QN E121.00003 000 PDF

CONTRACT NO.
: 705077
PROJECT TITLE:-
QAFCO-3 SHUTDOWN 2019
PROJECT NO: A3-17
DOCUMENT TITLE:
ADEQUACY CHECK REPORT FOR PRIMARY REFORMER STACK
DESIGN CONSULTANT: MAIN CONTRACTOR:
0 14/03/19 ISSUED FOR COMMENTS HT ALS KM
Prepared Checked Approved Approved

Rev Date Description
by by by Qcon by QAFCO
Document No. QN-E121.00003-000 Sht. 1 of

33 Rev. 0
ADEQUACY CHECK REPORT FOR
PRIMARY REFORMER STACK
CONTENTS
U U Page
ABBREVIATION......................................................................................................... 3
1- General ................................................................................................................. 4
1.1- Introduction
1.2- Design Methodology/Sketch
1.3- Input References
1.4- Codes and standard
1.5- Software
1.6- Input Data
2- Design Load............................................................................................................... 9
2.1- Dead and Live Load
2.2- Wind Load calculation
2.3- Vortex shedding (Dynamic effect)
2.4- Earthquake Load
3- Design of Stack Shell............................................................................................ 14
3.1- Basic Condition for Determining Allowable Stress
3.2- Longitudinal Compression (Case#1)
3.3- Longitudinal Compression and Bending Combination (Case#2)
3.4- Circumferential Stress (Case#3)
3.5- Combined Longitudinal and Circumferential Compressive Stress (Case#4)
3.6- Circumferential Compression in Stiffener
3.7- Ovalling Check
4- Design Of Stack Base Part ............................................................................................. 19
4.1- Anchor chair calculation
5- Deflection check.......................................................................................................... 25
6- Breeching Opening Stiffener Design............................................................................ 26
7- Platform cleat to Shell connection check................................................................... 28
8- Conclusion.................................................................................................................. 33
Doc No: QN-E121.00003-000 Rev.0 Page 2 of 33

ABBREVIATION:
QAFCO - Qatar Fertilizer Company

QCS - Qatar Construction Standards
ASME - American Society of Mechanical Engineers
ASCE - American Society of Civil Engineers
UBC - Uniform Building Code
AISC - American Institute of Steel Construction

1. GENERAL
13B
1.1 Introduction:
This report document contains the structural verification for the Primary reformer stack
that is installed in Qafco, Qatar. The stack is 34.8 meters in height, and external
diameter is 3460 mm from the base to the top. Wall thickness is 10 mm from base to
the elevation of 9195mm, 8mm for another 9550 mm meters and 6 mm for the 16000
mm.
Lining 50 mm, LWI 20 Castable 1204 degree C. Density: 930 kg/m3 on C.S chain link
reinforcement, inside of the shell.
There are 5 existing platforms located at an elevation of 5200, 11200, 17200, 23200 and
28475 mm, for maintenance and inspection purpose. Opening for gas inlet is provided
near the base of the stack, and the opening size is 3060 mm high and 2240 mm wide.
Now, a new platform will be constructed in the top section of the stack, located below
the nozzle elevation 27500 mm, shell thickness of 6 mm. The objective of this report is
to include this additional platform load in the stack design calculation and check if the
stack is adequately strengthened.
1.2 Design Methodology and Sketch:

The basic design code used for designing this stack is ASME STS-1-2006, “Steel Stacks”.
The design procedure followed in this report is briefly explained below. The structural
integrity and safety of the stack, under different loading conditions and failure scenarios
are taken into consideration.
1. The applicable loadings as per clause 4.3 are determined. These loadings majorly
include:
a. Dead Load
The dead load shall consist of weight of the steel stack, stiffeners, flanges, and
permanent accessories such as ladders, platforms.
b. Live load
The platform walkway area is calculated and live load is uniformly distributed over
this area.
c. Wind Load /Seismic load
Seismic loads are calculated in this report, but it has lesser effect compared to wind
action. Therefore, Wind pressure is the governing factor in this design.
2. Shell Strength check:

In operating condition, the stack structure (ie. cylindrical body and stiffeners) are
subjected to compressive and bending stresses in longitudinal and circumferential
direction, under various loading condition. As per clause 4.4.1 to 4.4.5, the design will
be checked for different load cases and the stresses are determined. Allowable stresses
are determined as per clause 4.4.

3. Dynamic effects due to wind:

The steel stack is a light weight, flexible structure with low inherent structural damping,
therefore the effects of dynamic effects of wind is considered. The stack will be checked
for vortex shedding and ovalling resonance. If the critical velocity exceeds the design
velocity, then the dynamic effects can be safely ignored.
4. Anchor chair calculation:

The Base plate thickness is calculated by assuming the baseplate is in compression
state. The anchor bolts are sized to resist the wind force/Moment. Pressure vessel
design handbook by Bednar forms the basis of this calculation. CodeCalc software is
used to perform this design.
5. Deflection check:
Pressure vessel Handbook by Moss, Procedure4.4 “deflection in towers” is used to
check the deflection in the stack. Deflection due to Uniform Vessel, Non-uniform load
case is considered.
6. Structural shell discontinuities/ Shell opening for Gas inlet:

a. The sides of the breeching opening act as columns or tension members to
withstand the reaction loads coming on the horizontal girder above and below.
The strength of the plane cut through the opening at any elevation shall be
adequate to withstand the applied load.
b. The top and bottom of breeching opening shall be adequately reinforced to
transfer the discontinuous of shell stress back to the full circumference of the
shell. The required section modulus is calculated and checked with the actual
section property.
7. Platform to Shell Connection:

Local stresses are developed at the Platform–to-shell Connection region. The maximum
reaction loads (taken from the platform structure design report) are applied at this
junction and the WRC analysis is performed using Codecalc software. Adequate
reinforcement will be provided to minimize the stresses.

Sketch
U
(Reference drawing: Primary Reformer Steel arrangement Stack, QA-UD-T121.00019-001)

1.3 Input References:
a. Primary stack assembly drawing ,” QA-UD-T121.00019-001

b. Anchor bolt detail drawing, QA-UD-T121.00019-003
c. General Requirements to Civil works and structures, CEMS-PT-S700.01004
d. Access Platform and detail drawing, QN-D121.00001-000
1.4 Codes and Standard:
The following Codes and Standards are referred:

a. ASME Steel Stacks, STS-1-2006
b. Qafco General Specification for civil works and structures
c. ASCE 7-10, For Wind loads
d. UBC 97 for Seismic loads
e. AISC Manual of Steel Construction (Allowable Stress Design, 9th Edition)
f. Structural Engineering Handbook, Gaylord & Gaylord : Section 30: Chimneys
1.5 Softwares used:
- CodeCalc for Anchor chair calculation.

