS CALCULATION (TUBES ON BOUNDARY) 28-29
2 SV1 & SV2 NOZZLE THICKNESS CALCULATION - INTERNAL PRESSURE 30
3 N1 NOZZLE THICKNESS CALCULATION - INTERNAL PRESSURE 31
4 N2 to N5 & N6 to N9 NOZZLE THICKNESS CALCULATION - INTERNAL PRESSURE 32
5 N10 NOZZLE THICKNESS CALCULATION - INTERNAL PRESSURE 33
N11, N12 , N13, LSa,LSb,LG1a, LG1b, LG2a, LG2b - NOZZLE THICKNESS CALCULATION -
6 34
INTERNAL PRESSURE
7 N14,N14a NOZZLE THICKNESS CALCULATION - INTERNAL PRESSURE 35

8 N1 NOZZLE COMPENSATION CHECK CALCULATIONS 36
9 N2 TO N9 COMPENSATION CHECK CALCULATIONS 37
10 MANHOLE COMPENSATION CHECK CALCULATIONS 38
11 HANDHOLE COMPENSATION CHECK CALCULATIONS 39
12 THICKNESS CALCULATION - ELLIPTICAL INTERNALDOORS (HAND HOLES) 40
13 THICKNESS CALCULATION - ELLIPTICAL INTERNALDOORS (MAN HOLES) 41
14 G1,G6 GUSSET THICKNESS CALCULATION 42
41 HEADER FOR PG & PS - THICKNESS CALCULATION 47
DESIGN DATA
S. No. DESCRIPTION UNITS PARAMETER
1 MODEL NO HIL-100-MP-5
2 DESIGN,MANUFACTURE & INSPECTION IBR 1950 WITH LATEST AMENDMENTS
3 MAXIMUM WORKING PRESSURE Kg/cm2.g 17.5
4 DESIGN PRESSURE Kg/cm2.g 17.5
5 HYDRO TEST PRESSURE Kg/cm2.g 26.25
a) SAFETY VALVE I : 17.5

6 SAFETY VALVE SET PRESSURE Kg/cm .g2
b) SAFETY VALVE II : 16.9
7 STEAM OUTLET TEMPERATURE ˚C 209
8 TOTAL HEATING SURFACE AREA m2 #REF!
9 a) MEMBRANE WW m2 #REF!
10 b) SHELL & TUBE m2 #REF!
11 EVAPORATION CAPACITY Kg/hr 8000
100% FOR SHELL & HEADERS

12 RADIOGRAPHY 10% FOR TUBE JOINTS
AS PER IBR 1950 WITH LATEST

13 HEAT TREATMENT AMENDMENTS
AS PER IBR 1950 WITH LATEST

14 CORROSION ALLOWANCE AMENDMENTS
15 JOINT EFFICIENCY 1 FOR SHELL & HEADERS
16 INSPECTION DOB, GUJARAT
17 CERTIFICATION IBR
VALUE
COMPONENT
(Kg/cm2.g)
LEAST CALCULATED WORKING Err:504 SHELL
PRESSURE
MAXIMUM METAL WORKING TEMPERATURE
MAX.WORKING MAX. ALLOWABLE

S. No. DESCRIPTION SIZE MATERIAL METAL TEMP. STRESS(Kg/cm2)
MEMBRANE WALL
1 237˚C (209˚C+28˚C)
ASSEMBLY
OD 50.8 x BS 3059 ERW

1.1 TUBES 849.72*
3.66THK. P-1 GR 320
1.2 HEADERS SA 106 - B 1203.27
1.3 BW FITTINGS SA 234 - WPB 1203.27
2 SHELL & TUBES HE 237˚C (209˚C+28˚C)
2.1 SHELL , TUBESHEETS SA 516 - 70 1407.21
2.2 PLAIN TUBES OD 76.2 x BS 3059 ERW 849.72*

3.66THK P-1 GR 320
OD 63.5 x BS 3059 ERW
2.3 PLAIN TUBES 849.72*
3.66THK P-1 GR 320
OD 76.2 x BS 3059 ERW

2.4 STAY TUBES 849.72*
6.35THK P-1 GR 320
2.5 NOZZLE PIPES SA 106 - B 1203.27
2.6 COMP. PAD SA 516 - 70 1407.21
2.7 FLANGES SA 516 - 70 1407.21
3 RISERS SA 106 - B 209˚C 1203.27
4 DOWN COMERS SA 106 - B 209˚C 1203.27
*- LOWER OF Et/1.5 OR Rm/2.4

LOWER OF 125/1.5 OR 360/2.4 IN [ Mpa ]
NOZZLE CONNECTION DATA
RF PAD REF. LINE REMA

NOZZLE FLANGE PROJCN. RKS
NOZZLE SERVICE
MARK OD SCH. / END CONN. FACE
DN RATINGSTD. WIDE THK.
mm THK. OD x THK. FINISH
ON MEMBERANE WALLS
RISER 80 / 168.3 x
R1 TO R4
CONNECTION 150 168.3 10.97 10.97 - - - - - 300 ± 3
L1 TO L12 DC 80 /
80 88.9 88.9 x 7.62 - - - - - 250 ± 3
CONNECTION 7.62
80 / - AS PER
D1 TO D4 DRAIN 25 33.4 FLANGED CONCENTRIC TABLE-
IBR -
4.55 GROOVES H DETAIL
I1 TO I4 INSPECTION 80/
200 219.1 FLANGED CONCENTRIC TABLE-
IBR - 500± 3
NOZZLE 12.7 GROOVES H
I5 TO I8 INSPECTION 80 /
80 88.9 FLANGED CONCENTRIC TABLE-
IBR - 250± 3
NOZZLE 7.62 GROOVES H
40 /
- RISER PIPE 150 168.3 - - - - - - -
7.11
40 /
- DC PIPE 150 168.3 - - - - - - -
7.11
40 /
- DC LINK 80 88.9 5.49 - - - - - - -
ON HE
160 / TABLE-
SV1 & SV2 SAFETY VALVE 50 60.3 FLANGED 125AARH IBR - - 1545 ± 3
8.74 H
120 / CONCENTRIC TABLE-

N1 STEAM OUTLET 200 219.1 FLANGED IBR 75 10 1545 ± 3
18.26 GROOVES H
N2 TO N5 RISER 80 / 168.3 x
150 168.3 - - - 75 10 1545 ± 3
CONNECTION 10.97 10.97
N6 TO N9 DC 80 / 168.3 x
150 168.3 - - - 75 10 1545 ± 3
CONNECTION 10.97 10.97
FEED WATER 160 / CONCENTRIC TABLE-
N10 50 60.3 FLANGED IBR - - 1520 ± 3
INLET 8.74 GROOVES H
N11 BLOWDOWN 25 33.4 FLANGED IBR - - 1545 ± 3
4.55 GROOVES H
AUXILLARY 80 / CONCENTRIC TABLE-

N12 NOZZLE 25 33.4 4.55 FLANGED GROOVES H IBR - - 1545 ± 3
N13 VENT 25 33.4 FLANGED IBR - - 1545 ± 3
4.55 GROOVES H
NOZZLE FOR PG 40 80 / CONCENTRIC TABLE-

N14 48.3 FLANGED IBR - - 1545 ± 3
& PS 5.08 GROOVES H
NOZZLE ON PG 40 80 / CONCENTRIC TABLE-

N14a 48.3 FLANGED IBR - - 125 ± 3
& PS HEADER 5.08 GROOVES H
25 33.4 IBR - - 1520 ± 3
LG1a,LG1b & 80 / CONCENTRIC TABLE-

LG2a, LG2b LEVEL GAUGE 25 33.4 4.55 FLANGED GROOVES H IBR - - 1520 ± 3
PRESSURE GUAGE SOCKET - AS

COUPLIN PER
PG & PS & 15 CL.3000 - - - -
PRESSURE SWITCH G WELDED DETAIL
INTERNAL 110 20 AS
CONCENTRIC PER
M MANHOLE I/S 406 x 306 25 - -
DOOR GROOVES DETAIL
INTERNAL 100 18 AS
CONCENTRIC PER
H1 TO H4 HANDHOLE I/S 178 x 127 - - -
DOOR GROOVES DETAIL
DOC. No.HIL-DTL-16-002-CAL-IBR-101 IBR CALCULATIONS 5-6 OF 53
HEAT TRANSFER AREA

S. No. DESCRIPTION UNITS FORMULA VALUE
1 SHELL & TUBE HE
1.1 1st PASS TUBES -
OUTSIDE DIA OF TUBE D mm - 63.5
LENGTH OF TUBE L mm - 3436
NO OF TUBE N - 60
mm2 41127092
HEAT TRANSFER AREA A
m2
πxDxLxN 41.13
1.2 2nd PASS TUBES -
NO OF TUBE N - 48
mm2 32901674
m2
πxDxLxN 32.90
1.3 OVER FRONT TUBE PLATE -
DIA OF TUBE PLATE D mm - 1550
HOLE CUT FOR PASS-1 TUBE H1 mm - 63.5
TOTAL NO OF PASS-1 TUBES N1 - 60
mm2 [(π/4) x D2] - [(π/4) x H12 x N1] - [(π/4) 1544891.5
m2 x H22 x N2] 1.54
DIA OF TUBE PLATE D mm - 1550

mm2 [(π/4) x D2] - [(π/4) x H12 x N1] - [(π/4) 1544891.5
m2 x H22 x N2] 1.54
TOTAL AREA A1 m 2 - 77
2 MEMBRANE WALL
2.1 RHS & LHS WATER WALL TUBES -
NO OF TUBE N - 28
FINS LENGTH Lf mm - 2987
FINS WIDTH Wf mm - 59.2
NO OF FINS Nf - 30
mm2 [π x D/2 x L x N] + 11978768
HEAT TRANSFER AREA A ( Lf x Wf x Nf )
m2 11.98
2.2 FRONT WATER WALL TUBES -
NO OF TUBE N - 32
NO OF FINS Nf - 30
mm2 [π x D/2 x L x N] + 10823716
HEAT TRANSFER AREA A [π x D/2 x L x N] +

m2 ( Lf x Wf x Nf ) 10.82
2.2 REAR WATER WALL TUBES -
NO OF TUBE N - 42
NO OF FINS Nf - 40
mm2 [π x D/2 x L x N] + 16454861
m2 16.45
TOTAL AREA A2 m2 - 39
3 BED COIL ASSEMBLY

