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IBR CALCULATIONS
AS PER INDIAN BOILER REGULATIONS,
1950 INDIAN BOILERS ACT, 1923, Edition
2010

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DESIGN DATA

Working Presure : 3.6 Kg/cm².

Max. Working Pressure : 10 Kg/cm².

Working Temperature : 148 ºC.

Max. Working Temperature: 253 ºC.

Hydrostatic test Pressure : 15 Kg/cm².

PWHT : YES

Radiography : Shell------------Full.

Head------------Full.

Weld Joint Efficiency :

Head : 1.00

Shell : 1.00

Corrosion Allowance: 3 mm (Only ASME Design)

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Material Specifications :

Shell : SA 516 Gr. 60

Dished End : SA 516 Gr. 60

RF Pads : SA 516 Gr. 60

Nozzle Pipe < 12” NB : SA 106 Gr. B

> 12” NB : SA 516 Gr. 60

Nozzle Flanges : SA 105.

Supports : SA 516 Gr. 60

Nozzle gaskets : SS316 Spiral wound with CS outer ring.

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DESIGN CALCULATIONS (STEAM SIDE PRESSURE PARTS)

Sl. No. Component description Page No.

1. SHELL 6

2. DISH 7

3. NOZZLE PIPE 8-12

4. COMPENSATION CALCULATION FOR 13-19

OPENING IN SHELL

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SHELL WALL THICKNESS CALCULATIONS

Regulation: 270

W.P. = [2fE (T-0.762)/(D+T-0.762)]

Where,

T = is thickness of the shell in mm,

D = Maximum internal diameter in mm = 894.4mm,

WP = Working pressure in N/mm2 i. e. 0.98 Mpa = 0.98 N/mm2

f = ( R/2.7 or Et/1.5 ) Which is small, E=R*0.4(Regulation 16d)

= (42.1842/2.7 )*100 or ((42.1842*0.40)/1.5)*100.

= 1562.37 1124.912

= 1124.912 Kg/cm² (smaller of 1562.37 and 1124.912)

E = Efficiency factor for welded shells = 1.00 for full radiographic examinations (ASME Sec VIII,
Division 1, Table UW-12)

Substituting the values in the above formula, we have

0.98 = [2*110.316.0*1.0 (T-0.762)/(894.4+T-0.762)]

0.69 = [(220.6320T-168.121)/(893.638+T)]

616.61+0.69T = 220.632T-168.121

219.942T = 784.931

T = 3.567 mm

Provided Thickness T = 10mm, Hence Safe.

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THICKNESS CALCULATIONS FOR DISHED END SUBJECT TO

PRESSURE ON CONCAVE SIDE

Regulation: 278

W.P = (2*f*(T-C))/(D*K);

Where K is the shape factor defined in Sub Regulation (a) of Regulation

277 & figure 23 D.

C = An additive thickness equivalent to 0.75 mm.

D = Outer Diameter of the Shell.

T = 10 mm.

W.P = (2*1124.912 (10-0.75)/(914.4*1.53)

= 14.875 > Actual Working Pressure (10 Kg/ cm²)

Conclusion: Hence Design Is Safe.

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NOZZLE WALL THICKNESS CALCULATIONS

NOZZLE N5 (3")

Regulation: 573

Minimum thickness of the nozzle "t" in mm

t = 0.04D + 2.5

Where, D = Out side diameter of connection = 88.9mm

= (0.04x88.9) + 2.5

t = 6.056 mm

Considering mill undertolerance of 12.5% we have

t = 6.056/0.875 = 6.92 mm

Provided thickness = 11.13 mm, Hence safe.

NOZZLE N2 (2")

Minimum thickness of the nozzle "t" in mm

t = 0.04D + 2.5

Where, D = Out side diameter of connection = 60.3mm

= (0.04x60.3) + 2.5

t = 4.912 mm

Considering mill undertolerance of 12.5% we have

t = 4.912/0.875 = 5.613 mm

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Provided thickness = 13.462 mm, Hence safe.

NOZZLE N3 (2")

Minimum thickness of the nozzle "t" in mm

t = 0.04D + 2.5

Where, D = Out side diameter of connection = 60.3mm

= (0.04x60.3) + 2.5

t = 4.912 mm

Considering mill undertolerance of 12.5% we have

t = 4.912/0.875 = 5.613 mm

Provided thickness = 13.462 mm, Hence safe.

NOZZLE N4 (2")

Minimum thickness of the nozzle "t" in mm

t = 0.04D + 2.5

Where, D = Out side diameter of connection = 60.3mm

= (0.04x60.3) + 2.5

t = 4.912 mm

Considering mill undertolerance of 12.5% we have

t = 4.912/0.875 = 5.613 mm

Provided thickness = 11.07 mm, Hence safe.