- CodeCalc Platform to Shell WRC analysis

1.6 Input Data:
Stack Geometric Data

Stack Outside Diameter : 3460 mm
Stack Height : 34800 mm
Design Condition
Wind Data: (Reference document: CEMS-PT-S700.01004)
U
Basic Wind Speed : 33.4 m/s EXPOSURE C

Wind code : ASCE 7-10
Seismic Data: (Reference document: CEMS-PT-S700.01004)

U
Seismic Category : ZONE 1 Z=0.075 (Qatar region)

Site Class : D
Risk category : III
Dead and Live load: (Reference document: CEMS-PT-S700.01004)

U
Dead Load includes Stack wall, platforms and ladders, stiffeners. Miscellaneous weight of
10% will be considered to the dead weight calculated.
Live load, uniformly distributed over the platform region: 5kN/m2
Lining 50 mm, LWI 20 Castable 1204 degree C. Density: 930 kg/m3 on C.S chain link
reinforcement.
Material : SA 36/S275 JR ( For Shell Plates)

EN 8.8 (For Anchor bolts)
Corrosion Allowance :0 mm
Internal Lining : 50 mm
Yield Strength @design temperature : 275 N/mm2
Elasticity Modulus : 190.95 KN/mm2
Minimum Shell Thickness : 6 mm

2.DESIGN LOADS
2.1 Dead and Live Load

Table-1 Dead and Live Load
No. Hz(n-1) Hz(n) Hi (mm) Ti (mm) Di (mm) Wsi (kN) Wli (kN) Wa (kN) Cumulative
weight
(mm) (mm)
(kN)
1 0 1720 1720 10 3440 14.6 14.6 415
2 1720 4220 2500 10 3440 21.2 21.2 400
3 4220 6720 2500 10 3440 21.2 10 31.2 379
4 6720 9220 2500 10 3440 21.2 21.2 348
5 9220 11720 2500 8 3444 17.0 10 27.0 327
6 11720 14220 2500 8 3444 17.0 17.0 300
7 14220 16720 2500 8 3444 17.0 17.0 283
8 16720 18800 2080 8 3444 14.1 10 24.1 266
9 18800 21300 2500 6 3448 12.8 12.8 242
10 21300 23800 2500 6 3448 12.8 10 22.8 229
11 23800 26300 2500 6 3448 12.8 12.8 206
12 26300 28800 2500 6 3448 12.8 150 162.8 193
13 28800 31300 2500 6 3448 12.8 12.8 31
14 31300 33800 2500 6 3448 12.8 12.8 18
15 33800 34800 1000 6 3448 5.1 5.1 5
Where:
No.: Section No.
Hz: Height above ground
Hi: Height of ith section
Ti: Un-corroded shell thickness of i section
Di: Stack inside diameter
Total
Wsi : Stack shell weight 225 kN
Wli : Live loads (5.0 kN/m²,Platform/Ladder ( 4 nos)) 190 kN
Wa : Wsi +Wli 415 kN
Wco: Lining and chain reinforcement weight 55 kN
Wt : Total load 495 kN
( including 10% additional load on Dead weight)

2.2 WIND LOAD CALCULATION

0B
Design Wind Load

1B
2B (In accordance with Document: CEMS-PT-S700.01004, ASCE 7, Section6.0, Wind loads)
qz=0.613 (V^2).I.Kzt.Kz .Kd (Eq.6-15)
Where:
qz: Wind pressure (N/m2)

Kzt : Topographic factor = 1.0
Kd : Wind directionality factor (Table 6-4, for Chimneys, Round): 0.95
Kz : Velocity pressure exposure coefficient(Table 6.3): 1.3(max)
Iw: Importance factor (Table 6.1, for category III): 1.15
Exposure C
V : basic wind speed based on 3sec gust velocity: 33.4 mps
Force due to wind:

F = qz * G* Cf * Af (Eq.6-25)
Where,
qz: Velocity Pressure at height ‘h’
G: Gust-effect factor = 0.85 (sec 6.5.8.1)
Cf: Shape factor = 0.83 (Round chimney, H/D>7, figure 6-19)
Af: Projected Area Normal to the wind = Do*Hi*1.2
(Additional factor of 1.2 is multiplied to take into account the platform and ladder, Stiffener
projections)
Do: Outside diameter of Stack

Hi: Height of the section

Table-2 WIND LOAD DUE TO ALONG WIND

No Hz(n-1) Hz(n) Hi Do Ti Kz q(z) Fx Vtotal M total
(mm) (mm) (mm) (mm) (mm) (㎏/m2) (kN) (kN) (kN-m)

1 0 1720 1720 3460 10 0.85 64.8 3.20 84.77 1525.9
2 1720 4220 2500 3460 10 0.85 64.8 4.65 81.57 1346.0
3 4220 6720 2500 3460 10 0.94 71.7 5.14 76.92 1153.9
4 6720 9220 2500 3460 10 0.98 74.7 5.36 71.78 969.0
5 9220 11720 2500 3460 8 1.04 79.3 5.69 66.42 797.0
6 11720 14220 2500 3460 8 1.09 83.1 5.96 60.73 637.7
7 14220 16720 2500 3460 8 1.13 86.1 6.18 54.77 492.9
8 16720 18800 2080 3460 8 1.13 86.1 5.14 48.58 364.4
9 18800 21300 2500 3460 6 1.17 89.2 6.40 43.44 260.6
10 21300 23800 2500 3460 6 1.21 92.2 6.62 37.04 166.7
11 23800 26300 2500 3460 6 1.24 94.5 6.78 30.42 91.3
12 26300 28800 2500 3460 6 1.26 96.1 6.89 23.63 42.5
13 28800 31300 2500 3460 6 1.26 96.1 6.89 16.74 58.6
14 31300 33800 2500 3460 6 1.28 97.6 7.00 9.85 20.9
15 33800 34800 1000 3460 6 1.3 99.1 2.84 2.84 2.1
where :
No.: section No.
Hz : height above ground
Hi : height of i section qz=Wind pressure
Ti : uncorroded shell thickness Fx : force by wind on the shell section
th
of i section Vtotal = Total Shear force by wind
Do : stack outside diameter=2600mm Mtotal = Total moment by wind
c.o.g: center of force is considered at 0.6h, which is safe above the actual point.
Wind Loads:
Base Shear: 84.77 kN
Base Moment: 1525.9 kN-m

2.3 Vortex Shedding

14B
Stack Natural Frequency in First Mode (in accordance with Gaylord Gaylord’s Handbook)
f1 = 3.9*D/H²*sqrt(E/Ws) : natural frequency (Hz) 2.8 Hz
Where:
D : diameter (in) 136.2 in= 3460 (mm)
H : height of stack 1370 in= 34800 (mm)
E: modulus of elasticity (psi) 27740000 psi= 1950315
(kg/cm2)
3
WS: unit weight of shell (lb/in3 ) 0.284 lb/in³= 0.00785(kg/cm )
Vortex Shedding (in accordance with ASME STS-1)
Vc = f1*D/St : critical wind speed (ft/sec) 158.76 ft/sec 48.4 (m/s)
where :
f1 : natural frequency in first mode (Hz) 2.8 Hz
D : stack diameter (ft) 11.4 ft= 3460 (mm)

St = strouhal number 0.2
= 0.2 when A/D ≥15 or single stack
= 0.16+(A/D-3)/300 when A/D < 15

A : center to center spacing for interference effects (ft) N/A
α'
Vzcr = b'(Zcr/33) *22*Vr/15 : mean hourly wind speed at Zcr 89.9 ft/sec = 27.4 (m/s)
Where:
b' : terrain exposure constants 0.65 FOR EXPOSURE C

