THERMAX LTD.

IBR CALCULATIONS
PUNE 411 019
INTEGRAL ECONOMISER
DESIGN CODE :- IBR 1950 & IT'S LATEST AMENDMENTS.
MODEL :- BDF-80/1-S
DRAWING N0. :-
ECONOMISER COILS MODULE I & II PL4-2PD-069524
PREPARED BY CHECKED BY APPROVED BY DATE
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THERMAX LTD. IBR CALCULATIONS
PUNE 411 019
DESIGN PRESSURE :- 44.50
CALCULATION PRESSURE :- 48.00 KGF/CM^2 (G)
DESIGN TEMPERATURE :- 191 deg. C
DESIGN TEMPERATURE :- 300 deg. C
(FOR PERMISSIBLE STRENGTH CALCULATION)
MATERIAL SPECIFICATION :
TUBE MATERIAL :- SA 210 Gr. "A1"
MIN. TENSILE STRENGTH @ ROOM TEMPERATURE (R20) = 4218.52 KGF/CM^2
YIELD STRENGTH CALCULATION :
YIELD STRENGTH @ 300 DEG.C ( 572 )DEG. F = 1946.14 KGF/CM^2
[1996.77 - (((1996.77-1926.46)/50) X (612-600))]
WHERE ,
YIELD STRENGTH @ 500 DEG. F ( 260 )DEG. C = 1996.77 KGF/CM^2
YIELD STRENGTH @ 600 DEG. F ( 316 )DEG. C = 1926.46 KGF/CM^2
[ AS PER ASME SECT.II, PART `D' TABLE Y-1 ]
PERMISSIBLE STRENGTH (R20/2.7) OR (Et/1.5) WHICHEVER IS LESS : (f1) : 1297.43 KGF/CM^2
MAXIMUM ALLOWABLE STRESS CALCULATION :
MAX. ALLOW. STRESS 300 DEG.C ( 572 )DEG. F = 1202.28 KGF/CM^2
[1202.28-(((1202.28-1202.28)/50) X (612-600))]
WHERE ,
MAX. ALLOW. STRESS 500 DEG. F ( 260 )DEG. C = 1202.28 KGF/CM^2
MAX. ALLOW. STRESS 600 DEG. F ( 316 )DEG. C = 1202.28 KGF/CM^2
[ AS PER ASME SECT.II, PART `D' TABLE 1A ]
MAXIMUM ALLOWABLE STRESS @ TEMP'RE 300 DEG.C:(f2): 1202.28 KGF/CM^2
PERMISSIBLE STRSS TO BE USED FOR COMPUTATION,
LOWER OF `f1' & `f2' = 1202.28 KGF/CM^2
PREPARED BY CHECKED BY APPROVED BY DATE
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THERMAX LTD. IBR CALCULATIONS
PUNE 411 019
MIN. REQUIRED THICKNESS OF TUBE, t min = (PxD)/(2xfxE+P)+C , FROM IBR 338
WHERE, CALCULATION PRESSURE : : P : 48.00 KGF/CM^2 (G)
EXTERNAL DIAMETER : D : IN MM
PROVIDED THICKNESS OF TUBES : T : IN MM
AVAILABLE THICKNESS (NO NEGATIVE TOLERANCE) : t : IN MM
PERMISSIBLE STRESS FOR STUB MATERIAL : f : IN KG/CM^2
MINIMUM LIGAMENT EFFICIENCY : : E : 1.00
COROSSION ALLOWANCE : : C : 0.75
THEREFORE,
O.D. THICKNESS THICKNESS THICKNESS f TOLERENCE
CHOSEN AVAILABLE REQD. (t min) ON THK.
38.1 3.66 3.66 1.50 1202.28 NIL
HENCE THICKNESS AVAILABLE IS GREATER THAN REQUIRED THICKNESS. SO, DESIGN IS SAFE

AS PER IBR CLAUSE 338 (C) (II) (a), PERMISSIBLE REDUCTION IN THK. OF TUBE AT ANY LOCATION
AROUND THE BEND EXTRADOS, IN PERCENT; BELOW THE CALCULATED MINIMUM PERMISSIBLE
DESIGN THICKNESS OF STRAIGHT TUBE, SHALL NOT EXCEED THE VALUE CALCULATED BY THE
FOLLOWING FORMULA,
PERMISSIBLE REDUCTION IN THK. DUE TO BENDING OF TUBES :- Ty = 100 / (4R/D + 2)
BENDING RADIUS :- : R : IN MM
OUTSIDE DIAMETER OF TUBE :- : D : IN MM
PERMISSIBLE MINIMUM THK. OF TUBE AROUND BEND EXTRADOS = tmin x [(100-Ty)/100].
WHERE,
"tmin" IS THE CALCULATED MINIMUM PERMISSIBLE DESIGN THK. OF STRAIGHT TUBE
TUBE OD BEND CAL. MIN.
RADIUS THK. OF TUBE
`D' `R' `tmin'
38.1 50 1.50
HOWEVER, AS PER IBR CLAUSE 338 (C) (II) , MAXIMUM PERMISSIBLE AMOUNT OF THINNING AT
ANY LOCATION AROUND THE BEND EXTRADOS ON COLD FORMED BENDS WITHOUT ANY HEAT
TREATMENT, IS 25% OF THE ACTUAL THICKNESS OF STRAIGHT TUBE.
TUBE OD ACTUAL
"mm" TUBE THK.
38.1 3.66
THEREFORE, MINIMUM PERMISSIBLE THICKNESS AFTER BENDING WITHOUT ANY SUBSEQUENT
HEAT TREATMENT IS THE HIGHER OF THE TWO VALUES CALCULATED ABOVE AS PER IBR
CLAUSES 338 (C) (II) (a) & 338 (C) (II) .
TUBE OD ACTUAL
"mm" TUBE THK.
38.1 3.66
PREPARED BY CHECKED BY APPROVED BY DATE
BVK BVK BVK 7/7/2014
13.79 1.29
WITHOUT HEAT TREATMENT IN "mm"
2.75
MINIMUM PERMISSIBLE THK. AROUND BEND EXTRADOS AS PER
IBR CLAUSE 338 (C) (II) WITHOUT HEAT TREATMENT IN "mm"
2.75
MINIMUM PERMISSIBLE THK. AROUND BEND EXTRADOS
TUBE THK. IN % AROUND BEND EXTRADOS
MATERIAL
SA 210, GRADE "A1"
PER. REDN. IN PERMISSIBLE MINIMUM THK.
"Ty" in "%" AS PER IBR 338 (C) (II) (a)
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