NO OF TUBE N - 12
mm 2
5668740
HEAT TRANSFER AREA A3 (π x D x L x N)
m2 5.66874
TOTAL AREA A3 m2 6
4 TOTAL HEAT TRANSFER AREA At m2 A1+A2+A3 122
TUBE THICKNESS CALCULATION - BED COILS

IBR REG. 338 (a)(b)( c )
LINE DESCRIPTION UNITS FORMULA VALUE REMARKS
No.
1 INPUT
E=1, BC & WW= 2,
2 LOCATION - CSH=3, RSH=4 2
3 TUBE DATA P.No.____

OUT SIDE
3.1 DIAMETER D mm - 50.8
3.2 THICKNESS t mm - 4.5 OK

3.3 MIN. THICKNESS tm mm - 4.05 REG. 58( d)
BS-3059 P-1
3.4 MATERIAL - GR. 320
3.5 BEND RADIUS R mm - 150
4 DESIGN PRESSURE P Kg/cm2.g - 17.5
WORKING
5 PRESSURE WP Kg/cm2.g - 17.5
5.1 STATIC HEAD h mm OF WC - 0

5.1.1 STATIC HEAD h Kg/cm2.g - 0
SAT. TEMP. AT
6 DESIGN PRESSURE
0
C - 209
7 ALL. STRESS AT 'T' Mpa - 83.33
7.1 ALL. STRESS AT 'T' f Kg/cm2.g - 849.73

8 MIN. YIELD STRENGTH Mpa 215
ALL. STRESS AT
8.1 HYD.TEST TEMP. fhydro. Mpa 0.9 x MIN. YIELD STRENGTH 193.5
(40
ALL.C)
0
STRESS AT
8.2 HYD.TEST TEMP. fhydro. Kg/cm2.g - 1973.16
(400C)
MIN. REQ THICKNESS AS
9 PER IBR mm 2.34 REG. 338( b)
10 OUTPUT
P Kg/cm .g 2
WORKING MTL.
12 TEMP. T 0
C 237
%THINNING OF REG. 338 (b)

13 TUBE th % 100/ [(4R/D)+2] 7.2 (ii)(a)
AVAILABLE THICKNESSS tb tm-((th x tm)/100)

14 AFTER THINNING mm 3.8 SAFE
HYD. TEST Phydro. Kg/cm2.g

15 PRESSURE P x 1.5 0
CALCULATED MIN. EQ.87

16 REQD. THICKNESS tr mm [(P x D) / ( 2 x f + P)] + C 0.75 REG. 338 (a)
[2 x fhydro. x (tb-C)] /
17 CAL. HYD.TEST WP WPhydro. Kg/cm2.g (D-tb+C) 248.27 SAFE
[2 x f x (tb-C)] /
18 CAL. WP WP Kg/cm2.g (D- tb+C) 106.92 SAFE
C= 0.75 IF P<70Kg/cm2.g
19 FACTOR C C= 0 IF P> 70Kg/cm2.g 0.75
ABBRIVIATIONS : E - ECO TUBES, BC - BED COILS, WW- WATER WALL TUBES, CSH - CONV. SH. RSH - RAD. SH.
BED COILS HEADER THICKNESS CALCULATION

IBR REG. 270 (a) , 342 , 215
No.
1 INPUT
2 HEADER DATA
OUT SIDE
3 DIAMETER D mm - 168.3
4 THICKNESS t mm - 7.11 OK
4.1 MIN. THICKNESS tm mm 6.22 SEC II -A
5 MATERIAL - SA106 GR B
6 DESIGN PRESSURE WP Kg/cm .g 2
- 17.5
7 WORKING PRESSURE WP Kg/cm2.g - 17.5
8 STATIC HEAD h mm OF WC - 0
8.1 STATIC HEAD h Kg/cm2.g - 0
WELD FACTOR /
9 EFFICIENCY OF E 0.63
LIGAMENT
SAT. TEMP. AT DESIGN

10 PRESSURE
0
C - 209
11 ALL. STRESS AT 'T' f Kg/cm2.g - 1203.27 118 Mpa

ALL. STRESS AT Mpa 216
12.1 HYD.TEST TEMP.(400C)
fhydro. 0.9 x MIN. YIELD STRENGTH
Kg/cm2.g 2202.60
13 LIGAMENT EFFICIENCY
13.1 TUBE DETAILS
13.1.1 DIAMETER Dt1 mm - 50.80
13.1.2 THICKNESS Tt1 mm 4.50
d1 mm
13.2 DC STUB DETAILS
13.2.1 DIAMETER Dt2 mm - 114.30
13.2.2 THICKNESS Tt2 mm - 8.56
13.2.3 HOLE DIAMETER d2 mm d2 = Dt2 - 2 x Tt2 97.18
13.5 PITCH DETAILS
13.5.1 LONGITUDINAL
PITCH pl1 mm - 100.00 B/W TUBES
13.5.3 CIRCUMFERENTIAL
PITCH 1 pc1 mm 132.18 B/W
HDR,TUBE
15 OUTPUT
LONGITUDINAL
15.1 EFFICIENCY OF El1 El1=(pl1 - d1)/pl1 1.00 REG.215
LIGAMENT B/W
TUBES
CIRCUMFERENTIAL
15.3 EFFICIENCY OF Ec1 Ec1=(pc1 - dav)/pc1 0.63 REG.215
LIGAMENT
16 DESIGN PRESSURE P Kg/cm2.g WP + h 17.5 1.72 Mpa
17 INTERNAL DIA Di mm D - (2 x tm) 155.86
BED COILS HEADER THICKNESS CALCULATION

IBR REG. 270 (a) , 342 , 215
No.
SAT. TEMP
WORKING MTL.
18 TEMP. T 0
C + 237
ADD. TEMP.

19 PRESSURE P x 1.5 26.25 2.57 Mpa
CALCULATED MIN. [(P x Di) / ((2 x f x E)- P)]

20 REQD. THICKNESS tr mm +0.7625 2.58 REG. 270 (a)
[2 x fhydro. xE x (tm-0.7625)] / (Di+tm-

21 CAL. HYD.TEST WP WPhydro. Mpa 0.7625) 9.24 SAFE
22 CAL. HYD.TEST WP WPhydro. Kg/cm2.g - 94.27

[2 x f. xE x (tm-0.7625)] / (Di+tm-
23 CAL. WP WP MPa 0.7625) 5.05 SAFE
24 CAL. WP WP Kg/cm2.g - 51.50

BED COIL LINK STUB THICKNESS CALCULATION - INTERNAL PRESSURE

IBR REG. 573(b)(ii), 564(a) & 270
No.
1 INPUT
2 NOZZLE DATA L1a TO L6a
3.1 NOZZLE OD DO mm 114.3
NOZZLE INSIDE
3.2 D mm - 99.32
DIAMETER
PROVIDED
3.3
THICKNESS
T mm - 8.56 OK
3.4 MIN. THICKNESS Tm mm - 7.49 SEC II -A
3.5 MATERIAL - SA 106-B
WORKING
5 WP Kg/cm2.g - 10.54
PRESSURE
SAT. TEMP. AT
6 C
0
- 186
DESIGN PRESSURE
7 ALL. STRESS AT 'T' Mpa - 118
MIN. YIELD
8 Mpa 240
STRENGTH
ALL. STRESS AT HYD.TEST Mpa 216
8.1 TEMP.(400C)
Kg/cm2.g 2202.60
9 WELD FACTOR E - - 1.00
10 OUTPUT
11 DESIGN PRESSURE P Kg/cm2.g WP + h 10.54
temp. C
0

13 P x 1.5 15.81 REG.601(a)
PRESSURE
REG.564(a)
CALCULATED MIN.
14.1 REQD. THICKNESS Tr1 mm [(P x D) / ( 2 x f x E - P)] + 0.7625 1.20 EQ.72
REG. 270
CALCULATED MIN.
14.2 REQD. THICKNESS t mm 0.04 x DO + 2.5 7.07 REG.573(b)
EQ.XII/10
(ii)
REG.573(b)
CALCULATED MIN.
14.3 REQD. THICKNESS Tr mm -- 7.07 (ii) , REG.
564(a)
15 CAL. HYD.TEST WP WPhydro. Kg/cm 2 [2 x fhydro. x E x (Tm-0.762)] / (D+Tm-0.762) 279.48 SAFE

16 CAL. WP WP Kg/cm2 [2 x f x E x (Tm-0.762)] / (D+Tm-0.762) 152.68 SAFE
TUBE THICKNESS CALCULATION - MEMBRANE WATER WALL

IBR REG. 338 (a)(b)( c )
No.
1 INPUT
E=1, BC & WW= 2,
2 LOCATION - CSH=3, RSH=4 2
3 TUBE DATA P.No.____

OUT SIDE
3.1 DIAMETER D mm - 50.8
3.2 THICKNESS t mm - 3.66 OK

3.3 MIN. THICKNESS tm mm - 3.29 REG. 58( d)
BS-3059
3.4 MATERIAL - ERW - P-I
GR. 320
3.5 BEND RADIUS R mm - 150
WORKING

SAT. TEMP. AT
6 DESIGN PRESSURE
0
C - 209

ALL. STRESS AT
8.1 HYD.TEST TEMP. fhydro. Mpa 0.9 x MIN. YIELD STRENGTH 193.5
(40
ALL.C)
0
STRESS AT
8.2 HYD.TEST TEMP. fhydro. Kg/cm2.g - 1973.16
(400C)
MIN. REQ THICKNESS AS
9 PER IBR mm 2.34 REG. 338( b)
10 OUTPUT
P Kg/cm .g 2
WORKING MTL.
12 TEMP. T 0
C 237
%THINNING OF REG. 338 (b)