α' : terrain exposure constants 0.154 FOR EXPOSURE C
Zcr: the elevation to 5/6 stack height (ft) 95.14 ft=29000(mm)
Vr = V*I0.5 : the reference design speed (mph) 80.1 mph= 35.8(m/s)
Vortex shedding occurrence evaluation
※ Vc= 48.4 m/sec > 1.2*Vzcr =32.88 m/sec

Since Vc > 1.2Vzcr , the response Vortex shedding can be ignored.
15BU

2.4 Earthquake Load

16B
Seismic Base Shear (in accordance with I.B.C 2009,UBC 1997)

V = C*W = 0.10*W =40 kN
where :
C= 0.1
C=Cv*I/(RT) 0.099
Cmax=2.5CaI/R 0.103
Cmin=0.11Ca I 0.013
Seismic zone : 1
Z : seismic zone factor (Table 16-I) 0.075
Cv : seismic coefficient given in table 16-R of UBC 0.18
Soil profile type : according to the contract spec Sd
R : behavior coefficient of building (Table 16-P-R U.B.C 97) 2.9
T : fundamental period of building =h^(3/4)*0.0488 0.69
I : seismic importance factor (Table 16-K) 1.0
Ca= seismic coefficient according to (Table 16-Q) 0.12

W : total weight = 330 kN ( Live load of 25% is considered)
Base Shear: 40.0kN
Base Moment: 820.0 kN-m
Note: Since, the Seismic load is lesser than the Wind loads, the governing case for the stack design
will be Wind case.

3. DESIGN OF STACK SHELL (in accordance with ASME STS-1)
Stack structural integrity and stability is checked for the various design loads calculated in the
earlier section. The actual and allowable stresses for the different load cases are determined as
per ASME STS-1 (clause 4.4). The calculation shown below verifies that the requirements of the
code are met and the stresses are well within the permissible limits.
3.1 Basic Condition for determining allowable stress
t/D ≤ (10*FY)/E,
6B
Since, this requirement is met; the stack must satisfy following four load cases:
7B
3.2 CASE 1 : Longitudinal Compression
P/A ≤ Scl where,
Scl = E*t*Y/(4*D*F.S) when t/D ≤ 2.8*FY/E
= FY(1-0.3*KS)*Y/F.S when 2.8*FY/E < t/D ≤ 10*FY/E
Y = 1 when Le/r ≤ 60 and FY ≤ 50ksi
= 21,600/(18,000+(Le/r)2) when Le/r > 60 and Fy ≤ 50ksi

2
8B KS = ((10*FY/E-t/D)/(7.2*FY/E))
3.3 CASE 2 : Longitudinal Compression and Bending Combination
P/A + M*D/(2*ISECTION) ≤ Sbl
3.4 CASE 3 : Circumferential Stress

3B
9B fc = qz*D/(288*t) (psi)
The circumferential stress shall be less than the allowable stress, Scc
fc ≤ Scc
where, Scc = 1.3*E*K*(t/D)1.5/(F.S*ls /D)
when 0≤ t/D ≤ 2.8*FY/E, K = 1
when 2.8*FY/E < t/D ≤ 10*FY/E,

K = 1.68*FY*D/(E*t)+0.465-0.0232*E*t/(FY*D)
3.5 CASE 4 : Combined Longitudinal and Circumferential Compressive Stress
(P/A + M*D/(2*ISECTION))/Sbl+(fc/SCC)2 ≤ 1.0

3.6 Circumferential Compression in Stiffener

4B
The size of stiffeners shall satisfy the following three requirements:

10B
The moment of inertia of plate section and stiffener

1B
IS+P 3= q*lS*D *F.S/(3456*E)

The area of plate section and stiffener
AS+P = q*lS*D*F.S/(288*Sccs)
Sccs = 0.25*E*I/(F.S*R2)
The section modulus of plate section and stiffener

12B
SS+P2 = qz*D *ls*F.S/(1830*Fy)
where,
Fy = Yield strength at design temperature : 0.275 kN/mm2
E = Modulus of elasticity at design temperature : 191.13 kN/mm2

F.S = Factor of Safety : 1.5
Le = two times the overall stack height for cantilever stack : 69600 mm
Scl = Allowable longitudinal compressive stress
Sbl = Allowable combined longitudinal compressive and bending stress
Scc = Allowable circumferential compressive stress
q = The external wind pressure or stack draft pressure
qz = The external wind pressure on stack at elevation under consideration

P = the dead load of stack above elevation under consideration
A = the cross-section area of stack plate
r = Radius of gyration of chimney at the considered section

Y = stress reduction factor
t = Shell thickness
D = Outside Diameter of Cylinder

LS = spacing of stiffeners: 9500mm

TABLE-3 SHELL
STRENGTH CHECK (1/2)
Hz1 A Sp ISECTION qz
(mm) (N/m^2)
No. Hz (mm) tr (mm) D (mm) (cm^2) (cm^3) (cm^4)
1 0 1720 10 3434 1075.7 93429.2 16041795.5 635.0

2 1720 4220 10 3434 1075.7 93429.2 16041795.5 635.0
3 4220 6720 10 3434 1075.7 93429.2 16041795.5 702.3
4 6720 9220 10 3434 1075.7 93429.2 16041795.5 732.2
5 9220 11720 8 3438 862.1 74786.3 12855768.2 777.0
6 11720 14220 8 3438 862.1 74786.3 12855768.2 814.3
7 14220 16720 8 3438 862.1 74786.3 12855768.2 844.2
8 16720 18800 8 3438 862.1 74786.3 12855768.2 844.2
9 18800 21300 6 3442 647.7 56122.0 9658600.9 874.1
10 21300 23800 6 3442 647.7 56122.0 9658600.9 904.0
11 23800 26300 6 3442 647.7 56122.0 9658600.9 926.4
12 26300 28800 6 3442 647.7 56122.0 9658600.9 941.3
13 28800 31300 6 3442 647.7 56122.0 9658600.9 941.3
14 31300 33800 6 3442 647.7 56122.0 9658600.9 956.3
15 33800 34800 6 3442 647.7 56122.0 9658600.9 971.2
Section Properties
U
Where:
No.: section no.
Hz: height above ground Hi: height of i section
D: Shell diameter of i section tr : corroded shell thickness of i section
A: corroded area of i section
Isection: moment of inertia of corroded section
Sp: Section modulus of section

