Plant, instrumentation & process calculations — in one place
Modular calculators built on transparent, unit-consistent engineering equations. Every estimate shows its formula and assumptions — nothing is a hardcoded lookup.
Logic Simulator
Simulator
freeBuild and simulate control logic from standard SAMA function blocks — summers, selects, limiters, logic gates, timers — chained together with live values.
Analytics and Calculator
Thermal Plant Estimator
Estimate thermal power plant heat rate, efficiency, fuel consumption and coal/gas cost from unit MW rating — free online calculator.
Unit Converter
Convert between engineering units for pressure, flow, temperature, length, and more.
Turbine & Boiler Protection
Reference registry of 117 turbine and boiler protection trip parameters — ETS, TSI, MFT, generator and auxiliary drive trips for USC plants.
Control Loops
Live time-stepped simulation of 13 real power plant control loops: drum level, combustion cross-limiting, steam temperature cascade, and more.
DP → Flow Wizard
Convert differential pressure to mass or volumetric flow for orifice plates, venturis and flow nozzles — step-by-step wizard.
4–20 mA Transmitter
Convert between 4–20 mA signal, percentage of range, and engineering units for any transmitter.
DP & Level
Calculate differential pressure level transmitter range for open and closed (wet-leg/dry-leg) tank applications.
I/P Converter
Convert between 4–20 mA current signal and 3–15 psi pneumatic output for I/P converters.
RTD
Convert between RTD resistance and temperature for Pt100 and other platinum resistance thermometers.
Thermocouple
Convert between thermocouple millivolt output and temperature for Type J, K, T, R, S and other types.
PID Controller
Calculate PID controller gains and simulate step response for process control loop tuning.
Cable & Gland Sizing
Predict instrumentation or power cable overall diameter from core count, size and armouring, and get the matching standard cable gland size.
Motor Protection
Calculate motor thermal overload, overcurrent and earth fault protection settings from motor nameplate FLC and locked-rotor data.
Transformer Protection
Auto-generate transformer overcurrent, earth fault, differential and REF protection settings from nameplate data.
Relay Settings (ABB/Siemens-style)
Calculate I>, I>>, I>>> phase overcurrent and I0>/I0>> earth fault relay pickup settings in primary amps and per-unit — for ABB, Siemens and equivalent numerical relays.
About & Support
About
Who runs Engineering Calculator Hub, what it is for, and the methodology behind its calculators — standards cited, assumptions disclosed, confidence tiers shown.
Reviews & Ratings
Read reviews and ratings from engineers using Engineering Calculator Hub.
Support the Project
Support the development of free engineering calculators for power plant, instrumentation and electrical engineers.
Contact
Have a question, found an issue with a calculator, or need assistance? Get in touch with Engineering Calculator Hub.
Logic Simulator
Simulator
Build and simulate control logic from standard SAMA function blocks — summers, selects, limiters, logic gates, timers — chained together with live values.
Power Plant
Thermal Plant Estimator
Estimate thermal power plant heat rate, efficiency, fuel consumption and coal/gas cost from unit MW rating — free online calculator.
Turbine & Boiler Protection
Reference registry of 117 turbine and boiler protection trip parameters — ETS, TSI, MFT, generator and auxiliary drive trips for USC plants.
Control Loops
Live time-stepped simulation of 13 real power plant control loops: drum level, combustion cross-limiting, steam temperature cascade, and more.
Plant Performance Indicators
Calculate Plant Load Factor, Plant Availability Factor, Auxiliary Power Consumption %, and specific coal/oil consumption from a day’s or shift’s generation and fuel figures.
Boiler Blowdown Rate
Calculate boiler blowdown rate and percentage from steam generation rate and feedwater/boiler water TDS limits.
Cooling Tower Performance
Calculate cooling tower range, approach, thermal effectiveness, and makeup water demand (evaporation, drift, blowdown) against ambient wet-bulb temperature.
Feedwater Heater (TTD & DCA)
Calculate Terminal Temperature Difference and Drain Cooler Approach for a feedwater heater from extraction pressure and process temperatures.
DP Flow — ISO 5167
Steam, water and gas flow from differential pressure using full ISO 5167: Reader-Harris/Gallagher discharge coefficient, IF97 steam properties, thermal expansion, limits of use and uncertainty.