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NOZZLE MH1 (18")

Minimum thickness of the nozzle "t" in mm

t = 0.04D + 2.5

Where, D = Out side diameter of connection = 457.2mm

= (0.04x457.2) + 2.5

t = 20.788 mm

Considering mill undertolerance of 12.5% we have

t = 20.788/0.875 = 23.737 mm

Provided thickness = 25 mm, Hence safe.

NOZZLE LL1 (2")

Minimum thickness of the nozzle "t" in mm

t = 0.04D + 2.5

Where, D = Out side diameter of connection = 60.3mm

= (0.04x60.3) + 2.5

t = 4.912 mm

Considering mill undertolerance of 12.5% we have

t = 4.912/0.875 = 5.613 mm

Provided thickness = 16.764 mm, Hence safe.

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NOZZLE LL2 (2")

Minimum thickness of the nozzle "t" in mm

t = 0.04D + 2.5

Where, D = Out side diameter of connection = 60.3mm

= (0.04x60.3) + 2.5

t = 4.912 mm

Considering mill undertolerance of 12.5% we have

t = 4.912/0.875 = 5.613 mm

Provided thickness = 16.764 mm, Hence safe.

NOZZLE N9 (2")

Minimum thickness of the nozzle "t" in mm

t = 0.04D + 2.5

Where, D = Out side diameter of connection = 60.3mm

= (0.04x60.3) + 2.5

t = 4.912 mm

Considering mill undertolerance of 12.5% we have

t = 4.912/0.875 = 5.613 mm

Provided thickness = 13.462 mm, Hence safe.

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NOZZLE N10 (1.5")

Minimum thickness of the nozzle "t" in mm

t = 0.04D + 2.5

Where, D = Out side diameter of connection = 48.3mm

= (0.04x48.3) + 2.5

t = 4.432 mm

Considering mill undertolerance of 12.5% we have

t = 4.432/0.875 = 5.065 mm

Provided thickness = 16.002 mm, Hence safe.

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COMPENSATION CALCULATIONS

Regulation: 570 & 571

Where the width of opening (Measured in a direction parallel to
longitudinal axis of the boiler) exceeds 2 1/2 times the thickness
of shell plate in mm plus 69.85 mm, compensation shall be provided.

i.e = 2.5 x T + 69.85

Where, T = Thickness of shell in mm = 10mm

= 2.5x10 + 69.85 = 94.85mm

i) Width of opening for 18" Nozzle = 457.2mm, Hence compensation

required.

ii) Width of opening for 3" Nozzle = 88.9mm, Hence compensation

required.

iii) Width of opening for 2" Nozzle = 60.3mm, Hence compensation not
required.

iv) Width of opening for 1.5" Nozzle = 48.3mm, Hence compensation

not required.

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I) Calculations For 18" Nozzle:-

A)Area to be compensated = W x Tmin ………. Eqn. 1

Where, W = Maxm. width of opening cut in shell in mm

Tmin = Thickness of unpierced shell in mm

Tmin = [(D x W.P/2xfxe-W.P) + 0.762]

D = Inner dia of shell in mm = 894.4mm

W.P = Working pressure in N/mm2 = 0.9806N/mm2

e = Efficiency of longitudinal weld joint = 1

C = Constant = 0.762

f = Permissible working stress in N/mm2 = 110.316.0/mm2

Hence Tmin = [((894.4 x 0.9806)/(2x110.316x1 – 0.9806)) + 0.762]

Tmin = [4.06+0.762] = 4.768mm

From Eqn. 1 we have

Area to be compensated = 457.2 x 4.768

= 2179.92 mm2

B) Compensating Area available:-

i) Compensation available due to shell

= (Ts – Tmin)x2(75+Ts); Where Ts= Actual thickness of shell=14mm

= (10-4.768)x2(75+10)

= 889.44 mm2

ii) Portion of branch available for compensation

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C = 2(100+Ts)[Tn-(T1+T2)]S2/S1 ………. Eqn. 2

T2 = Minimum thickness of branch

= (W.P x D/2fe)+0.762
= (0.9806x894.4/2x118.0x1)+0.762

T2 = 4.478mm

Where, Tn=Actual thickness of branch in mm = 25mm

T1=Thickness required to withstand external loading in mm =
3.567mm,unless the loading is known to be such as to
Require a greater thickness and is=0 where there is no
external loading.
S2= Minimum Tensile strength of branch (SA 106 Gr. B) in
N/mm2 = 415 N/mm2
S1= Minimum Tensile strength of compensating pad (SA 516 Gr.
60) in N/mm2 = 485 N/mm2
D= Major ID of the frame =
e= Efficiency of longitudinal weld joint
f= Permissible working stress in N/mm2
W.P = Working pressure in N/mm2 = 0.98 N/mm2