Table-4 SHELL
STRENGTH CHECK (2/2)
M A B C D E F G (F+G)
(kN-m) fc P/A MD/2I Sbl=Scl Scc Unity
(N/mm^2) (N/mm^2) (kN/mm2) (N/mm2) check
No. (N/mm^2) (B+C)/D (A/E) Combined
Stress
Ratio
1 1525.9 0.111 3.8575 16.33 98.525 9.994 0.205 0.01114 0.205
2 1346.0 0.111 3.7218 14.41 98.525 9.994 0.184 0.01114 0.184
3 1153.9 0.123 3.5247 12.35 98.525 9.994 0.161 0.01232 0.161
4 969.0 0.128 3.2345 10.37 98.525 9.994 0.138 0.01284 0.138
5 797.0 0.170 3.7901 10.66 78.728 7.147 0.184 0.02385 0.184
6 637.7 0.179 3.4770 8.53 78.728 7.147 0.152 0.02499 0.153
7 492.9 0.185 3.2800 6.59 78.728 7.147 0.125 0.02591 0.126
8 364.4 0.185 3.0829 4.87 78.728 7.147 0.101 0.02591 0.102
9 260.6 0.256 3.7308 4.64 58.977 4.639 0.142 0.05517 0.145
10 166.7 0.265 3.5338 2.97 58.977 4.639 0.110 0.05706 0.114
11 91.3 0.271 3.1825 1.63 58.977 4.639 0.082 0.05847 0.085
12 42.5 0.276 2.9856 0.76 58.977 4.639 0.063 0.05941 0.067
13 58.6 0.276 0.4726 1.04 58.977 4.639 0.026 0.05941 0.029
14 20.9 0.280 0.2757 0.37 58.977 4.639 0.011 0.06036 0.015
15 2.1 0.284 0.0788 0.04 58.977 4.639 0.002 0.06130 0.006
Stresses check
U
The Stresses under different load cases are checked and are found to be well within the
acceptable limit.
3.7 Oval ling Check (in accordance with ASME STS-1)
Oval ling natural frequency (f0)
f0=680*tr/D2 (Hz), where tr: corroded thickness
f0=1.25 Hz
Critical wind velocity for oval ling (Vco)
Vco=f0*D/(2*S) (ft/s) 35.4 ft/s
where,
S = Strouhl number =
0.2
Since, Vco<Vz (mean hourly wind speed), therefore stiffeners are required.

Required minimum section modulus of stiffeners (Ss):
Ss = (2.52x10-3)(vco)2*D2*Is/σa (in^3) = 0.62 in^3

Is= Spacing between circumferential stiffeners: 9500 mm
σa = allowable tensile stress in stack stiffener = 0.6Fy =20450 psi
Min. Stiffener Size selected: 75*75*8
Note: The actual section modulus is more than the required. Therefore, the selected stiffener size is
safe.
Stiffener design: Circumferential compression check
1. Minimum Moment of Inertia:
=0.291 in4
2. Minimum Shell + Stiffener Area:
=0.26 in2
3. Required Section modulus:
=3.29 in3
Min. Stiffener size selected is angle 75*75*8
Note: Min. section modulus of plate section alone is more than the required. Therefore,
stiffener size selected is OK.

4. DESIGN OF STACK BASE PART

5B
UAnchor Chair calculation:

The calculation is performed in CodeCalc software. The anchor chair dimensions are taken from
existing stack drawing. The figure shown below is taken from the software, shows the input
anchor chair dimensions. The dead load and wind load/moment calculated in previous pages are
taken as loads to check the anchor chair design.
Input:
Analyze or Design the Basering AORD Analyze
Design Temperature for Basering RNGTMP 85.00 C
Thickness of Basering TBA 25.0000 mm
Basering Material S275
Basering Material UNS Number
Inside Diameter of Basering DI 3410.000 mm
Outside Diameter of Basering DO 3740.000 mm
Bolt Material SA-193 B7

Bolt Material UNS Number G41400
Bolt Operating Allowable Stress SA 172.38 MPa
Bolt Ambient Allowable Stress SABAMB 172.38 MPa
Diameter of Bolt Circle DC 3590.000 mm
Nominal Diameter of Bolts BND 42.0000 mm
Type of Thread Series TEMA Metric Thread
Number of Bolts NGIV 24
Skirt Material S275

Skirt Material UNS Number
Skirt Operating Allowable Stress SKTOPE 180.00 MPa
Skirt Ambient Allowable Stress SKTAMB 180.00 MPa
Skirt Thickness TS 10.0000 mm

Skirt Temperature SKTTEM 220.0000 C

Outside Diameter of Skirt at Base DS 3460.000 mm
Outside Diameter of Skirt at Bottom Head SKTHED 3460.000 mm
Joint Efficiency of Skirt Weld ARCJNT 1.0000
Nominal Compressive Stress of Concrete FPC 20.6 MPa
Thickness of Gusset Plates TGA 15.0000 mm

Temperature for Gusset Plates GUSTMP 85.0000 C
Average Width of Gusset Plates AVGWDT 300.0000 mm
Gusset Material S275
Gusset Material UNS Number
Gusset Plate Elastic Modulus E 199955.0 MPa
Gusset Plate Yield Stress SY 275.00 MPa
Gusset Operating Allowable Stress Sgus 180.00 MPa
Height of Gussets HG 280.0000 mm
Distance from Bolts to Gussets CG 70.0000 mm
Number of Gussets per bolt NG 2
Thickness of Top Ring/Plate TTA 38.0000 mm

Radial Width of the Top Ring/Plate TOPWTH 130.0000 mm
Top Ring or Plate Type per Moss Continuous Ring
External Corrosion Allowance CA 0.0000 mm
Dead Weight of Vessel DW 0.4950E+06 N

Operating Weight of Vessel ROW 0.4950E+06 N
Test Weight of Vessel TW 0.0000 N
Operating Moment on Basering ROM 0.1525E+10 N-mm
Test Moment on Basering TM 0.0000 N-mm
Calculation:
U
RESULTS FOR BASERING ANALYSIS : ANALYZE OPTION

U
1. Calculation of load per bolt:
Calculation of Load per Bolt, Operating Condition:

W/Bolt = (( 4 * M/DC ) - W ) / RN per Jawad Farr, Eq. 12.3
W/Bolt = (( 4 * .15244E+10 / 3590.000 ) - 494999 ) / 24
W/Bolt = 50144.8281 N
Required Area for Each Bolt, Based on Max Load 290.9302 mm^2
Area Available in a Single Bolt 1018.2180 mm^2
Area Available in all the Bolts 24437.2305 mm^2
Bolt Stress Based on Approximate Analysis 49.25 MPa
Note: The anchor bolt size and quantity is ok as the available area is more than the
required bolt area.

2. Basering/Baseplate thickness calculation:

Thickness of Basering under compression:
This is a equation for a simple cantilever beam. The beam is assumed to be
supported at the bottom shell, and loaded with uniform concrete load due to
combined stack weight and bending moment due to wind.
Geometry property:
Concrete Contact Area of Base Ring 1853147.00 mm^2 (Base ring area)
Concrete Contact Section Modulus of Base Ring 1586552832.00 mm^3
(Circular ring section modulus)
Stresa cting on concrete:
Calculation of Concrete Load, Operating Condition:

SC = ((ABT*SA+W)/CA) + M/CZ per Jawad & Farr Eq. 12.1
SC = ((24437.2305*172 +494999 )/1853147 ) + .15250E+10/.15866E+10
SC = 3.50 MPa
Thickness of cantilever, t :
Method 1:
Calculation of Basering Thickness, (Simplified):
TB = RW * SQRT( 3 * SC / S ) + CA per Jawad & Farr Eq. 12.12
TB = 140.0000 * SQRT( 3 * 3 / 352 ) + 0.0000
TB = 24.1664 mm
Method 2:
Results of Neutral Axis Shift Calculation:
Bearing Pressure on Concrete 1.60 MPa
Stress in Bolt 30.00 MPa
Calculation of Basering Thickness, (N.A. Shift):

TBNA = RW * SQRT( 3 * SCNA / S) + CA per Jawad & Farr Eq. 12.12
TBNA = 140.0000 * SQRT( 3 * 1 / 352 ) + 0.0000
TBNA = 16.3515 mm