Turbine Stage Flow (Stodola)
Steam flow through a turbine stage group from inlet and exit pressures with the Stodola ellipse law and exact IAPWS-IF97 specific volume.
FW Heater Extraction Flow
Extraction steam flow of a closed feedwater heater from an exact IF97 energy balance, with cascaded drain and heat-loss factor; also TTD and DCA.
Desuperheater Spray Flow
Spray-water flow to cool superheated steam to a target temperature from an exact IAPWS-IF97 mass and energy balance, with superheat-margin check.
Condenser Cooling-Water Flow
Cooling-water flow for a steam surface condenser from exhaust heat load using IF97 enthalpies, with TTD, LMTD and water-to-steam ratio.
Tracer Dilution Flow
Primary flow measurement by tracer dilution: constant-rate injection with GUM uncertainty and slug injection by trapezoid integration.
Duct Flow — Pitot Traverse
Flue-gas and air flow in ducts from a multi-point pitot traverse: gas density from Orsat and moisture, actual, standard and normal flow.
Ultrasonic Transit-Time Flow
Flow and speed of sound from upstream and downstream ultrasonic transit times, with an IAPWS-IF97 water sound-speed plausibility check.
DM Plant Resin Regeneration
Calculate cation/softener resin bed run length and throughput before regeneration from exchange capacity and raw water hardness.
Coal & Fuel Handling
GCV to NCV conversion, daily coal requirement, and stock days-of-cover calculators for thermal power plant fuel planning.
Combustion Emissions (CO₂/SO₂)
Calculate stoichiometric CO2 and SO2 emission rate from fuel ultimate analysis (carbon and sulfur content) and firing rate.
Instrumentation
DP → Flow Wizard
Convert differential pressure to mass or volumetric flow for orifice plates, venturis and flow nozzles — step-by-step wizard.
DP → Flow (Calibrated)
Calculate steam, water, or air flow from a DP transmitter’s calibrated range alone — real IAPWS-IF97 steam tables, no pipe or orifice diameter required.
Steam Properties
Calculate real steam density and specific volume from pressure and temperature using IAPWS-IF97 — not an ideal-gas approximation.
4–20 mA Transmitter
Convert between 4–20 mA signal, percentage of range, and engineering units for any transmitter.
DP & Level
Calculate differential pressure level transmitter range for open and closed (wet-leg/dry-leg) tank applications.
Orifice Plate
Size an orifice plate flow element and calculate discharge coefficient, beta ratio and differential pressure.
Control Valve Sizing
Calculate control valve flow coefficient (Cv) for liquid and gas service.
I/P Converter
Convert between 4–20 mA current signal and 3–15 psi pneumatic output for I/P converters.
RTD
Convert between RTD resistance and temperature for Pt100 and other platinum resistance thermometers.
Thermocouple
Convert between thermocouple millivolt output and temperature for Type J, K, T, R, S and other types.
PID Controller
Calculate PID controller gains and simulate step response for process control loop tuning.
Loop Uncertainty
Calculate total measurement loop uncertainty by combining individual instrument accuracy contributions.
Valve Cavitation
Check a control valve for cavitation and flashing risk from upstream/downstream pressure and vapor pressure.
Cable & Gland Sizing
Predict instrumentation or power cable overall diameter from core count, size and armouring, and get the matching standard cable gland size.
SIL / PFDavg Verification
Calculate PFDavg and the achievable SIL for a safety instrumented function from subsystem failure rates, architecture, and proof-test interval.
Pressure Gauge Range Selection
Select a standard pressure gauge range so normal operating pressure falls in the recommended 25-75% of full scale.
Interface Level (Two-Liquid DP)
Calculate DP transmitter calibration values and current interface level for a two-liquid (e.g. oil-water) interface measurement.
4–20 mA Loop Power Budget
Check whether a 4-20mA loop’s supply voltage covers the transmitter’s minimum voltage plus all series wiring and load resistances at 20mA.
Electrical
Short Circuit / Fault
Calculate three-phase and single-phase-to-ground short circuit fault current per IEC 60909 — free online electrical fault calculator.
IDMT Relay Curves
Calculate IDMT relay operating time for Standard/Very/Extremely Inverse curves per IEC 60255 and IEEE C37.112 — free relay curve calculator.
