CHIMNEY DESIGN AS PER IS 6533 (PART 1 & 2) 1989.

DESIGN INPUTS

1. Fuel : natural gas

2. Fuel consumption : 123.5 kg/hr
3. Flue gas Produced : 2223 kg/hr
4. Flue gas temperature : 250 C Max.

CHIMNEY HEIGHT CALCULATIONS:

Sulphur in fuel : max. 4.5 %
SO2 produced : 11.88 kg/hr
Required Chimney Height = 14 x ( SO2 produced /hr)0.3
= 14 x (11.88)0.3
= 29.42 m.
Proposed height of chimney = 30 m. Hence sufficient.

CALCULATION OF FLUE GAS VELOCITY AT CHIMNEY STACK:

Flue gas flow rate : 2223 kg/hr
(273 + 0)
Density of flue gas = --------------- x 1.295
(273 + 250)
= 0.675 kg/m3

2223
So, Volumetric Flow rate, Q = ---------------- = 0.914 m3/s
0.675 x 3600
Chimney DiameterD = 400 mm
4x Q
Flue Gas Velocity v = ----------
Pi x D2
4 x 0.914
= ----------------------
0.6 x pi x (0.400)2

= 12 m/s
Flue gas velocity is within permissible limits. Hence Safe.

WIND VELOCITY : 42 m/s.( As per area of installation)

FOR DESIGNING, WE WILL ASSUME WIND PRESSURE = 150 kg/cm 2.

DATA FOR DESIGN CALCULATION OF CHIMNEY:
Top Diameter of Chimney, D
Bottom Diameter of Chimney, Db
Height of Chimney, H
Max. exhaust gas temperature, Tc
Wind pressure, Wp
Corrosion allowance, C
Height of cylindrical section I
Height of cylindrical section II
Height of cylindrical section III
Height of Flare section I
Height of Flare section II
Height of Flare section III
Total Height of Chimney
: 400 mm
: 900 mm
: 30 m
: 300 C
: 150 kg/m2
: 3 mm ( for 20 yrs life)
: 5 m , thk : 6 mm
: 5 m, thk : 8 mm
: 5 m, thk : 12 mm
: 5 m, thk : 12 mm
: 5 m, thk: 12 mm
: 5 m, thk : 12 mm
= 30 m.
DESIGN CALCULATIONS FOR CHIMNEY:

1. CALCULATION FOR CYLINDRICAL SECTION 1:

Inner diameter of the section, di = 400 mm

Height of the section, H1 = 5000 mm
Thickness of the section without corrosion,t = 3 mm
Thickness of the section with corrosion, tc = 6 mm
Inner diameter of the chimney without corrosion, d= di + ( 2 x t)
= 406 mm
Outer diameter of the chimney with corrosion, dc = di + ( 2 x tc)
= 412 mm
Mean Diameter without corrosion dm = d + t
= 406 + 3 = 409 mm
Total Height from top, h1 = 5000 mm = 5 m
pi
Cross sectional area of chimney = Af1 = ---- x (dc2 – d2)
4
= 0.7854 x (41.2 2 – 40.6 2)
= 38.55 cm2
Total Wight of section 1 (with corrosion allowance), W1 = 330 kg.
( 10 % Extra weight considered for ladder)

Exposed area to wind = 5 x 0.412 = 2.06 m2

Wind Force WF1 = 2.06 x 150 = 309 kg.
h1
Bending Moment BM1 = WF1 x ------
2
500
= 309 x ------
2
= 77250 kg.cm

pi ( dc4 – d4)
Section Modulus, Z1 = ------ x -------------------
32 dc

pi (( 41.2) 4 – (40.6)4)
= ------ x -------------------------
32 41.2

= 391.29 cm3.
 W1 BM1
Total Stress = ----------- + ----------
Af1 Z1

330 77250
= ----------- + ----------
38.55 391.29

= 206 kg/cm2.

h1 5000 dm 409
---- = --------- = 12.22 , -------- = -------- = 136.33
dm 409 t 3

As per IS 6533, allowable stress is , fas1= 126 MPa

Temperature Factor for 300 C, Kt= 0.67
Allowable stress = 126 x 0.67 = 84.42 Mpa = 860.84 kg/cm2.

Actual total stress is less than allowable stress. Hence the thickness ( 3 + 3 ) 6
mm is sufficient.