3. Top ring thickness design under Tension:

The thickness is calculated using simple beam formulae. The beam is
supported between 2 gussets with a point load in the middle equal to the
maximum bolt load.
Method 1:
Required Thickness of Top Ring/Plate in Tension:

(Calculated as a fixed beam per Megyesy)
FT = (SA*ABSS), Bolt Allowable Stress * Area
RM = (FT*2.0*CG)/8.0, Bending Moment
SB = (1.5*BASOPE), Allowable stress * 1.5
WT = (TOPWTH - BND), Width of Section
T = SQRT( 6 * RM / ( SB * WT )) + CA
T = SQRT( 6 * 3071518 / ( 352 * 88.0000 )) + 0.0000
T = 24.3743 mm
Method 2:
Required Thickness of Continuous Top Ring per Moss:
a = ( Dc-Ds )/2 Skirt Distance to Bolt Circle
P = Sa * Abss Maximum Bolt Load
l = Avgwdt Average Gusset Width
g1 = Gamma 1 Constant Term f( b/l )
g2 = Gamma 2 Constant Term f( b/l )
g = Flat distance/2 Nut 1/2 Dimension (from Tema)
Fb = ( 1.5 * Basope ) Allowable Stress
Mo = P/(4 pi)[1.3(ln((2lsin(pi a/l)/(pi g)))+1]-[(.7-g2)P/(4 pi)]

Tc = ( 6 * Mo / Fb )^1/2 + CA Required Thickness
Tc = ( 6 * 26731 / 352 )^1/2 + 0.0000
Tc = 21.3308 mm

4. Required Thickness of gusset:
In Tension:
Tensile stress is force ( derived from allowable bolt stress times bolt area)
by the area of the gusset ( thickness * half times width of the gusset)
Required Thickness of Gusset in Tension (based on avg. crossection) [T]:

= (( SA * ABSS ) / ( NG * Sgus * ( AVGWDT )) + CA
= (( 172.4 * 1018.218 ) / ( 2 * 180.0 * 300.000 )) + 0.000
= 1.6251 mm
Actual thickness as entered by user 15.0000 mm
In Compression:
In Compression, the software uses iterative process to calculate the required
thickness. Calculation is performed as per AISC 1.5.1.3. The actual compression is
calculated and compared with allowable compression per AISC. The thickness is then
modified and another calculation performed until the actual and allowed compression
is within one half of one percent of one another.
Required Thickness of Gusset in Compression, per AISC E2-1 9th Ed.

1. Allowed Compression at Given Thickness:
Factor Kl/r Per E2-1 129.1811
Factor Cc Per E2-1 119.8022
All. Buckling Str. per E2-2 61.70 MPa
Act. Buckling Str. at Given Thickness 19.50 MPa
Required Gusset thickness, + CA 10.2330 mm
2. Allowed Compression at Calculated Thickness:

Factor Kl/r Per E2-1 189.3590
Factor Cc Per E2-1 119.8022
All. Buckling Str. per E2-2 28.72 MPa
Act. Buckling Str. at Calculated Thickness 28.59 MPa
SUMMARY OF BASERING THICKNESS CALCULATIONS

Required Basering Thickness (simplfied) 24.1664 mm
Required Basering Thickness (N.A. Shift) 16.3515 mm
Actual Basering Thickness as entered by user 25.0000 mm
Required Top Ring/Plate Thickness as a Fixed-Beam 24.3743 mm

Required Top Ring Thickness per Moss(Type 4) 21.3308 mm
Actual Top Ring Thickness as entered by user 38.0000 mm
Required Gusset thickness, + CA 10.2330 mm

Actual Gusset Thickness as entered by user 15.0000 mm
Note: The stresses in base ring, Top ring, gusset and bolts are within the allowable
limit. The actual thickness is more than the required thickness. Therefore the Anchor
chair design is safe.

5. Bottom section of Stack shell (Referred to as skirt in the below

calculation):
Software performs the stress calculation (In both Tension and compression) for
this bottom Shell section. The below calculation shows that the required
thickness is less than the actual provided. Therefore the corroded shell
thickness of 10 mm is also more than required thickness of 5.49 mm.
TENSILE STRESS CALCULATIONS FOR SKIRT AT TOP HEAD:

S = M/( PI*R^2*T ) - F/(2*PI*R*T)
Operating Dead Load Test Load
Skirt Rad. Given by User 1730.0000 1730.0000 1730.0000 mm
Skirt Thkn. Given by User 10.0000 10.0000 10.0000 mm
Bndg. Mom. Given by User 0.153E+10 0.153E+10 0.000E+00 N-mm
Axial Force Given by User 495000.0 495000.0 0.0 N
Actual Stress in Skirt 11.7 11.7 0.0 MPa
Allowed Stress in Skirt 144.0 144.0 216.0 MPa
THICKNESS CALCULATION FOR SKIRT:

Required Thickness 0.8097 0.8097 0.0000 mm
Actual Thickness as Given 10.0000 10.0000 10.0000 mm
COMPRESSIVE STRESS CALCULATIONS AT BASE OF SKIRT:

S = M/(PI*R^2*T) + F/(2*PI*R*T)
Skirt Rad. Given by User 1730.0000 1730.0000 1730.0000 mm
Skirt Thkn. Given by User 10.0000 10.0000 10.0000 mm
Bndg. Mom. Given by User 0.153E+10 0.153E+10 0.000E+00 N-mm
Axial Force Given by User 495000.0 495000.0 0.0 N
Actual Stress in Skirt 20.8 20.8 0.0 MPa
Allowed Stress in Skirt 67.7 67.7 101.6 MPa
THICKNESS CALCULATION FOR SKIRT AXIAL COMPRESSION:

Required Thickness 5.4870 5.4870 0.0000 mm
SUMMARY OF SKIRT THICKNESS:

Req. Thickness, Tension 0.8097 0.8097 0.0000 mm
Req. Thickness, Comp. 5.4870 5.4870 0.0000 mm

5. Deflection Check
Deflection of the stack under Wind

Load
Deflection due to Uniform Vessel, Non-uniform load can be obtained from the formula as
below:
(Reference Dennis Moss : Procedure 4.4 Tower Deflection)
L = Length of stack, in
I = Moment of inertia (Mid section), in^4
wmax = uniformly distributed load at top of vessel , lb/in.
wmin = uniformly distributed load at bottom of vessel , lb/in.
E = Modulus of Elasticity, psi
d = deflection, inch
Calculation for the deflection of the Stack :

U U
L = 1370.1 (34.8 m) in
I = 116329 in^4
Wmin = 12.6 (224.2 kg/m) lb/in
Wmax = 19.2 (342.5 kg/m) lb/in
E = 27740000 psi
Deflection, d = 2.4 inch
= 61 mm
Permissible Deflection h/200 = 174 mm
The deflection of the stack is less than the allowable deflection.