Relay Settings (ABB/Siemens-style)
Calculate I>, I>>, I>>> phase overcurrent and I0>/I0>> earth fault relay pickup settings in primary amps and per-unit — for ABB, Siemens and equivalent numerical relays.
CT Sizing & Burden
Size current transformers for protection and metering — knee-point voltage, burden, and accuracy class calculations.
Transformer Protection
Auto-generate transformer overcurrent, earth fault, differential and REF protection settings from nameplate data.
Motor Protection
Calculate motor thermal overload, overcurrent and earth fault protection settings from motor nameplate FLC and locked-rotor data.
LSIG Breaker Settings
Calculate Long-time, Short-time, Instantaneous and Ground fault (LSIG) circuit breaker trip unit settings.
Relay Coordination
Check time-current coordination and discrimination margin between upstream and downstream protection relays.
Cable Sizing & Volt Drop
Size power cables for current-carrying capacity and voltage drop, with derating for grouping, temperature and installation method.
Short-Circuit Withstand
Calculate minimum cable cross-sectional area to withstand short-circuit fault current using the adiabatic equation.
Motor Starting Dip
Estimate voltage dip during DOL motor starting and its impact on the supply network and other connected loads.
Power Factor Correction
Calculate the capacitor bank kVAR needed to correct power factor from an existing value to a target value.
Battery / DC Sizing
Size a substation DC battery bank for control, protection and emergency load duty cycles.
Transformer Loading
Calculate transformer iron loss, copper loss, efficiency and loading at any load point from nameplate data.
Grounding Grid Design
Calculate substation grounding grid resistance and screen ground potential rise against IEEE 80 tolerable touch voltage.
NGR Sizing
Size a neutral grounding resistor for a resistance-grounded MV system from system voltage and target fault current.
Generator Sizing
Size a standby generator for connected running load and the DOL starting surge of the largest motor.
Voltage Unbalance & Derating
Calculate three-phase voltage unbalance and the resulting motor derating factor per NEMA MG-1.
Transformer Inrush
Estimate transformer energization inrush current and decay time to check protection relay settings.
Process & Mechanical
Pipe Pressure Drop
Calculate pipe friction pressure drop, velocity and flow regime using the Darcy-Weisbach equation with Swamee-Jain friction factor.
Pipe Wall Thickness (ASME B31.3)
Calculate minimum required process piping wall thickness per ASME B31.3, with corrosion allowance and mill tolerance.
Relief Valve Sizing (API 520)
Preliminary relief valve orifice area sizing for gas/vapor and liquid service per API 520 Part I core equations.
Pump NPSH & Affinity Laws
Calculate NPSH available, check margin against NPSH required, and apply pump affinity laws for a speed change.
Pump Specific Speed
Calculate centrifugal pump specific speed (Ns) and get an impeller type (radial/mixed/axial) selection guide.
Fan / Blower Laws & Power
Apply fan affinity laws for a speed change and calculate fan shaft power from flow, pressure rise and efficiency.
Compressor Power (Adiabatic)
Calculate ideal-gas adiabatic compression work, discharge temperature, and shaft power from suction/discharge pressure and mass flow.
Bearing L10 Life (ISO 281)
Calculate rolling element bearing L10 life in revolutions and hours from dynamic load rating and equivalent load.
Heat Exchanger LMTD & Area
Calculate log mean temperature difference (LMTD) and required heat transfer area for a heat exchanger from its four terminal temperatures.
Horizontal Tank Volume (Dip Chart)
Calculate partial and total volume of a horizontal cylindrical tank from diameter, length and liquid fill depth — exact circular-segment geometry.
Vertical Tank Volume
Calculate vertical storage tank volume from diameter and cylinder height, with optional hemispherical or conical heads.
Pressure Vessel Wall Thickness (ASME VIII)
Calculate minimum shell thickness for a thin-wall pressure vessel per ASME Section VIII Division 1, UG-27.
Pipe Insulation Heat Loss
Calculate steady-state heat loss through cylindrical pipe or vessel insulation from thickness, conductivity and surface conditions.
Thermal (Linear) Expansion
Calculate linear thermal expansion of pipe or equipment from length, material coefficient, and temperature change.