From Eqn. 2 above, we have

C = 2(100+10)[25-(3.567+4.478)]415/485
C = 2(110)[16.955]0.86
C = 3207.886 mm2

iii) Portion of weld available for compensation

D = Total cross sectional area of the internal and

external welding

= Tc x Tc; where Tc = Thickness of compensating

pad in mm = 10mm

= 10 x 10

= 100 mm2
iv) Compensation due to pad plate

Z = 2 x w x Tc x S3/S1 ………. Eqn. 3

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Where,
W = Width of compensation plate in mm = 210 mm
Tc = Thickness of compensating plates in mm = 10 mm
S3 = Minimum tensile strength of compensation plate(SA 516 Gr.
60) in N/mm2 = 485 N/mm2
S1 = Minimum tensile strength of Shell plate (SA 516 Gr. 60)
in N/mm2 = 485 N/mm2

From Eqn. 3 above, we have

Z = 2x210x10x(485/485)

Z = 4200 mm2

Hence, Compensation provided:-

Adding B(i)+B(ii)+B(iii)+B(iv), from above, we have

= 889.44+3207.886+100+4200

= 8397.326 mm2

Compensation required:-

= 2179.92 mm2

Conclusion: Since, compensation provided (8397.326 mm2) is

greater than the compensation required (2179.92 mm2). Hence
Safe.

Conclusion: Hence Design Is Safe.

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II) Calculations For 3" Nozzle:-

A) Area to be compensated = W x Tmin ………. Eqn. 1

Where, W = Maxm. width of opening cut in shell in mm

Tmin = Thickness of unpierced shell in mm

Tmin = [(D x W.P/2xfxe-W.P) + 0.762]

D = Inner dia of shell in mm = 894.4mm

W.P = Working pressure in N/mm2 = 0.9806N/mm2

e = Efficiency of longitudinal weld joint = 1

C = Constant = 0.762

f = Permissible working stress in N/mm2 = 110.316.0/mm2

Hence Tmin = [((894.4 x 0.9806)/(2x110.316x1 – 0.9806)) + 0.762]

Tmin = [4.06+0.762] = 4.768mm

From Eqn. 1 we have

Area to be compensated = 88.9 x 4.768

= 423.875 mm2

C) Compensating Area available:-

i) Compensation available due to shell

= (Ts – Tmin)x2(75+Ts); Where Ts= Actual thickness of shell=10mm

= (10-4.768)x2(75+10)

= 889.44 mm2

ii) Portion of branch available for compensation

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C = 2(100+Ts)[Tn-(T1+T2)]S2/S1 ………. Eqn. 2

T2 = Minimum thickness of branch

= (W.P x D/2fe)+0.762
= (0.9806x894.4/2x118.0x1)+0.762

T2 = 4.478mm

Where, Tn=Actual thickness of branch in mm = 11.13mm

T1=Thickness required to withstand external loading in mm =
3.567mm,unless the loading is known to be such as to
Require a greater thickness and is=0 where there is no
external loading.
S2= Minimum Tensile strength of branch (SA 106 Gr. B) in
N/mm2 = 415 N/mm2
S1= Minimum Tensile strength of compensating pad (SA 516 Gr.
60) in N/mm2 = 485 N/mm2
D= Major ID of the frame =
e= Efficiency of longitudinal weld joint
f= Permissible working stress in N/mm2
W.P = Working pressure in N/mm2 = 0.98 N/mm2

From Eqn. 2 above, we have

C = 2(100+10)[11.13-(3.567+4.478)]415/485
C = 2(110)[3.085]0.86
C = 583.682 mm2

iii) Portion of weld available for compensation

D = Total cross sectional area of the internal and

external welding

= Tc x Tc; where Tc = Thickness of compensating

pad in mm = 10mm

= 10 x 10

= 100 mm2
iv) Compensation due to pad plate

Z = 2 x w x Tc x S3/S1 ………. Eqn. 3

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Where,
W = Width of compensation plate in mm = 45 mm
Tc = Thickness of compensating plates in mm = 10 mm
S3 = Minimum tensile strength of compensation plate(SA 516 Gr.
60) in N/mm2 = 485 N/mm2
S1 = Minimum tensile strength of Shell plate (SA 516 Gr. 60)
in N/mm2 = 485 N/mm2

From Eqn. 3 above, we have

Z = 2x45x10x(485/485)

Z = 900 mm2

Hence, Compensation provided:-

Adding B(i)+B(ii)+B(iii)+B(iv), from above, we have

= 889.44+583.682+100+900

= 2473.122 mm2

Compensation required:-

= 423.875 mm2

Conclusion: Since, compensation provided (2473.122 mm2) is

greater than the compensation required (423.875 mm2). Hence
Safe.

Conclusion: Hence Design Is Safe.

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