2. CALCULATION FOR CYLINDRICAL SECTION 2:

Inner diameter of the section, di = 400 mm

Height of the section, H1 = 5000 mm
Thickness of the section without corrosion,t = 3 mm
Thickness of the section with corrosion, tc = 8 mm
Inner diameter of the chimney without corrosion, d= di + ( 2 x t)
= 406 mm

Outer diameter of the chimney with corrosion, dc = di + ( 2 x tc)

= 416 mm

Mean Diameter without corrosion dm = d + t

= 406 + 5 = 411 mm
Total Height from top, h2 = 10000 mm = 10 m

pi
Cross sectional area of chimney = Af2 = ---- x (dc2 – d2)
4
= 0.7854 x (41.6 2 – 40.6 2)
= 64.56 cm2
 Total Wight of section 2 (with corrosion allowance), W = 442.5 kg.
( 10 % Extra weight considered for ladder)
W2 = 402.5 + 330 = 772.5 kg

Exposed area to wind = 5 x 0.416 = 2.08 m2

Area = 2.06 + 2.08 = 4.14 m2.

Wind Force WF2 = 4.14 x 150 = 621 kg.

h2
Bending Moment BM2 = WF2 x ------
2
1000
= 621 x ------
2
= 310500 kg.cm
pi ( dc4 – d4)
Section Modulus, Z2 = ------ x -------------------
32 dc

pi (( 41.6) 4 – (40.6)4)
= ------ x -------------------------
33 41.6

= 655.46 cm3.

W2 BM2
Total Stress = ----------- + ----------
Af2 Z2
772.5 310500
= ----------- + ----------
64.56 655.46

= 485.69 kg/cm2.
h2 10000 dm 411
---- = --------- = 24.33 , -------- = -------- = 82.20
dm 411 t 5

As per IS 6533, allowable stress is , fas2= 118 MPa

Temperature Factor for 300 C, Kt= 0.67
Allowable stress = 118 x 0.67 = 79.06 Mpa = 806.19 kg/cm2.

Actual total stress is less than allowable stress.

Hence the thickness ( 5 + 3 ) 8 mm is sufficient.
3. CALCULATION FOR CYLINDRICAL SECTION 3:

Inner diameter of the section, di = 400 mm

Height of the section, H3 = 5000 mm
Thickness of the section without corrosion,t = 3 mm
Thickness of the section with corrosion, tc = 12 mm
Inner diameter of the chimney without corrosion, d= di + ( 2 x t)
= 406 mm
Outer diameter of the chimney with corrosion, dc = di + ( 2 x tc)
= 424 mm
Mean Diameter without corrosion dm = d + t
= 406 + 9 = 415 mm
Total Height from top, h3 = 15000 mm = 15 m
pi
Cross sectional area of chimney = Af3 = ---- x (dc2 – d2)
4
= 0.7854 x (42.4 2 – 40.6 2)
= 117.34 cm2
Total Wight of section 2 (with corrosion allowance), W = 670.5 kg.
( 10 % Extra weight considered for ladder)
W3 = 670.5 + 772.5 = 1443 kg

Exposed area to wind = 5 x 0.424 = 2.12 m2

Area = 4.14 + 2.12 = 6.26 m2.
Wind Force WF3 = 6.26 x 150 = 939 kg.
h3
Bending Moment BM3 = WF3 x ------
2
1500
= 939 x ------
2
= 704256 kg.cm

pi ( dc4 – d4)
Section Modulus, Z3 = ------ x -------------------
32 dc
pi(( 42.4) – (40.6)4)
4

= ------ x -------------------------
32 42.4

= 1192.07 cm3.
 W3 BM3
Total Stress = ----------- + ----------
Af3 Z3

1443 704256
= ----------- + ----------
117.34 1192.07

= 603.08 kg/cm2.

h3 15000 dm 411
---- = --------- = 36.14 , -------- = -------- = 46.11
dm 415 t 9

As per IS 6533, allowable stress is , fas3= 95.5 MPa

Temperature Factor for 300 C, Kt= 0.67
Allowable stress = 95.5 x 0.67 = 63.985 Mpa = 652.47 kg/cm2.

Actual total stress is less than allowable stress. Hence the thickness ( 9 + 3 ) 12
mm is sufficient.

4. CALCULATION FOR FLARE SECTION 1:

Inner diameter of the section at top , di 1 = 400 mm

Inner diameter of the section at bottom, di2 = 566 mm
Height of the section, H4 = 5000 mm
Thickness of the section without corrosion,t = 3 mm
Thickness of the section with corrosion, tc = 12 mm
Inner diameter of the chimney at top without corrosion,
d1= di1 + ( 2 x t) = 406 mm
Inner diameter of the chimney at top without corrosion,
d2= di2 + ( 2 x t) = 572 mm

Outer diameter of the chimney at top with corrosion,

dc1 = di1 + ( 2 x tc) = 424 mm
Outer diameter of the chimney at bottom with corrosion,
dc2 = di2 + ( 2 x tc) = 590 mm