Gas Compression Work
Calculate ideal-gas isothermal and adiabatic compression work and power for compressor sizing estimates.
Bolt Torque & Preload
Calculate bolt tightening torque from target clamp force and nut factor (T=K×D×F), or clamp force from ISO 898-1 bolt grade and ISO 724 stress area.
Gear Ratio & Speed/Torque
Calculate gear ratio, output speed and output torque from tooth counts and mesh efficiency.
Belt / Pulley Speed Ratio
Calculate driven pulley speed and belt speed from pulley diameters and driving speed.
HVAC & Refrigeration
Sensible Heat Load
Calculate HVAC sensible cooling or heating load from airflow and temperature difference, in imperial or metric units.
Duct Sizing (Velocity Method)
Calculate required duct cross-sectional area and round-duct diameter from airflow and design velocity.
Refrigeration Tons ⇌ kW/BTU
Convert refrigeration capacity between tons, kW and BTU/hr using the standard 1 ton = 3.5168 kW definition.
Civil Engineering
Beam Analysis (Deflection, Moment, Shear)
Calculate beam deflection, maximum bending moment and shear force for simply-supported and cantilever beams, point load or UDL.
Section Properties (I, S)
Calculate moment of inertia and section modulus for rectangular, circular, and hollow-circular sections.
Column Buckling (Euler)
Calculate Euler critical buckling load and slenderness ratio for a column with any standard end-support condition.
Combined Axial & Bending Stress
Calculate combined axial and bending stress on a structural section from axial load, bending moment, area and section modulus.
Steel Weight (Bar/Plate/Pipe)
Calculate the weight of round bar, flat plate, or pipe steel sections from dimensions and density.
Concrete Volume & Weight
Calculate concrete volume and weight for slabs, columns, and footings from dimensions and unit weight.
Water-Cement Ratio
Calculate water-cement ratio, or solve for water or cement quantity from a target ratio.
Concrete Nominal Mix (IS 456)
Calculate cement, sand and aggregate quantities for IS 456:2000 nominal concrete mixes M5 to M20.
Rebar Weight & Quantity
Calculate reinforcement bar weight from diameter and length, with the familiar d²/162 site rule of thumb shown alongside.
Earth Pressure (Rankine)
Calculate active and passive earth pressure on a retaining wall using Rankine theory, with optional cohesion.
Soil Phase & Effective Stress
Calculate void ratio, porosity, and effective (Terzaghi) stress from total stress and pore water pressure.
Manning's Open Channel Flow
Calculate open channel flow velocity and discharge using Manning’s equation for rectangular and trapezoidal channels.
Weir Flow (Rectangular)
Calculate discharge over a rectangular sharp-crested weir using the Francis formula.
Land Area & Earthwork Volume
Calculate triangle and trapezoid land area, slope grade, and cut/fill earthwork volume by the average end area method.
Reference
Unit Converter
Convert between engineering units for pressure, flow, temperature, length, and more.
Formula Library
Searchable reference library of engineering formulas for instrumentation, process, and electrical calculations.
KKS Code Reference
Kraftwerk-Kennzeichensystem (KKS) tag-building methodology and a click-down Area → System → Subsystem explorer, plus signal suffix codes (XB, XG, XH, XQ...) — for a supercritical coal-fired unit.
ISA-5.1 Tag Reference
Complete ANSI/ISA-5.1 instrument identification letter table and common tag combinations (PT, FIC, PSHH...), with a direct comparison to KKS — free searchable reference.
Calculation History
Your saved calculation history for this device.
Support the Project
Support the development of free engineering calculators for power plant, instrumentation and electrical engineers.
Reviews & Ratings
Read reviews and ratings from engineers using Engineering Calculator Hub.
Engineering Guides
Plain-language engineering guides for power plant and instrumentation engineers: ISO 5167 flow measurement, IAPWS-IF97 steam tables, feedwater heaters, SAMA diagrams, heat rate and condensers.
About
Who runs Engineering Calculator Hub, what it is for, and the methodology behind its calculators — standards cited, assumptions disclosed, confidence tiers shown.
Contact
Have a question, found an issue with a calculator, or need assistance? Get in touch with Engineering Calculator Hub.
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Terms of use and disclaimer for Engineering Calculator Hub: informational use only, no warranty, acceptable use and third-party services.