AD
DEQUACY CHEECK REPORT FOR
PRIMARY REF
FORMER STAC
CK
6. Breaching
B Op
pening Stifffener Design
n
Breeeching ope ening Stiffeener desig
gn (Type I)
( As per "Steel Plate
P Engineeering Data" ,P
Part V, Self supported
s sta
acks)
Input Datta
Breechingg opening sizze(length x width)
w : 3060
0mmx 2240 mm m 10
0624.34 in22
Maximum width w=2/3
3.Do 7.57 ft
Inside Are
ea of Stack A= π.D^2/4 14
4573.86 in22
Duct locattion around 7.5' abovee ground
Vertical Stiffener
S des
sign:
Area Required:
= 21.10 in2
2
where,
W': Arc length off the 2400 mm
m
opening
94.49 in
hickness of sttack at opening location
t: Max. th 10.00 mm m
0.39 in
de Diameter of Stack
Do: Outsid 3460 mm m
11.35 feeet
C: As sho
own in figure 3
3050.00 mm m
10.01 feeet
Stiffener size
s selected
d : 20 thk platte
Stack Wall Area (Corrroded) 130.66 in2
2
Total Area
A Provide
ed 135.31 in2
2
Doc No: QN-E121.00003-000 Rev.0

0 Page
e 26 of 33
AD
DEQUACY CHEECK REPORT FOR
PRIMARY REF
FORMER STAC
CK
Circular Ring Design(W

With
Stiffener)):
UDL Load
d carried by Ring
R :
= 1
1186.86 lb//in
where,
V: Total Direct
D load 495.00 kN
N
111375 lb
M1: Wind Moment at the
t given poiint 1525.9 kN
N.m
135
504215 lb.in
Bending moment
m in sttack cut-out region
r 'Mq'
= 883
3024.09 lb.in
Total Bending momennt M=M1

1+Mq 14387
7239.09 lb.in
Allowable Bending Strress' Sa' = 25
5816.00 psi
Required Section mo odulus = 557.30 in3
3
'Zr'
Stiffener size
s selectedd : 6 thk plate
e +10thk ring g
Section modulus
m in Sttack wall = 5701 in3 3
Note: Secction moduluss of stack sh hell is sufficie
ent. Thereforre, the stiffen
ner plate prov
vided
is OK.
Doc No: QN-E121.00003-000 Rev.0

0 Page
e 27 of 33
7.Platform cleat to Shell Joint check Description: Platform cleat
Diameter Basis for Vessel Vbasis OD

Cylindrical or Spherical Vessel Cylsph Cylindrical
Internal Corrosion Allowance Cas 0.0000 mm
Vessel Diameter Dv 3460.000 mm
Vessel Thickness Tv 6.000 mm
Design Temperature 220.00 C

Vessel Material S275
Vessel UNS Number
Vessel Cold S.I. Allowable Smc 180.00 MPa
Vessel Hot S.I. Allowable Smh 180.00 MPa
Attachment Type Type Rectangular

Parameter C11 C11 75.00 mm
Parameter C22 C22 200.00 mm
Thickness of Reinforcing Pad Tpad 6.000 mm

Pad Parameter C11P C11p 250.000 mm
Pad Parameter C22P C22p 400.000 mm
Design Internal Pressure Dp 0.001 MPa

Include Pressure Thrust No
External Forces and Moments in WRC 107 Convention:

Radial Load (SUS) P 34769.0 N
Longitudinal Shear (SUS) Vl 56603.0 N
Circumferential Shear (SUS) Vc 41371.0 N
Circumferential Moment (SUS) Mc 110000.0 N-mm
Longitudinal Moment (SUS) Ml 987000.0 N-mm
Torsional Moment (SUS) Mt 10000000.0 N-mm
Use Interactive Control No

WRC107 Version Version March 1979 ( B1 & B2 )
Include Pressure Stress Indices per Div. 2 No

Compute Pressure Stress per WRC-368 No
WRC 107 Stress Calculation for SUStained loads:

Radial Load P 34769.0 N
Circumferential Shear VC 41371.0 N
Longitudinal Shear VL 56603.0 N
Circumferential Moment MC 110000.0 N-mm
Longitudinal Moment ML 987000.0 N-mm
Torsional Moment MT 10000000.0 N-mm
Dimensionless Parameters used : Gamma = 144.17
Dimensionless Loads for Cylindrical Shells at Attachment Junction:

-------------------------------------------------------------------
Curves read for 1979 B1/B2 Beta Figure Value Location
-------------------------------------------------------------------
N(PHI) / ( P/Rm ) 0.050 4C 24.633 (A,B)
N(PHI) / ( P/Rm ) 0.050 3C 22.338 (C,D)
M(PHI) / ( P ) 0.032 2C1 0.127 (A,B)
M(PHI) / ( P ) 0.032 1C 0.176 (C,D)
N(PHI) / ( MC/(Rm**2 * Beta) ) 0.030 3A 2.202 (A,B,C,D)
M(PHI) / ( MC/(Rm * Beta) ) 0.032 1A 0.099 (A,B,C,D)
N(PHI) / ( ML/(Rm**2 * Beta) ) 0.042 3B 11.876 (A,B,C,D)
M(PHI) / ( ML/(Rm * Beta) ) 0.035 1B1 0.056 (A,B,C,D)
N(x) / ( P/Rm ) 0.041 3C 24.135 (A,B)

N(x) / ( P/Rm ) 0.041 4C 25.397 (C,D)

M(x) / ( P ) 0.043 1C1 0.152 (A,B)
M(x) / ( P ) 0.043 2C 0.106 (C,D)
N(x) / ( MC/(Rm**2 * Beta) ) 0.030 4A 2.824 (A,B,C,D)
M(x) / ( MC/(Rm * Beta) ) 0.039 2A 0.057 (A,B,C,D)
N(x) / ( ML/(Rm**2 * Beta) ) 0.042 4B 3.199 (A,B,C,D)
M(x) / ( ML/(Rm * Beta) ) 0.043 2B1 0.080 (A,B,C,D)
Stress Concentration Factors Kn = 1.00, Kb = 1.00

Stresses in the Vessel at the Attachment Junction
| Stress Values at |
| ( MPa) |
Type of | |
Stress Load| Au Al Bu Bl Cu Cl Du Dl |
-------------------------------------------------------------------------
Circ. Memb. P | -41.3 -41.3 -41.3 -41.3 -37.4 -37.4 -37.4 -37.4|
Circ. Bend. P | -183.7 183.7 -183.7 183.7 -255.3 255.3 -255.3 255.3|
Circ. Memb. MC | 0.0 0.0 0.0 0.0 -0.1 -0.1 0.1 0.1|
Circ. Memb. MC | 0.0 0.0 0.0 0.0 -8.1 8.1 8.1 -8.1|
Circ. Memb. ML | -5.5 -5.5 5.5 5.5 0.0 0.0 0.0 0.0|
Circ. Bend. ML | -38.5 38.5 38.5 -38.5 0.0 0.0 0.0 0.0|
| |
Tot. Circ. Str.| -269.0 175.4 -180.9 109.5 -300.9 226.0 -284.6 209.9|
-------------------------------------------------------------------------
Long. Memb. P | -40.4 -40.4 -40.4 -40.4 -42.5 -42.5 -42.5 -42.5|
Long. Bend. P | -220.1 220.1 -220.1 220.1 -153.7 153.7 -153.7 153.7|
Long. Memb. MC | 0.0 0.0 0.0 0.0 -0.2 -0.2 0.2 0.2|
Long. Bend. MC | 0.0 0.0 0.0 0.0 -3.8 3.8 3.8 -3.8|
Long. Memb. ML | -2.5 -2.5 2.5 2.5 0.0 0.0 0.0 0.0|
Long. Bend. ML | -44.4 44.4 44.4 -44.4 0.0 0.0 0.0 0.0|
| |
Tot. Long. Str.| -307.4 221.6 -213.6 137.7 -200.2 114.8 -192.2 107.5|
-------------------------------------------------------------------------
Shear VC | 23.0 23.0 -23.0 -23.0 0.0 0.0 0.0 0.0|
Shear VL | 0.0 0.0 0.0 0.0 -11.8 -11.8 11.8 11.8|
Shear MT | 222.2 222.2 222.2 222.2 222.2 222.2 222.2 222.2|
| |
Tot. Shear| 245.1 245.1 199.2 199.2 210.4 210.4 233.9 233.9|
-------------------------------------------------------------------------
Str. Int. | 534.1 492.4 399.7 399.3 466.9 435.2 476.9 479.0|
Dimensionless Parameters used : Gamma = 287.83