13 TUBE th % 100/ [(4R/D)+2] 7.2 (ii)(a)
AVAILABLE THICKNESSS tb tm-((th x tm)/100)

14 AFTER THINNING mm 3.1 SAFE

15 PRESSURE P x 1.5 0
CALCULATED MIN. EQ.87

16 REQD. THICKNESS tr mm [(P x D) / ( 2 x f + P)] + C 0.75 REG. 338 (a)
[2 x fhydro. x (tb-C)] /
17 CAL. HYD.TEST WP WPhydro. Kg/cm2.g (D-tb+C) 187.61 SAFE
[2 x f x (tb-C)] /
18 CAL. WP WP Kg/cm2.g (D- tb+C) 80.79 SAFE
C= 0.75 IF P<70Kg/cm2.g
19 FACTOR C C= 0 IF P> 70Kg/cm2.g 0.75
ABBRIVIATIONS : E - ECO TUBES, BC - BED COILS, WW- WATER WALL TUBES, CSH - CONV. SH. RSH - RAD. SH.
WW BOTTOM HEADER THICKNESS CALCULATION

IBR REG. 270 (a),215
No.
1 INPUT
2 HEADER DATA P.No.____
3 OUT SIDE DIAMETER D mm - 168.3
4 THICKNESS T mm - 7.11 OK
5 MATERIAL - SA 106 - B
6 DESIGN PRESSURE WP Kg/cm2.g - 17.5
WELD FACTOR /
9 EFFICIENCY OF E - 0.58
LIGAMENT
10 PRESSURE
0
C - 209
12.1 TEMP.(400C)
fhydro. 0.9 x MIN YIELD STRENGTH
Kg/cm2.g 2202.60
13.1 WW TUBE DETAILS
13.1.1 DIAMETER OF TUBE Dt mm - 50.80
13.1.2 TUBE THK. Tt mm - 3.66
d mm
13.2 BC TUBE DETAILS
13.2.1 DIAMETER Dt mm - 50.80
13.2.2 THK. Tt mm - 4.50
13.2.3 DIAMETER OF HOLES d mm d = Dt - 2 x Tt 41.80
13.3 PITCH DETAILS
13.3.1 LONGITUDINAL PITCH pl mm - 110.00
13.3.2 LONGITUDINAL PITCH pl mm - 100.00
PITCH pc mm - 132.18
14 OUTPUT
LONGITUDINAL
15 EFFICIENCY OF El E=(p -d)/p 1.00 REG.215
LIGAMENT
LONGITUDINAL
EFFICIENCY OF El E=(p -d)/p 0.58 REG.215
LIGAMENT
CIRCUMFERENTIAL
15.1 EFFICIENCY OF Ec Ec=(pc - dav)/pc 0.84 REG.215
LIGAMENT

18 WORKING MTL. TEMP. T 0
C SAT. TEMP + ADD. TEMP. 237 REG. 340(d)
19 HYD. TEST PRESSURE Phydro. Kg/cm2.g P x 1.5 26.25 2.57 Mpa
20 REQD. THICKNESS tr mm + 0.7625 2.73 REG. 270 (a)
[2 x fhydro. xE x (Tm-0.7625)] / (D+Tm-
21 CAL. HYD.TEST WP WPhydro. Mpa
0.7625) 8.51 SAFE
21.1 CAL. HYD.TEST WP WPhydro. Kg/cm2 86.76
[2 x f. xE x (Tm-0.7625)] / (D+Tm-0.7625)
22 CAL. WP WP MPa 4.65 SAFE
22.1 CAL. WP WP Kg/cm2 47.39
WW LHS/ RHS TOP HEADER THICKNESS CALCULATION

IBR REG. 270 (a) , 342 , 215
No.
1 INPUT
2 HEADER DATA
OUT SIDE
- 17.5
WELD FACTOR /
LIGAMENT

10 PRESSURE
0
C - 209

12.1 HYD.TEST TEMP.(400C)
Kg/cm2.g 2202.60
13.1 TUBE DETAILS
13.1.1 DIAMETER Dt1 mm - 50.80
13.1.2 THICKNESS Tt1 mm 3.66
d1 mm
13.2 FRONT/ REAR WW HEADERS DETAILS
13.2.1 DIAMETER Dt2 mm - 114.30
13.3 RISERS DETAILS
13.3.1 DIAMETER Dt3 mm - 114.30
13.5 PITCH DETAILS
13.5.1 LONGITUDINAL
PITCH pl1 mm - 110.00 B/W TUBES
PITCH 1 pc1 mm 119.50 B/W
HDR,TUBE
PITCH 2 pc2 mm 76.40 B/W BEND
TUBES
PITCH 3 pc3 mm 186.42 B/WRISERS
TUBES &
14 END PLATE
1=FOR ENDS INTEGRAL WITH/FLANGED/BUTT WELDED TO HEADER
14.1 2=FOR ENDS STRENGTH WELDED TO HEADER 2
14.2 K - 0.28 REG. 342
WW LHS/ RHS TOP HEADER THICKNESS CALCULATION

IBR REG. 270 (a) , 342 , 215
No.
14.3 C mm - 1
15 OUTPUT
LONGITUDINAL
LIGAMENT B/W
TUBES
CIRCUMFERENTIAL
LIGAMENT
CIRCUMFERENTIAL
LIGAMENT
CIRCUMFERENTIAL
LIGAMENT
SAT. TEMP
WORKING MTL.
18 TEMP. T 0
C + 237
ADD. TEMP.

19 PRESSURE P x 1.5 26.25 2.57 Mpa



[2 x f. xE x (tm-0.7625)] / (Di+tm-
24 CAL. WP WP Kg/cm2.g - 71.32

25 END PLATE
25.1 MATERIAL - SA 516 Gr.70
25.2 ALL. STRESS AT 'T' - 1407.21 138 MPa

MIN. REQ
25.3 THICKNESS Te mm C + SQRT[(P x Di2 x K) / f )] 12.62 REG. 342
25.4 PROVIDED THICKNESS TP mm 16 SAFE

WW TOP FRONT HEADER THICKNESS CALCULATION

IBR REG. 270 (a) , 342 , 215
No.
1 INPUT
2 HEADER DATA
5 MATERIAL - SA 106 GR B
6 DESIGN PRESSURE WP Kg/cm .g
2
- 17.5
WELD FACTOR /
LIGAMENT
10 PRESSURE C
0
- 209
11 ALL. STRESS AT 'T' f Kg/cm .g
2
- 1203.27 118 Mpa
12 MIN. YIELD STRENGTH 240
12.1 TEMP.(400C)
Kg/cm2.g 2202.60
13.1 TUBE DETAILS
13.2 DIA OF TUBE Dt mm - 50.80
13.3 THICKNESS OF TUBE Tt mm - 3.66
d mm
LONGITUDINAL PITCH
13.5 OF TUBE HOLES pl mm - 110.00
14 END PLATE
1=FOR ENDS INTEGRAL WITH/FLANGED/BUTT WELDED TO HEADER
14.1 2=FOR ENDS STRENGTH WELDED TO HEADER 2
14.2 k - 0.28
REG. 342
14.3 C mm - 1
15 OUTPUT
LONGITUDINAL
16 EFFICIENCY OF El El=(pl - d)/pl 1.00 REG.215
LIGAMENT
18 INTERNAL DIA Di mm D-(2tm) 99.32
19 WORKING MTL. TEMP. T C
0
SAT. TEMP + ADD. TEMP. 237
20 HYD. TEST PRESSURE Phydro. Kg/cm .g
2
P x 1.5 26.25 2.57 Mpa
CALCULATED MIN.
21 REQD. THICKNESS tr mm [(P x Di) / ((2 x f x E)- P)] +0.7625 1.49 REG. 270 (a)
[2 x fhydro. xE x (tm-0.7625)] /
22 CAL. HYD.TEST WP WPhydro. Mpa (Di+tm-0.7625) 27.41 SAFE
22.1 CAL. HYD.TEST WP WPhydro. Kg/cm2.g 279.46

[2 x f. xE x (tm-0.7625)] /
23 CAL. WP WP MPa (D+tm-0.7625) 14.97 SAFE
23.1 CAL. WP WP Kg/cm2.g 152.67
24 END PLATE ( MATERIAL - SA 516 Gr. 70)
24.1 MIN. REQ THICKNESS Te mm C + SQRT[(P x Di2 x k) / f )] 6.86 REG. 342
WW TOP REAR HEADER THICKNESS CALCULATION

IBR REG. 270 (a) , 342 , 215
No.
1 INPUT
2 HEADER DATA
5 MIN. THICKNESS tm mm 7.49 SEC II -A
WELD FACTOR /
LIGAMENT
11 SAT. TEMP. 0
C - 209
12.1 ALL. STRESS AT 'T' f Kg/cm2.g - 1203.27 118 Mpa
ALL. STRESS AT HYD.TEST fhydro. Mpa 216
13.1 TEMP.(400C) 0.9 x MIN. YIELD STRENGTH
Kg/cm2.g 2202.60
14.1 INTERMITTENT HEADER DETAILS
14.2 DIA OF TUBE1 Dt1 mm - 114.30
14.3 THICKNESS OF TUBE 1 Tt1 mm - 6.02
d1 mm
14.5 TUBE DETAILS
14.6 DIA OF TUBE2 Dt2 mm - 50.80
14.7 THICKNESS OF TUBE 2 Tt2 mm - 3.66
14.8 DIA OF TUBE HOLES 2 d2 mm d2 = Dt2 - (2 x Tt2) 43.48
14.9 LONGITUDINAL PITCH pl mm - 180.00
15 END PLATE
1=FOR ENDS INTEGRAL WITH/FLANGED/BUTT WELDED TO HEADER 2=FOR ENDS
15.1 STRENGTH WELDED TO HEADER 2
15.2 K - 0.28
REG. 342
15.3 C mm - 1
16 OUTPUT
LONGITUDINAL
17 EFFICIENCY OF El El=(pl - dav)/pl 0.88 REG.215
LIGAMENT
20 WORKING MTL. TEMP. T C
0
SAT. TEMP + ADD. TEMP. 237
21 HYD. TEST PRESSURE Phydro. Kg/cm2.g P x 1.5 26.25 2.57 Mpa
[2 x fhydro. xE x (tm-0.7625)] /
23 CAL. HYD.TEST WP WPhydro. Mpa (Di+tm-0.7625) 24.10 SAFE
[2 x f. xE x (tm-0.7625)] /
24 CAL. WP WP MPa (Di+tm-0.7625) 13.16 SAFE
24.1 CAL. WP WP Kg/cm2.g 134.23
25.1 MIN REQ. THICKNESS Te mm C + SQRT[(P x Di2 x K) / f )] 6.86 REG. 342