Dimensionless Loads for Cylindrical Shells at Pad edge:
-------------------------------------------------------------------
Curves read for 1979 B1/B2 Beta Figure Value Location
-------------------------------------------------------------------
N(PHI) / ( P/Rm ) 0.114 4C 33.576 (A,B)
N(PHI) / ( P/Rm ) 0.114 3C 16.707 (C,D)
M(PHI) / ( P ) 0.086 2C1 0.031 (A,B)
M(PHI) / ( P ) 0.086 1C ! 0.070 (C,D)
N(PHI) / ( MC/(Rm**2 * Beta) ) 0.085 3A 12.143 (A,B,C,D)
M(PHI) / ( MC/(Rm * Beta) ) 0.084 1A 0.071 (A,B,C,D)
N(PHI) / ( ML/(Rm**2 * Beta) ) 0.099 3B 27.100 (A,B,C,D)
M(PHI) / ( ML/(Rm * Beta) ) 0.086 1B1 0.019 (A,B,C,D)
N(x) / ( P/Rm ) 0.101 3C 19.525 (A,B)

N(x) / ( P/Rm ) 0.101 4C 35.886 (C,D)
M(x) / ( P ) 0.103 1C1 0.052 (A,B)
M(x) / ( P ) 0.103 2C ! 0.036 (C,D)
N(x) / ( MC/(Rm**2 * Beta) ) 0.085 4A 22.668 (A,B,C,D)
M(x) / ( MC/(Rm * Beta) ) 0.095 2A 0.029 (A,B,C,D)
N(x) / ( ML/(Rm**2 * Beta) ) 0.099 4B 11.375 (A,B,C,D)
M(x) / ( ML/(Rm * Beta) ) 0.093 2B1 0.024 (A,B,C,D)
Stress Concentration Factors Kn = 1.00, Kb = 1.00

Stresses in the Vessel at the Edge of Reinforcing Pad
| Stress Values at |
| ( MPa) |
Type of | |
Stress Load| Au Al Bu Bl Cu Cl Du Dl |
-------------------------------------------------------------------------
Circ. Memb. P | -112.7 -112.7 -112.7 -112.7 -56.1 -56.1 -56.1 -56.1|
Circ. Bend. P | -182.1 182.1 -182.1 182.1 -406.0 406.0 -406.0 406.0|
Circ. Memb. MC | 0.0 0.0 0.0 0.0 -0.4 -0.4 0.4 0.4|
Circ. Memb. MC | 0.0 0.0 0.0 0.0 -9.0 9.0 9.0 -9.0|
Circ. Memb. ML | -13.3 -13.3 13.3 13.3 0.0 0.0 0.0 0.0|
Circ. Bend. ML | -21.7 21.7 21.7 -21.7 0.0 0.0 0.0 0.0|
| |
Tot. Circ. Str.| -329.7 77.8 -259.8 61.0 -471.5 358.5 -452.6 341.3|
-------------------------------------------------------------------------
Long. Memb. P | -65.5 -65.5 -65.5 -65.5 -120.4 -120.4 -120.4 -120.4|
Long. Bend. P | -304.0 304.0 -304.0 304.0 -210.5 210.5 -210.5 210.5|
Long. Memb. MC | 0.0 0.0 0.0 0.0 -1.3 -1.3 1.3 1.3|
Long. Bend. MC | 0.0 0.0 0.0 0.0 -3.2 3.2 3.2 -3.2|
Long. Memb. ML | -7.9 -7.9 7.9 7.9 0.0 0.0 0.0 0.0|
Long. Bend. ML | -24.2 24.2 24.2 -24.2 0.0 0.0 0.0 0.0|
| |
Tot. Long. Str.| -401.6 254.8 -337.5 222.2 -335.4 92.0 -326.4 88.2|
-------------------------------------------------------------------------
Shear VC | 13.8 13.8 -13.8 -13.8 0.0 0.0 0.0 0.0|
Shear VL | 0.0 0.0 0.0 0.0 -11.8 -11.8 11.8 11.8|
Shear MT | 66.6 66.6 66.6 66.6 66.6 66.6 66.6 66.6|
| |
Tot. Shear| 80.4 80.4 52.9 52.9 54.9 54.9 78.4 78.4|
-------------------------------------------------------------------------
Str. Int. | 453.8 285.9 364.3 238.0 490.8 369.4 490.2 363.7|
WRC 107/537 Stress Summations:
Vessel Stress Summation at Attachment Junction
Type of Stress Values at |

Stress Int. (MPa ) |
Location Au Al Bu Bl Cu Cl Du Dl |
-------------------------------------------------------------------------
Circ. Pm (SUS) 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1|
Circ. Pl (SUS) -46.8 -46.8 -35.7 -35.7 -37.5 -37.5 -37.3 -37.3|
Circ. Q (SUS) -222.2 222.2 -145.2 145.2 -263.5 263.5 -247.2 247.2|
-------------------------------------------------------------------------
Long. Pm (SUS) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0|
Long. Pl (SUS) -42.9 -42.9 -37.9 -37.9 -42.7 -42.7 -42.4 -42.4|
Long. Q (SUS) -264.5 264.5 -175.7 175.7 -157.5 157.5 -149.8 149.8|
-------------------------------------------------------------------------
Shear Pm (SUS) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0|
Shear Pl (SUS) 23.0 23.0 -23.0 -23.0 -11.8 -11.8 11.8 11.8|
Shear Q (SUS) 222.2 222.2 222.2 222.2 222.2 222.2 222.2 222.2|
Pm (SUS) 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1|
-------------------------------------------------------------------------
Pm+Pl (SUS) 67.9 67.9 59.8 59.8 52.1 52.1 51.9 51.9|
-------------------------------------------------------------------------
Pm+Pl+Q (Total) 534.0 492.4 399.7 399.3 466.8 435.2 476.9 479.0|

Stress Summation Comparison:
Type of | Max. S.I. S.I. Allowable | Result |

Stress Int. | MPa | |
-------------------------------------------------------------------------
Pm (SUS) | 0.07 180.00 | Passed |
Pm+Pl (SUS) | 67.87 270.00 | Passed |
Pm+Pl+Q (TOTAL)| 534.04 540.00 | Passed |
WRC 107/537 Stress Summations:
Vessel Stress Summation at Reinforcing Pad Edge
Type of Stress Values at |