REAR WALL INTERMITTENT HEADER THICKNESS CALCULATION

IBR REG. 270 (a) , 342 , 215
LINE
DESCRIPTION UNITS FORMULA VALUE REMARKS
No.
1 INPUT
OUTSIDE
5 MATERIAL - SA 106 GR B
- 10.54
WORKING
WELD FACTOR /
LIGAMENT
SAT. TEMP. AT
10 DESIGN PRESSURE
0
C - 186

Mpa 216
12.1 ALL. STRESS AT
HYD.TEST TEMP.(400C)
Kg/cm2.g 2202.60
13.1 INTERMITTNT PIPE DETAILS

13.2 DIAMETER
TUBE 1
OF
Dt1 mm - 114.30
13.3 TUBE THICKNESS Tt1 mm 6.02
d1 mm
13.5 TUBE DETAILS
13.6 DIAMETER
TUBE 2
OF
Dt2 mm - 50.80
13.7 THICKNESS Tt2 mm 3.66
13.8 HOLE DIAMETER
OF TUBE 2 d2 mm d2 = Dt2 - 2 x Tt2 43.48
13.9 PITCH DETAILS

13.10 LONGITUDINAL
1
PITCH
pl1 mm - 180
13.11 LONGITUDINAL
2
PITCH
pl2 mm - 110
13.12 CIRCUMFERENTIAL
PITCH 1 pc1 mm - 160.29
14 END PLATE
14.1 1=FOR ENDS INTEGRAL WITH/FLANGED/BUTT WELDED TO HEADER

ENDS STRENGTH WELDED TO HEADER
2=FOR
2
14.2 K - 0.28
REG. 342
14.3 C mm - 1

IBR REG. 270 (a) , 342 , 215
LINE
No.
15 OUTPUT
LONGITUDINAL
15.1 EFFICIENCY OF El1 El1=(pl1 - dav)/pl1 0.88 REG.215
LIGAMENT
LONGITUDINAL
LIGAMENT
CIRCUMFERENTIAL
LIGAMENT
16 DESIGN PRESSURE P Kg/cm2.g WP + h 10.54 1 Mpa
SAT. TEMP
WORKING MTL.
18 TEMP. T 0
C + 214
ADD. TEMP.
19 PRESSURE P x 1.5 15.81 1.55 Mpa



[2 x f. xE x (tm-0.7625)] / (Di+tm-
23.1 CAL. WP WP Kg/cm2.g - 53.64

24.1 MIN REQ. THICKNESS Te mm C + SQRT[(P x Di2 x K) / f )] 6.95 REG. 342


IBR REG. 270 (a) , 342 , 215
LINE
No.
RISER STUB THICKNESS CALCULATION - INTERNAL PRESSURE

IBR REG. 573(b)(ii), 564(a) & 270
No.
1 INPUT
2 NOZZLE DATA R1 TO R4
NOZZLE INSIDE
3.2 D mm - 99.32
DIAMETER
PROVIDED
3.3
THICKNESS
T mm - 8.56 OK
3.5 MATERIAL - SA 106 Gr. B
WORKING
5 WP Kg/cm2.g - 17.5
PRESSURE
SAT. TEMP. AT
6 C
0
- 209
DESIGN PRESSURE
MIN. YIELD
8 Mpa 240
STRENGTH
8.1 TEMP.(400C)
Kg/cm2.g 2202.60
10 OUTPUT
temp. C
0

13 P x 1.5 26.25 REG.601(a)
PRESSURE
REG.564(a)
CALCULATED MIN.
REG. 270
CALCULATED MIN.
EQ.XII/10
(ii)
REG.573(b)
CALCULATED MIN.
564(a)

WW LINK STUB THICKNESS CALCULATION - INTERNAL PRESSURE

IBR REG. 573(b)(ii), 564(a) & 270
No.
1 INPUT
2 NOZZLE DATA L1 TO L6
NOZZLE INSIDE
3.2 D mm - 99.32
DIAMETER
PROVIDED
3.3
THICKNESS
T mm - 8.56 OK
WORKING
5 WP Kg/cm2.g - 10.54
PRESSURE
SAT. TEMP. AT
6 C
0
- 186
DESIGN PRESSURE
MIN. YIELD
8 Mpa 240
STRENGTH
8.1 TEMP.(400C)
Kg/cm2.g 2202.60
10 OUTPUT
temp. C
0

13 P x 1.5 15.81 REG.601(a)
PRESSURE
REG.564(a)
CALCULATED MIN.
REG. 270
CALCULATED MIN.
EQ.XII/10
(ii)
REG.573(b)
CALCULATED MIN.
564(a)

NOZZLE THICKNESS CALCULATION - INTERNAL PRESSURE

IBR REG. 573(b)(ii), 564(a) & 270
No.
1 INPUT
2 NOZZLE DATA I1 TO I4 P.No.____
NOZZLE INSIDE
3.2 D mm - 149.10
DIAMETER
PROVIDED
3.3
THICKNESS
T mm - 10.97 OK
WORKING
5 WP Kg/cm2.g - 17.5
PRESSURE
SAT. TEMP. AT
6 C
0
- 209
DESIGN PRESSURE
MIN. YIELD
8 Mpa 240
STRENGTH
8.1 TEMP.(400C)
fhydro. 0.9 X MIN. YIELD STRENGTH
Kg/cm2.g 2202.60
10 OUTPUT
temp. C
0

13 P x 1.5 26.25 REG.601(a)
PRESSURE
CALCULATED MIN. REG.564(a)

14.1 Tr1 mm [(P x D) / ( 2 x f x E - P)] + E 1.85 EQ.72
REQD. THICKNESS REG. 270
15 CAL. HYD.TEST WP WPhydro. Kg/cm2 [2 x fhydrox E. x (Tm-0.762)] / (D+Tm-0.762) 246.47 SAFE


IBR REG. 573(b)(ii), 564(a) & 270
No.
1 INPUT
2 NOZZLE DATA I5 TO I8 P.No.____
NOZZLE INSIDE
3.2 D mm - 75.57
DIAMETER
PROVIDED
3.3
THICKNESS
T mm - 7.62 OK
WORKING
5 WP Kg/cm2.g - 17.5
PRESSURE
SAT. TEMP. AT
6 C
0
- 209
DESIGN PRESSURE
MIN. YIELD
8 Mpa 240
STRENGTH
8.1 TEMP.(400C)
Kg/cm2.g 2202.60
10 OUTPUT
temp. C
0

13 P x 1.5 26.25 REG.601(a)
PRESSURE

CALCULATED MIN.
14.2 t mm 0.04 x DO + 2.5 6.06 REG.573(b) (ii)
REQD. THICKNESS EQ.XII/10
CALCULATED MIN.
14.3 Tr mm -- 6.06 REG.573(b) (ii)
REQD. THICKNESS , REG. 564(a)


IBR REG. 573(b)(ii), 564(a) & 270
No.
1 INPUT
2 NOZZLE DATA D1 TO D4 P.No.____
NOZZLE INSIDE
3.2 D mm - 25.44
DIAMETER
PROVIDED
3.3
THICKNESS
T mm - 4.55 OK
WORKING
5 WP Kg/cm2.g - 17.5
PRESSURE
SAT. TEMP. AT
6 C
0
- 209
DESIGN PRESSURE
MIN. YIELD
8 Mpa 240
STRENGTH
8.1 TEMP.(400C)
Kg/cm2.g 2202.60
10 OUTPUT
temp. C
0

13 P x 1.5 26.25 REG.601(a)
PRESSURE

CALCULATED MIN.
14.2 t mm 0.04 x DO + 2.5 3.84 REG.573(b) (ii)
CALCULATED MIN.
14.3 Tr mm -- 3.84 REG.573(b) (ii)
REQD. THICKNESS , REG. 564(a)

RISER PIPE THICKNESS CALCULATION

IBR REG. 270
LINE
No.
1 INPUT
2 PIPE DATA
OUTSIDE
4.1 MIN. THICKNESS tm mm - 5.27 SEC II -A
5 MATERIAL - SA 106 Gr.B

WORKING
WELD FACTOR /
9 EFFICIENCY OF E - 1
LIGAMENT
SAT. TEMP. AT
10 DESIGN PRESSURE C
0
- 209

MIN. YIELD
12 STRENGTH Mpa 240
Mpa 216
12.1 ALL. STRESS AT f .
HYD.TEST TEMP.(400C) hydro 0.9 x MIN YIELD STRENGTH
Kg/cm2.g 2202.60
13 OUTPUT

WORKING MTL.
16 TEMP. T C
0 SAT. TEMP + ADD. TEMP. 237 REG. 340(d)
Phydro. Kg/cm2.g Mpa

18 REQD. THICKNESS tr mm + 0.7625 1.52
REG. 270 (a)
% THINNING OF
19 PIPE th % 20.00
THICKNESSS AFTER
19.1 CONSIDERING
THINNING
tf mm tm - ((th x tm)/100) 4.21 SAFE
PERCENTAGE
[2 x fhydro. xE x (tf-0.7625)] /
20 CAL. HYD.TEST WP WPhydro. Mpa (Di+tf-0.7625) 13.91 SAFE

[2 x f. xE x (tf-0.7625)] /
21 CAL. WP WP MPa (Di+tf-0.7625) 7.60 SAFE
21.1 CAL. WP WP Kg/cm2 77.47

DC PIPE THICKNESS CALCULATION

IBR REG. 270
LINE
No.
1 INPUT
2 PIPE DATA P.No.____
OUT SIDE
5 MATERIAL - SA 106 Gr.B
WORKING
WELD FACTOR /
9 EFFICIENCY OF E - 1
LIGAMENT
SAT. TEMP. AT
10 DESIGN PRESSURE C
0
- 209