Stress Int. (MPa ) |
Location Au Al Bu Bl Cu Cl Du Dl |
-------------------------------------------------------------------------
Circ. Pm (SUS) 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1|
Circ. Pl (SUS) -125.9 -125.9 -99.4 -99.4 -56.5 -56.5 -55.6 -55.6|
Circ. Q (SUS) -203.8 203.8 -160.4 160.4 -415.0 415.0 -397.0 397.0|
-------------------------------------------------------------------------
Long. Pm (SUS) 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1|
Long. Pl (SUS) -73.4 -73.4 -57.6 -57.6 -121.7 -121.7 -119.1 -119.1|
Long. Q (SUS) -328.2 328.2 -279.9 279.9 -213.7 213.7 -207.3 207.3|
-------------------------------------------------------------------------
Shear Pm (SUS) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0|
Shear Pl (SUS) 13.8 13.8 -13.8 -13.8 -11.8 -11.8 11.8 11.8|
Shear Q (SUS) 66.6 66.6 66.6 66.6 66.6 66.6 66.6 66.6|
Pm (SUS) 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1|
-------------------------------------------------------------------------
Pm+Pl (SUS) 129.2 129.2 103.4 103.4 123.7 123.7 121.2 121.2|
-------------------------------------------------------------------------
Pm+Pl+Q (Total) 453.7 286.0 364.2 238.1 490.7 369.5 490.1 363.8|
Stress Summation Comparison:
Type of | Max. S.I. S.I. Allowable | Result |

Stress Int. | MPa | |
-------------------------------------------------------------------------
Pm (SUS) | 0.14 180.00 | Passed |
Pm+Pl (SUS) | 129.19 270.00 | Passed |
Pm+Pl+Q (TOTAL)| 490.71 540.00 | Passed |
Note: From the reaction table, the maximum load case is selected and the Platform cleat to
shell region analysis is performed for that load case. The stresses are checked and are within
the limit.

The reinforcement detail is shown below:

8. Conclusion:
The Stack is checked under different failure scenarios and the existing design is safe for the
additional platform loads.
The maximum combined longitudinal and circumferential compressive stress ratio in Stack
shell is 0.205, which is less than 1. The section property at the duct opening region is also
sufficient.
The dynamic wind load effects on the steel structure are ignored as the critical velocity is
1.2 times more than the mean hourly speed.
The maximum deflection at the top of the stack is 61mm, which is less than permissible
value of 174 mm.
The required thickness in anchor chair base ring, gusset plate, and top ring are less than the
actual thickness. Also, the bolt size and quantity provided are sufficient to withstand the
bending moment caused by wind.
Platform cleat –RF pad--Shell junction attachment detail is shown in the report above. The
analysis is performed with the maximum reaction loads coming at this region and the safe
pad and the cleat dimensions are determined.

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CONTRACT NO.

PROJECT NO: A3-17

DESIGN CONSULTANT: MAIN CONTRACTOR:

0 14/03/19 ISSUED FOR COMMENTS HT ALS KM

Prepared Checked Approved Approved

Document No. QN-E121.00003-000 Sht. 1 of

Doc No: QN-E121.00003-000 Rev.0 Page 2 of 33

QAFCO - Qatar Fertilizer Company

Doc No: QN-E121.00003-000 Rev.0 Page 3 of 33

1.2 Design Methodology and Sketch:

2. Shell Strength check:

Doc No: QN-E121.00003-000 Rev.0 Page 4 of 33

3. Dynamic effects due to wind:

4. Anchor chair calculation:

6. Structural shell discontinuities/ Shell opening for Gas inlet:

7. Platform to Shell Connection:

Doc No: QN-E121.00003-000 Rev.0 Page 5 of 33

(Reference drawing: Primary Reformer Steel arrangement Stack, QA-UD-T121.00019-001)

Doc No: QN-E121.00003-000 Rev.0 Page 6 of 33

1.3 Input References:

a. Primary stack assembly drawing ,” QA-UD-T121.00019-001

1.4 Codes and Standard:

The following Codes and Standards are referred:

1.5 Softwares used:

- CodeCalc for Anchor chair calculation.

Doc No: QN-E121.00003-000 Rev.0 Page 7 of 33

1.6 Input Data:

Stack Geometric Data

Basic Wind Speed : 33.4 m/s EXPOSURE C

Seismic Data: (Reference document: CEMS-PT-S700.01004)

Seismic Category : ZONE 1 Z=0.075 (Qatar region)

Dead and Live load: (Reference document: CEMS-PT-S700.01004)

Material : SA 36/S275 JR ( For Shell Plates)

Doc No: QN-E121.00003-000 Rev.0 Page 8 of 33

2.1 Dead and Live Load

2 1720 4220 2500 10 3440 21.2 21.2 400

3 4220 6720 2500 10 3440 21.2 10 31.2 379

4 6720 9220 2500 10 3440 21.2 21.2 348

5 9220 11720 2500 8 3444 17.0 10 27.0 327

6 11720 14220 2500 8 3444 17.0 17.0 300

7 14220 16720 2500 8 3444 17.0 17.0 283

8 16720 18800 2080 8 3444 14.1 10 24.1 266

9 18800 21300 2500 6 3448 12.8 12.8 242

10 21300 23800 2500 6 3448 12.8 10 22.8 229

11 23800 26300 2500 6 3448 12.8 12.8 206

12 26300 28800 2500 6 3448 12.8 150 162.8 193

13 28800 31300 2500 6 3448 12.8 12.8 31

14 31300 33800 2500 6 3448 12.8 12.8 18

15 33800 34800 1000 6 3448 5.1 5.1 5

Doc No: QN-E121.00003-000 Rev.0 Page 9 of 33

2.2 WIND LOAD CALCULATION

Design Wind Load

2B (In accordance with Document: CEMS-PT-S700.01004, ASCE 7, Section6.0, Wind loads)

qz=0.613 (V^2).I.Kzt.Kz .Kd (Eq.6-15)

qz: Wind pressure (N/m2)

Force due to wind:

Do: Outside diameter of Stack

Doc No: QN-E121.00003-000 Rev.0 Page 10 of 33

Table-2 WIND LOAD DUE TO ALONG WIND

(mm) (mm) (mm) (mm) (mm) (㎏/m2) (kN) (kN) (kN-m)

Base Shear: 84.77 kN

Base Moment: 1525.9 kN-m

Doc No: QN-E121.00003-000 Rev.0 Page 11 of 33

f1 = 3.9D/H²sqrt(E/Ws) : natural frequency (Hz) 2.8 Hz

Scl = EtY/(4DF.S) when t/D ≤ 2.8*FY/E

= FY(1-0.3KS)Y/F.S when 2.8FY/E < t/D ≤ 10FY/E

P/A + MD/(2ISECTION) ≤ Sbl

when 2.8FY/E < t/D ≤ 10FY/E,

(P/A + MD/(2ISECTION))/Sbl+(fc/SCC)2 ≤ 1.0

IS+P 3= qlSD F.S/(3456E)

SS+P2 = qzD lsF.S/(1830Fy)

Vco=f0D/(2S) (ft/s) 35.4 ft/s

Ss = (2.52x10-3)(vco)2D2Is/σa (in^3) = 0.62 in^3

Min. Stiffener size selected is angle 75758