MIN. YIELD
12 STRENGTH Mpa 240
Mpa 216
12.1 ALL. STRESS AT f .
HYD.TEST TEMP.(400C) hydro
0.9 x MIN YIELD STRENGTH
Kg/cm2.g 2202.60
13 OUTPUT

WORKING MTL.
16 TEMP. T C
0 SAT. TEMP + ADD. TEMP. 237 REG. 340(d)

18 REQD. THICKNESS tr mm + 0.7625 1.52
REG. 270 (a)
% THINNING OF
19 PIPE th % 20.00
THICKNESSS AFTER
19.1 CONSIDERING
THINNING
tf mm tm - ((th x tm)/100) 4.21 SAFE
PERCENTAGE
[2 x fhydro. xE x (tf-0.7625)] /
20 CAL. HYD.TEST WP WPhydro. Mpa (Di+tf-0.7625) 13.91 SAFE

[2 x f. xE x (tf-0.7625)] /
21 CAL. WP WP MPa (Di+tf-0.7625) 7.60 SAFE
21.1 CAL. WP WP Kg/cm2.g 77.47

SHELL THICKNESS CALCULATION - INTERNAL PRESSURE

IBR REG. 564(a) & 270
LINE
No. DESCRIPTION UNITS FORMULA VALUE REMARKS
1 INPUT
2 SHELL DATA
3.1 SHELL INSIDE D mm - 1550

DIAMETER
PROVIDED
3.2 T mm - 12 SAFE
THICKNESS
3.3 MATERIAL - SA 516 Gr. 70

WORKING
5 WP Kg/cm2.g - 17.5
PRESSURE
SAT. TEMP. AT
6 C
0
- 209
DESIGN PRESSURE
7.1 ALL. STRESS AT 'T' f Kg/cm2 - 1407.21
MIN YIELD
8 STRENGTH Mpa 260
ALL. STRESS AT HYD.TEST
8.1 TEMP.(400C) Mpa 0.9 x MIN. YIELD STRENGTH 234
ALL. STRESS AT HYD.TEST
8.2 TEMP.(400C) fhydro. Kg/cm2 - 2386.14

10 OUTPUT
SAT. TEMP
WORKING MTL.
12 t C
0
+ 237
TEMP. ADD. TEMP.

13 P x 1.5 26.25 REG.601(a)
PRESSURE
Tr mm
15 CAL. HYD.TEST WP WPhydro. Kg/cm2 [2 x fhydro. x E x(T-0.762)] / (D+T-0.762) 34.35 SAFE
16 CAL. WP WP Kg/cm2 [2 x f x E x (T-0.762)] / (D+T-0.762) 20.26 SAFE
MAX.
17 UNCOMPENSATED DUO mm 2.5 x T + 2.75*25.4 99.85 REG.571
OPENING IN SHELL
TUBE SHEET THICKNESS CALCULATION

IBR REG. 574,589
LINE
DESCRIPTION UNITS FORMULA
No.
1 INPUT
2 TUBE SHEET
3 PROVIDED TUBE SHEET THICKNESS T mm -
4 MATERIAL -
5 DESIGN PRESSURE P Kg/cm2.g -
6 WORKING PRESSURE WP Kg/cm2.g -
7 STATIC HEAD h mm OF WC -
8 STATIC HEAD h Kg/cm2.g -
9 SAT. TEMP. AT DESIGN PRESSURE 0
C -
10 ALL. STRESS AT 'T' Mpa -
11 ALL. STRESS AT 'T' f Kg/cm2.g -
12 MIN. YIELD STRENGTH Mpa
13 ALL. STRESS AT HYD.TEST TEMP.(400C) fhydro. Mpa 0.9 x MIN. YIELD STRENGTH
DIA OF LARGEST CIRCLE B/W STAYING
14 POINTS d mm -
15 COEFFICIENT C -
16 ADDITIONAL THICKNESS e1 mm -
17 FLAT PLATE MARGIN
17.1 THICKNESS IN THIRTY SECONDS IN AN INCH t inch T*32/25.4
Cp=3.47 FOR PLATES EXPOSED TO
17.2 Cp FLAME Cp=3.70 FOR PLATES NOT
EXPOSED TO FLAME
17.3 PROVIDED FLAT PLATE MARGIN WMP mm
19 CALCULATING STRESS f1 Kg/cm2.g 0.85f

20 CALCULATING STRESS - HYDROTEST f1h Kg/cm2.g 0.85fhydro
21 DESIGN PRESSURE P Kg/cm2.g WP + h
22 WORKING MTL. TEMP. t 0
C SAT. TEMP + ADD. TEMP.
23 HYD. TEST PRESSURE Phydro. Kg/cm2.g P x 1.5
24 CALCULATED MIN. REQD. THICKNESS OF TUBE SHEET e mm (C*d*SQRT(P/f1)+ e1)+ 10%
25 CALCULATED MIN. REQD. THICKNESS FOR HYDROTEST eh mm (C*d*(Phydro/f1h)^0.5+ e1)
26 CALC. WOKING PRESSURE Kg/cm2.g ((T - e1)/(Cd))2 x f1

27 FLAT PLATE MARGIN
inch WM=(Cp*(t-1))/(P^0.5) P
28 MAX. WIDTH OF MARGIN WM in lbf/in2
mm
VALUE REMARKS
16 #REF!
SA 516 Gr.70
17.5 248.9 psi
17.5
0
0
209
138
1407.21
260
234
280.00
0.40
0.75
20.16
3.47 REG. 589
106.00 OK
1196.13
#REF!
17.5
237
26.3 REG.601(a)
15.73 REG.574
#REF! REG.574
22.18 SAFE
4.21
REG.589
107.03
PITCH OF TUBES CALCULATION

IBR REG. 580
LINE
1 INPUT
2 PITCH OF TUBES P.No.____
PROVIDED TUBE PLATE
3 THICKNESS T mm - 16 NOT OK
4 PASS 1
4.1 TUBE OUTER DIA mm - 63.5
4.2 TUBE HOLE DIA D1 mm - 64.02
4.3 PROVIDED THICKNESS T1 mm - 3.66

BS 3059 ERW
4.4 MATERIAL - p-1 Gr.320
4.5 PITCH OF TUBES Δ1 mm - 90
5 PASS 2
5.1 TUBE OUTER DIA mm - 63.5
5.2 TUBE HOLE DIA D2 mm - 64.02

BS 3059 ERW
5.4 PROVIDED THICKNESS T2 mm - 3.66
5.5 PITCH OF TUBES Δ2 mm - 90
6 OUTPUT
7 PASS 1
7.1 MIN. LIGAMENT REQUIRED mm (D1/8)+12.7 20.70 REG.580
CALC. MIN. THICKNESS OF

7.2 TUBE PLATE B/W TUBE mm (0.125xD1)+5.08 13.08 REG.580
HOLES
CALC. MIN. C/S OF PLATE
7.3 B/W TUBE HOLES mm2 (4.32xD1)+16.129 292.70 REG.580
mm
7.5 ACTUAL LIGAMENT mm Δ1-D1 25.98 OK

ACTUAL C/S OF PLATE B/W
7.6 TUBE HOLES mm2 (Δ1-D1)xT 415.68 OK
8 PASS 2
8.1 MIN. LIGAMENT REQUIRED mm (D2/8)+12.7 20.70 REG.580
CALC. MIN. THICKNESS OF

8.2 TUBE PLATE B/W TUBE mm (3.175xD2)+5.08 208.34 REG.580
HOLES
CALC. MIN. C/S OF PLATE

8.3 B/W TUBE HOLES mm2 (4.32xD2)+16.129 292.70 REG.580
MIN. REQ. TUBE PLATE

8.4 THICKNESS mm 14.29 REG.580
8.5 ACTUAL LIGAMENT mm Δ2-D2 25.98 OK

ACTUAL C/S OF PLATE B/W
8.6 TUBE HOLES mm2 (Δ2-D2)xT 415.68 OK
PLAIN TUBES THICKNESS CALCULATION (TUBES IN NEST)

IBR REG. 579
LINE
1 INPUT
2 PLAIN TUBES
DESIGN PRESSURE
3 /EXTERNAL PRESSURE P Kg/cm2.g - 17.5

INTERNAL WORKING
6 IP Kg/cm2.g - 0.106
PRESSURE
7 SAT. TEMP. AT DESIGN - 209
C
0
PRESSURE
8.1 ALL. STRESS AT 'T' f Kg/cm .g
2
- 849.73
9 MIN YIELD STRENGTH Mpa 215
ALL. STRESS AT HYD.TEST Mpa 193.5
9.1 TEMP.(400C)
Kg/cm2.g 1973.16
10 HYD. TEST PRESSURE Phydro. Kg/cm2.g P x 1.5 26.25 REG.601(a)
11 PASS 1
11.1 TUBE OUTER DIA D1 mm - 63.5
PROVIDED THICKNESS mm - 3.66
11.2 MIN. THICKNESS T1 mm - 3.294 OK
BS 3059 ERW
11.4 CORROSION C mm - 0.75

ALLOWANCE
mm
MIN. REQ. THICKNESS

11.6 UNDER EXTERNAL mm - 3.12 REG. 579( c )
PRESSURE
12 PASS 2
BS 3059 ERW

MIN. REQ. THICKNESS
12.4 UNDER INTERNAL mm - 2.4 REG. 579( d )
PRESSURE
MIN. REQ. THICKNESS

12.5 UNDER EXTERNAL mm - 3.12 REG. 579( c )
PRESSURE
13 OUTPUT

IBR REG. 579
LINE
SAT. TEMP
14 WORKING MTL. TEMP. t C
0 + 237
ADD. TEMP.
15 PASS 1
CALC. MIN THICKNESS
15.1 UNDER EXTERNAL te1 mm te1=((PxD1)/(1.6xf))+C 1.57 REG.579( b )
PRESSURE
CALC. MIN THICKNESS

15.2 UNDER INTERNAL ti1 mm ti1=((IPxD1)/(IP+2f))+C 0.75 REG.579( d )
PRESSURE
CALCULATED MIN. REQD.

15.3 THICKNESS FOR HYDROTEST th1 mm th1=((PhydroxD1)/(1.6xfhydro))+C 1.28
MAX AREA SUPPORTED

BY ONE TUBE mm2 7014.80
15.4 A1 -
cm2 70.15
LOAD ON THE AREA
15.5 SUPPORTED BY TUBE kg Px A1 1227.59
LOAD ON THE AREA

15.6 SUPPORTED BY TUBE kg Phydro x A1 1841.39
DURING HYDROTEST
RESISTING LOAD OF
15.7 ONE TUBE kg (f*(D1-T1)*T1*π)/100 5294.14 SAFE
RESISTING LOAD OF ONE
15.8 TUBE DURING HYDROTEST kg (fhydro*(D1-T1)*T1*π)/100 12293.49 SAFE
CALC. EXTERNAL
15.9 Kg/cm2.g ((T1 - C) x 1.6f) / (D1) 54.47
WORKING PRESSURE
16 PASS 2
CALC. MIN THICKNESS
16.1 UNDER EXTERNAL te2 mm te2=((PxD2)/(1.6xf))+C 1.57 REG.579( b )
PRESSURE
CALC. MIN THICKNESS

16.2 UNDER INTERNAL ti2 mm ti2=((IPxD2)/(IP+2f))+C 0.75 REG.579( d )
PRESSURE

MAX AREA SUPPORTED

BY ONE TUBE mm2 7014.80
16.4 A2 -
cm2 70.15
LOAD ON THE AREA
16.5 SUPPORTED BY TUBE kg Px A2 1227.59
LOAD ON THE AREA

DURING HYDROTEST
RESISTING LOAD OF
16.7 ONE TUBE kg (f*(D2-T2)*T2*π)/100 5294.14 SAFE
CALC. EXTERNAL
16.9 Kg/cm2.g ((T2 - C) x 1.6f) / (D2) 54.47
WORKING PRESSURE

IBR REG. 579
LINE
STAY TUBES THICKNESS CALCULATION (TUBES ON BOUNDARY)

IBR REG. 581,148
LINE
1 INPUT
2 STAY TUBES
INTERNAL WORKING
4.1 PRESSURE IP Kg/cm2.g - 0.106
6 PRESSURE
0
C - 209
7 ALL. STRESS AT 'T' Mpa - 70 REG.148

8.1 TEMP.(400C)
Kg/cm2.g 1973.16
10 PASS 1
10.2 MIN. THICKNESS T1 mm - 3.29 NOT OK
BS 3059 ERW
10.4 CORROSION ALLOWANCE C mm 0.75

mm
MIN. REQ. THICKNESS UNDER
10.6 EXTERNAL PRESSURE mm - 3.12 REG. 579( c )
11 PASS 2
BS 3059 ERW

11.5 INTERNAL PRESSURE mm 2.4 REG. 579( d )

12 OUTPUT
C SAT. TEMP + ADD. TEMP. 237
14 PASS 1
CALC. MIN THICKNESS
14.1 UNDER EXTERNAL PRESSURE te1 mm te1=((PxD1)/(1.6xf))+C 1.72 REG.579( b )
CALC. MIN THICKNESS

14.2 UNDER INTERNAL PRESSURE ti1 mm ti1=((IPxD1)/(IP+2f))+C 0.75 REG.579( d )

MAX AREA SUPPORTED mm2 25911.00
14.4 BY ONE TUBE A1 - REG.150
cm2 259.11

IBR REG. 581,148
LINE
LOAD ON THE AREA
14.5 SUPPORTED BY TUBE kg Px A1 4534.43 REG.579( d )
LOAD ON THE AREA

DURING HYDROTEST
14.7 TUBE kg (f*(D1-T1)*T1*π)/100 4447.26 NOT SAFE
CALC. EXTERNAL
14.9 WORKING PRESSURE Kg/cm2.g ((T1 - C) x 1.6f) / (D1) 45.76
15 PASS 2
CALC. MIN THICKNESS
CALC. MIN THICKNESS

15.2 UNDER INTERNAL PRESSURE ti2 mm ti2=((IPxD2)/(IP+2f))+C 0.75 REG.579( b )

cm2 179.16
LOAD ON THE AREA
LOAD ON THE AREA

DURING HYDROTEST
15.7 TUBE kg (f*(D2-T2)*T2*π)/100 4447.26 SAFE
CALC. EXTERNAL
15.9 Kg/cm2.g ((T2 - C) x 1.6f) / (D2) 45.76
WORKING PRESSURE

IBR REG. 581,148
LINE
1 INPUT
2 STAY TUBES
INTERNAL WORKING
4.1 PRESSURE IP Kg/cm2.g - 0.106
6 PRESSURE
0
C - 209
7 ALL. STRESS AT 'T' Mpa - 70 REG.148

8.1 TEMP.(400C)
Kg/cm2.g 1973.16
10 STAY TUBES
10.2 PROVIDED THICKNESS mm - 6.35
BS 3059 ERW
10.5 CORROSION ALLOWANCE C mm 0.75

mm
12 OUTPUT
14 STAY TUBES
CALC. MIN THICKNESS
CALC. MIN THICKNESS

14.2 UNDER INTERNAL PRESSURE ti1 mm ti1=((IPxD1)/(IP+2f))+C 0.76 REG.579( d )

cm2 385.88
LOAD ON THE AREA
LOAD ON THE AREA

DURING HYDROTEST
14.7 TUBE kg (f*(D1-T1)*T1*π)/100 9033.20 SAFE
CALC. EXTERNAL
14.9 Kg/cm2.g ((T1 - C) x 1.6f) / (D1) 74.42
WORKING PRESSURE

IBR REG. 581,148
LINE

IBR REG. 573(b)(ii), 564(a) & 270
No.
1 INPUT
2 NOZZLE DATA SV1,SV2
NOZZLE INSIDE
3.2 D mm - 39.41
DIAMETER
PROVIDED
3.3
THICKNESS
T mm - 5.08 OK
WORKING
5 WP Kg/cm2.g - 17.5
PRESSURE
SAT. TEMP. AT
6 C
0
- 209
DESIGN PRESSURE
MIN. YIELD
8 Mpa 240
STRENGTH
8.1 TEMP.(400C)
Kg/cm2.g 2202.60
10 OUTPUT
temp. C
0

13 P x 1.5 26.25 REG.601(a)
PRESSURE
14.1 Tr1 mm [(P x D) / ( 2 x f x E - P)] + 0.7625 1.05 EQ.72
CALCULATED MIN.
14.2 t mm 0.04 x DO + 2.5 4.43 REG.573(b) (ii)
CALCULATED MIN. REG.573(b)

14.3 Tr mm -- 4.43 (ii) , REG.
REQD. THICKNESS 564(a)

MAX.
17 UNCOMPENSATED DUO mm 2.5 x Ts + 2.75*25.4 99.85 REG.571
OPENING IN SHELL
18 OPENING IN SHELL DSO mm DO + 3 51.30
COMPENSATION CHECK NOT
19 REQUIREMENT REQUIRED

IBR REG. 573(b)(ii), 564(a) & 270
No.
1 INPUT
2 NOZZLE DATA N1
NOZZLE INSIDE
3.2 D mm - 99.32
DIAMETER
PROVIDED
3.3
THICKNESS
T mm - 8.56 OK
WORKING
5 WP Kg/cm2.g - 17.5
PRESSURE
SAT. TEMP. AT
6 C
0
- 209
DESIGN PRESSURE
MIN. YIELD
8 Mpa 240
STRENGTH
8.1 TEMP.(400C)
Kg/cm2.g 2202.60
10 OUTPUT
temp. C
0

13 P x 1.5 26.25 REG.601(a)
PRESSURE
14.1 Tr1 mm [(P x D) / ( 2 x f x E - P)] + 0.7625 1.49 EQ.72
CALCULATED MIN.
14.2 t mm 0.04 x DO + 2.5 7.07 REG.573(b) (ii)

14.3 Tr mm -- 7.07 (ii) , REG.

MAX.
OPENING IN SHELL
COMPENSATION CHECK

IBR REG. 573(b)(ii), 564(a) & 270
No.
1 INPUT
2 NOZZLE DATA N2 TO N3
NOZZLE INSIDE
3.2 D mm - 99.32
DIAMETER
PROVIDED
3.3
THICKNESS
T mm - 8.56 OK
WORKING
5 WP Kg/cm2.g - 17.5
PRESSURE
SAT. TEMP. AT
6 C
0
- 209
DESIGN PRESSURE
MIN. YIELD
8 Mpa 240
STRENGTH
8.1 TEMP.(400C)
Kg/cm2.g 2202.60
10 OUTPUT
temp. C
0

13 P x 1.5 26.25 REG.601(a)
PRESSURE
REG.564(a)
14.1 CALCULATED MIN. Tr1 mm [(P x D) / ( 2 x f x E - P)] + 0.7625 1.49 EQ.72
CALCULATED MIN.
14.2 t mm 0.04 x DO + 2.5 7.07 REG.573(b) (ii)

14.3 Tr mm -- 7.07 (ii) , REG.

MAX.
OPENING IN SHELL
COMPENSATION CHECK

IBR REG. 573(b)(ii), 564(a) & 270
No.
1 INPUT
2 NOZZLE DATA N10
NOZZLE INSIDE
3.2 D mm - 45.01
DIAMETER
PROVIDED
3.3
THICKNESS
T mm - 8.74 OK
WORKING
5 WP Kg/cm2.g - 10.54
PRESSURE
SAT. TEMP. AT
6 C
0
- 186
DESIGN PRESSURE
MIN. YIELD
8 Mpa 240
STRENGTH
8.1 TEMP.(400C)
Kg/cm2.g 2202.60
10 OUTPUT
temp. C
0

13 P x 1.5 15.81 REG.601(a)
PRESSURE
14.1 Tr1 mm [(P x D) / ( 2 x f x E - P)] + 0.7625 0.96 EQ.72
CALCULATED MIN.
14.2 t mm 0.04 x DO + 2.5 4.91 REG.573(b) (ii)

14.3 Tr mm -- 4.91 (ii) , REG.

MAX.
OPENING IN SHELL

IBR REG. 573(b)(ii), 564(a) & 270
No.
1 INPUT
N11, N12 ,N13, LSa,LSb,LG1a, LG1b,

2 NOZZLE DATA LG2a, LG2b

NOZZLE INSIDE
3.2 D mm - 25.44
DIAMETER
PROVIDED
3.3 THICKNESS T mm - 4.55 OK
WORKING
5 WP Kg/cm2.g - 10.54
PRESSURE
SAT. TEMP. AT
6 C
0
- 186
DESIGN PRESSURE
MIN. YIELD
8 STRENGTH Mpa 240

8.1 TEMP.(400C)
Kg/cm2.g 2202.60
10 OUTPUT
11 DESIGN PRESSURE P Kg/cm .g
2
WP + h 10.54
temp. C
0

13 P x 1.5 15.81 REG.601(a)
PRESSURE
14.1 Tr1 mm [(P x D) / ( 2 x f x E - P)] + 0.7625 0.87 EQ.72
CALCULATED MIN.
14.2 t mm 0.04 x DO + 2.5 3.84 REG.573(b) (ii)

14.3 Tr mm -- 3.84 (ii) , REG.
15 CAL. HYD.TEST WP WPhydro. Kg/cm2 [2 x fhydro. x E x (Tm-0.762)] / (D+Tm-0.762) 494.87 SAFE

MAX.
OPENING IN SHELL

IBR REG. 573(b)(ii), 564(a) & 270
No.
1 INPUT
2 NOZZLE DATA N14 , N14a
NOZZLE INSIDE
3.2 D mm - 39.41
DIAMETER
PROVIDED
3.3
THICKNESS
T mm - 5.08 OK
WORKING
5 WP Kg/cm2.g - 10.54
PRESSURE
SAT. TEMP. AT
6 C
0
- 186
DESIGN PRESSURE
MIN. YIELD
8 Mpa 240
STRENGTH
8.1 TEMP.(400C)
Kg/cm2.g 2202.60
10 OUTPUT
temp. C
0

13 P x 1.5 15.81 REG.601(a)
PRESSURE
14.1 Tr1 mm [(P x D) / ( 2 x f x E - P)] + 0.7625 0.94 EQ.72
CALCULATED MIN.
14.2 t mm 0.04 x DO + 2.5 4.43 REG.573(b) (ii)

14.3 Tr mm -- 4.43 (ii) , REG.

MAX.
OPENING IN SHELL
COMPENSATION CHECK CALCULATIONS

IBR REG. 571
LINE
1 INPUT
2 DESIGN PRESSURE P Kg/cm .g 2
- 10.54
3 WORKING MTL. TEMP. C
0
- 214
4 SHELL DATA -
4.1 INSIDE DIAMETER D mm - 2200
4.2 PROVIDED THK. Ts mm - 10
4.3 MATERIAL - SA 516-70
4.4 ALL. STRESS AT 'T' S1 Kg/cm2.g - 1407.21 138 Mpa
5 NOZZLE DATA SV1,SV2
5.2 INSIDE DIAMETER D mm - 75.57
5.3 PROVIDED THK . Tn mm - 7.62 OK
5.4 MIN. THICKNESS Tm mm 6.67 SEC II -A
5.7 NOZZLE I/S PROJ. a mm - 0
5.8 NOZZLE O/S PROJ. b mm - 100
6 PAD DETAILS - P.No.____
6.1 PAD REQUIREMENT REQUIRED
6.2 PAD WIDTH w mm - 75 OK
Tc mm
8 OUTPUT
9 REQD. THICKNESS- T1 mm [(P x D) / ( 2 x f x E - P)] + 0.762 9.03 EQ.72
SHELL REG. 270
CALCULATED MIN. REG.564(a) EQ.72

REG. 270
10 REQD. THICKNESS- T2+T3 mm 1.09
[(P x D) / ( 2 x f x E - P)] + 0.762 REG.573(b) (ii)
NOZZLE EQ.XII/10
MAX.
OPENING IN SHELL
12 OPENING IN SHELL W mm DO + 3 91.90

AREA TO BE
13 A mm2 W x T1 830.04
COMPENSATED
14 COMPENSATION AREA B + C+ D + Z 1215.28 ADEQUATE
AREA AVAILABLE IN
14.1 SHELL B mm2 2 x (76.2+Ts) x (Ts-T1) 166.89
AREA AVAILABLE IN
14.2 NOZZLE C mm2 2 x (101.6+Ts) x [Tm-(T2+T3)] x (S2/S1) 1048.39
14.3 FILLET WELDS AREA D mm2 - 0.00

14.4 AREA AS PAD Z mm 2
2 x w x Tc x (S3/S1) 0.00
14.5 PAD SIZE 75 X 0


IBR REG. 571
LINE
1 INPUT
- 10.54
0
- 214
4 SHELL DATA -
5 NOZZLE DATA N1
Tc mm
8 OUTPUT
SHELL REG. 270

REG. 270
[(P x D) / ( 2 x f x E - P)] + 0.762 REG.573(b) (ii)
NOZZLE EQ.XII/10
MAX.
OPENING IN SHELL

AREA TO BE
13 A mm2 W x T1 1547.17
COMPENSATED
AREA AVAILABLE IN
AREA AVAILABLE IN

2 x w x Tc x (S3/S1) 0.00


IBR REG. 571
LINE
1 INPUT
- 10.54
0
- 214
4 SHELL DATA -
5 NOZZLE DATA N2 TO N9
Tc mm
8 OUTPUT
SHELL REG. 270

REG. 270
[(P x D) / ( 2 x f x E - P)] + 0.762 REG.573(b) (ii)
NOZZLE EQ.XII/10
MAX.
OPENING IN SHELL
AREA TO BE
13 A mm2 W x T1 1547.17
COMPENSATED
AREA AVAILABLE IN
AREA AVAILABLE IN

2 x w x Tc x (S3/S1) 0.00


IBR REG. 571
LINE
1 INPUT
- 10.54

0
- 214
4 SHELL DATA -
5 NOZZLE DATA M
5.1 NOZZLE OD DO mm 456
5.3 PROVIDED THK . Tn mm - 25 OK
6 PAD DETAILS -
6.3 PAD THICKNESS Tc mm - 10

8 OUTPUT
SHELL REG. 270

REG. 270
[(P x D) / ( 2 x f x E - P)] + 0.762 REG.573(b) (ii)
NOZZLE EQ.XII/10
MAX.
OPENING IN SHELL
AREA TO BE
13 A mm2 W x T1 4145.66
COMPENSATED
AREA AVAILABLE IN
AREA AVAILABLE IN
14.2 NOZZLE C mm2 2 x (101.6+Ts) x [Tn-(T2+T3)] x (S2/S1) 3633.89

2 x w x Tc x (S3/S1) 2000.00
14.5 PAD SIZE 100 X 10


IBR REG. 571
LINE
1 INPUT
2 DESIGN PRESSURE P Kg/cm .g2
- 10.54

0
- 214
4 SHELL DATA -
5 NOZZLE DATA H1 TO H4
5.1 NOZZLE OD DO mm 178
5.3 PROVIDED THK . Tn mm - 0
5.4 MATERIAL - -
5.6 ALL. STRESS AT 'T' S2 Kg/cm2.g - 0 0 Mpa
6 PAD DETAILS -
6.2 PAD WIDTH w mm - 100 ADEQUATE
6.3 PAD THICKNESS Tc mm - 10

8 OUTPUT
SHELL REG. 270
MAX.
OPENING IN SHELL
11 OPENING IN SHELL W mm DO 178.00

AREA TO BE
12 A mm2 W x T1 1607.69
COMPENSATED
13 COMPENSATION AREA B+D+Z 2166.89 ADEQUATE
AREA AVAILABLE IN

14.4 AREA AS PAD Z mm2 2 x w x Tc x (S3/S1) 2000.00
14.5 PAD SIZE 100 X 10
THICKNESS CALCULATION - ELLIPTICAL INTERNALDOORS (HAND HOLES)

IBR REG. 554A
No.
1 INPUT
2 NOZZLE DATA H1 to H4
NOZZLE INSIDE
3 DIMENSIONS
3.1 MAJOR AXIS b mm - 178 I/S 178x 127
3.2 MINOR AXIS a mm - 127
3.3 MATERIAL - SA 516 Gr. 70
SAT. TEMP. AT
6 C
0
- 186
DESIGN PRESSURE
7 WORKING MTL. TEMP. temp. 0
8.2 MIN. YIELD STRENGTH Mpa 260
8.3 TEMP.(400C)
Kg/cm2.g 2386.14
9 BOLT DATA
9.1 BOLT MATERIAL - SA 193 Gr. B7
9.2 BOLT SIZE d mm - 24
A mm2
FOR DESIGN
9.4 DESIGN STRESS VALUE f N/mm2 - 50 TEMP. UP TO
300OC
FULL LOAD CAPACITY OF

9.5 ONE BOLT W N fxA 0.00
10 OUTPUT
2
MAX (WP + h, P) 10.54 1.03 Mpa
12 P x 1.5 15.8 REG.601(a)
PRESSURE
CALCULATED MIN.
13 tr mm SQRT [(0.35x P x (2-(a/b)) x a2 + W) / f] 7.38 REG.554A
REQD. THICKNESS
CALCULATED MIN.
14 REQD. THICKNESS trh mm SQRT [(0.35x P hx (2-(a/b)) x a2 + W) / fh] 6.94 REG.554A
FOR HYDROTEST
PROVIDED MIN.
15 THICKNESS t mm 16 SAFE
CALC. WORKING Mpa 4.86

16 (t2f - W) / (0.35 x (2-(a/b)) x a2)
PRESSURE Kg/cm2.g 49.60
THICKNESS CALCULATION - ELLIPTICAL INTERNALDOORS (MAN HOLES)

IBR REG. 554A
No.
1 INPUT
2 NOZZLE DATA M
NOZZLE INSIDE
3 DIMENSIONS
406 I/S306
406 x
3.1 MAJOR AXIS b mm -
3.2 MINOR AXIS a mm - 306
3.3 MATERIAL - SA 516 - 70

WORKING
5 WP Kg/cm2.g - 10.54
PRESSURE
5.1.1 STATIC HEAD h Kg/cm .g 2
- 0
SAT. TEMP. AT
6 C
0
- 186
DESIGN PRESSURE
WORKING MTL. SAT. TEMP

7 temp. C
0
+ 214
TEMP. ADD. TEMP.

MIN. YIELD
8.2 STRENGTH Mpa 260

8.3 TEMP.(400C)
Kg/cm2.g 2386.14
9 BOLT DATA
9.1 BOLT MATERIAL SA 193 Gr. B7
9.2 BOLT SIZE d mm - OK 32.00 REG.166( a )
A mm2
DESIGN STRESS FOR DESIGN

9.4 f N/mm2 - 50.00 TEMP. UP TO
VALUE 300OC
FULL LOAD CAPACITY OF
9.5 ONE BOLT W N fxA 0.00
10 OUTPUT
MAX (WP + h, P) 10.54 1.03 Mpa
12 P x 1.5 15.81 REG.601(a)
PRESSURE
CALCULATED MIN.
13 tr mm SQRT [(0.35x P x (2-(a/b)) x a2 + W) / f] 17.49 REG.554A
REQD. THICKNESS

14 THICKNESS FOR trh mm SQRT [(0.35x P hx (2-(a/b)) x a2 + W) / fh] 16.45 REG.554A
HYDROTEST
PROVIDED MIN.
15 THICKNESS t mm 25 SAFE
CALC. WORKING Mpa 2.11

16 (t2f - W) / (0.35 x (2-(a/b)) x a2)
PRESSURE Kg/cm2.g 21.53
GUSSET THICKNESS CALCULATION

IBR REG. 591
LINE
1 INPUT
2 GUSSET G1 , G4 P.No.____
3 MATERIAL - SA 516 Gr.70
5 WORKING WP - 17.5
Kg/cm2.g
PRESSURE
SAT. TEMP. AT
7 C
0
- 209
DESIGN PRESSURE
THICKNESS OF
8 GUSSET T mm - 14 OK
DEG 60
9 ANGLE V - OK
RAD 1.05
10 WIDTH OF GUSSET C mm - 146
MPa 485.00
11 MIN. TENSILE STRESS - ASME SECII-D
Kg/cm2.g 4945.64
AREA SUPPORTED BY mm2 42695.00
12 THE GUSSET A -
cm2 426.95
13 OUTPUT
2
WP + h 17.5
SAT. TEMP
0 + 237
ADD. TEMP.

F Kg
EFFECTIVE LOAD ON THE
18 GUSSET Fe Kg (F/Sin V) 0.00
mm2 2044.00
19 C/S AREA OF GUSSET Ac (C x T)
cm2 20.44
STRESS DUE TO
20 EFFECTIVE LOAD (CALC. Kg/cm2 Fe/Ac 0.00 SAFE
WORKING PRESSURE)
LOAD ON AREA
21 SUPPORTED BY GUSSET Fhydro. Kg (Phydro x A) 11207.44
DURING HYDROTEST
22 GUSSET DURING Fehydro Kg (Fhydro./ Sin V) 12941.23
HYDROTEST
STRESS DUE TO
23 EFFECTIVE LOAD DURING Kg/cm2 Fehydro/Ac 633.13 SAFE
HYDROTEST

IBR REG. 591
LINE
1 INPUT
2 GUSSET G2 , G5
5 WORKING WP - 17.5
Kg/cm2.g
PRESSURE
SAT. TEMP. AT
7 C
0
- 209
DESIGN PRESSURE
THICKNESS OF
DEG 60
9 ANGLE V - OK
RAD 1.05
MPa 485.00
11 MIN. TENSILE STRESS ASME SECII-D
Kg/cm2.g 4945.64
12 THE GUSSET A -
cm2 476.74
13 OUTPUT
2
WP + h 17.5
SAT. TEMP
0 + 237
ADD. TEMP.

F Kg
mm2 2310.00
cm2 23.10
STRESS DUE TO
WORKING PRESSURE)
LOAD ON AREA
DURING HYDROTEST
HYDROTEST
STRESS DUE TO
HYDROTEST

IBR REG. 591
LINE
1 INPUT
2 GUSSET G3 , G6
5 WORKING WP - 17.5
Kg/cm2.g
PRESSURE
SAT. TEMP. AT
7 C
0
- 209
DESIGN PRESSURE
THICKNESS OF
DEG 60
9 ANGLE V - OK
RAD 1.05
MPa 485
11 MIN. TENSILE STRESS ASME SECII-D
Kg/cm2.g 4945.64
12 THE GUSSET A -
cm2 666.06
13 OUTPUT
2
WP + h 17.5
SAT. TEMP
0 + 237
ADD. TEMP.

F Kg
mm2 3168.00
cm2 31.68
STRESS DUE TO
WORKING PRESSURE)
LOAD ON AREA
DURING HYDROTEST
HYDROTEST
STRESS DUE TO
HYDROTEST
HEADER FOR PG & PS - THICKNESS CALCULATION

IBR REG. 270 (a)
No.
1 INPUT
OUT SIDE
4 NOM. THICKNESS mm - 5.54
4.1 MIN. THICKNESS t mm - 4.85 OK
5 MATERIAL - SA106 Gr.B
WELD FACTOR /
LIGAMENT
SAT. TEMP. AT
10 DESIGN PRESSURE
0
C - 186

MIN. YIELD
12 STRENGTH Mpa 240
12.1 HYD.TEST TEMP. fhydro. 0.9 x MIN. YIELD STRENGTH
(400C) Kg/cm2.g 2202.60
14 OUTPUT
15 DESIGN PRESSURE P Kg/cm2.g WP + h 10.54 1 Mpa
16 INTERNAL DIA Di mm D - (2 x t) 50.605
SAT. TEMP
WORKING MTL.
17 TEMP. T 0
C + 214
ADD. TEMP.

[2 x fhydro. xE x (t-0.7625)] / (Di+t-

20.1 CAL. HYD.TEST WP WPhydro. Kg/cm2.g - 329.04

[2 x f. xE x (t-0.7625)] / (Di+t-
21 CAL. WP WP MPa 0.7625) 17.63 SAFE
21.1 CAL. WP WP Kg/cm2.g - 179.75


Boiler Calucation Sheet

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DOC. No.

HIL-DTL-17-019-CAL-IBR-102 IBR CALCULATIONS 1 OF 51

IBR CALCULATIONS FOR 10TPH COMBI BOILER

REV.NO. REVISION NOTE PREPARED CHECKED APPROVED DATE

7 N14,N14a NOZZLE THICKNESS CALCULATION - INTERNAL PRESSURE 35

S. No. DESCRIPTION UNITS PARAMETER

2 DESIGN,MANUFACTURE & INSPECTION IBR 1950 WITH LATEST AMENDMENTS

3 MAXIMUM WORKING PRESSURE Kg/cm2.g 17.5

4 DESIGN PRESSURE Kg/cm2.g 17.5

5 HYDRO TEST PRESSURE Kg/cm2.g 26.25

a) SAFETY VALVE I : 17.5

b) SAFETY VALVE II : 16.9

7 STEAM OUTLET TEMPERATURE ˚C 209

8 TOTAL HEATING SURFACE AREA m2 #REF!

10 b) SHELL & TUBE m2 #REF!

11 EVAPORATION CAPACITY Kg/hr 8000

100% FOR SHELL & HEADERS

AS PER IBR 1950 WITH LATEST

AS PER IBR 1950 WITH LATEST

15 JOINT EFFICIENCY 1 FOR SHELL & HEADERS

16 INSPECTION DOB, GUJARAT

MAXIMUM METAL WORKING TEMPERATURE

MAX.WORKING MAX. ALLOWABLE

OD 50.8 x BS 3059 ERW

1.2 HEADERS SA 106 - B 1203.27

1.3 BW FITTINGS SA 234 - WPB 1203.27

2 SHELL & TUBES HE 237˚C (209˚C+28˚C)

2.1 SHELL , TUBESHEETS SA 516 - 70 1407.21

2.2 PLAIN TUBES OD 76.2 x BS 3059 ERW 849.72*

OD 76.2 x BS 3059 ERW

2.5 NOZZLE PIPES SA 106 - B 1203.27

2.6 COMP. PAD SA 516 - 70 1407.21

2.7 FLANGES SA 516 - 70 1407.21

3 RISERS SA 106 - B 209˚C 1203.27

4 DOWN COMERS SA 106 - B 209˚C 1203.27

*- LOWER OF Et/1.5 OR Rm/2.4

NOZZLE CONNECTION DATA

RF PAD REF. LINE REMA

120 / CONCENTRIC TABLE-

AUXILLARY 80 / CONCENTRIC TABLE-

NOZZLE FOR PG 40 80 / CONCENTRIC TABLE-

NOZZLE ON PG 40 80 / CONCENTRIC TABLE-

25 33.4 IBR - - 1520 ± 3

LG1a,LG1b & 80 / CONCENTRIC TABLE-

PRESSURE GUAGE SOCKET - AS

HEAT TRANSFER AREA

DIA OF TUBE PLATE D mm - 1550

HEAT TRANSFER AREA A [π x D/2 x L x N] +

3 BED COIL ASSEMBLY

TUBE THICKNESS CALCULATION - BED COILS

3 TUBE DATA P.No.____

3.2 THICKNESS t mm - 4.5 OK

5.1 STATIC HEAD h mm OF WC - 0

7 ALL. STRESS AT 'T' Mpa - 83.33

7.1 ALL. STRESS AT 'T' f Kg/cm2.g - 849.73

%THINNING OF REG. 338 (b)

AVAILABLE THICKNESSS tb tm-((th x tm)/100)

HYD. TEST Phydro. Kg/cm2.g

CALCULATED MIN. EQ.87

BED COILS HEADER THICKNESS CALCULATION

SAT. TEMP. AT DESIGN

11 ALL. STRESS AT 'T' f Kg/cm2.g - 1203.27 118 Mpa

BED COILS HEADER THICKNESS CALCULATION

HYD. TEST Phydro. Kg/cm2.g