Mean Diameter without corrosion at bottom dm = d2 + t

= 572 + 9 = 581 mm
Total Height from top, h4 = 20000 mm = 20 m
 pi
Cross sectional area of chimney = Af4 = ---- x (dc22 – d22)
4
= 0.7854 x (59.0 2 – 57.2 2)
= 164.27 cm2
Total Wight of section 2 (with corrosion allowance), W = 806 kg.
( 10 % Extra weight considered for ladder)
W4 = 1443 + 806 = 2249 kg
Exposed area to wind = 2.535 m2
Area = 6.26 + 2.535 = 8.795 m2.
Wind Force WF4 = 8.795 x 150 = 1319.25 kg.
H4
Bending Moment BM4 = WF4 x ------
2
2000
= 1336.8 x ------
2
= 1319250 kg.cm

pi ( dc24 – d24)
Section Modulus, Z4 = ------ x -------------------
32 dc2
pi(( 59.0) – (57.2)4)
4

= ------ x -------------------------
32 59.0
3
= 2350.2 cm .
W4 BM4
Total Stress = ----------- + ----------
Af4 Z4
2249.5 1319250
= ----------- + ----------
164.27 2350.2
2
= 575.03 kg/cm .

h4 20000 dm 581
---- = --------- = 34.42 , -------- = -------- = 64.56
dm 581 t 9

As per IS 6533, allowable stress is , fas1= 99 MPa

Temperature Factor for 300 C, Kt= 0.67
Allowable stress = 99 x 0.67 = 66.33 Mpa = 676.38 kg/cm2.

Actual total stress is less than allowable stress.

Hence the thickness ( 9 + 3 ) 12 mm is sufficient.
5. CALCULATION FOR FLARE SECTION 2:

Inner diameter of the section at top , di 1 = 566 mm

Inner diameter of the section at bottom, di2 = 733 mm
Height of the section, H4 = 5000 mm
Thickness of the section without corrosion,t = 3 mm
Thickness of the section with corrosion, tc = 12 mm
Inner diameter of the chimney at top without corrosion,
d1= di1 + ( 2 x t) = 572 mm
Inner diameter of the chimney at top without corrosion,
d2= di2 + ( 2 x t) = 739 mm

Outer diameter of the chimney at top with corrosion,

dc1 = di1 + ( 2 x tc) = 590 mm
Outer diameter of the chimney at bottom with corrosion,
dc2 = di2 + ( 2 x tc) = 757 mm

Mean Diameter without corrosion at bottom dm = d2 + t

= 739 + 9 = 748 mm
Total Height from top, h5 = 25000 mm = 25 m

pi
Cross sectional area of chimney = Af5 = ---- x (dc22 – d22)
4

= 0.7854 x (75.7 2 – 73.9 2)

= 211.49 cm2
Total Wight of section 2 (with corrosion allowance), W = 1076.5 kg.
( 10 % Extra weight considered for ladder)
W5 = 2249.5 + 1076.5 = 3326 kg

Exposed area to wind = 3.3675 m2

Area = 8.795 + 3.3675 = 12.1625 m2.

Wind Force WF5 = 12.1625 x 150 = 1824.375 kg.

H5
Bending Moment BM5 = WF5 x ------
2
2500
= 1824.375 x ------
2
= 2280469 kg.cm
 pi ( dc24 – d24)
Section Modulus, Z5 = ------ x -------------------
32 dc2

pi (( 75.7) 4 – (73.9)4)
= ------ x -------------------------
32 75.7
3
= 3908.33 cm .
W5 BM5
Total Stress = ----------- + ----------
Af5 Z5

3326 2280469
= ----------- + ----------
211.5 3908.33

= 599.22 kg/cm2.

h4 25000 dm 748
---- = --------- = 33.42 , -------- = -------- = 83.11
dm 748 t 9

As per IS 6533, allowable stress is , fas5= 101 MPa

Temperature Factor for 300 C, Kt= 0.67
Allowable stress = 101 x 0.67 = 67.67 Mpa = 690.04 kg/cm2.

Actual total stress is less than allowable stress. Hence the thickness ( 9 + 3 ) 12
mm is sufficient.

6. CALCULATION FOR FLARE SECTION 3:

Inner diameter of the section at top , di 1 = 733 mm

Inner diameter of the section at bottom, di2 = 900 mm
Height of the section, H4 = 5000 mm
Thickness of the section without corrosion,t = 3 mm
Thickness of the section with corrosion, tc = 12 mm
Inner diameter of the chimney at top without corrosion,
d1= di1 + ( 2 x t) = 739 mm
Inner diameter of the chimney at top without corrosion,
d2= di2 + ( 2 x t) = 906 mm
Outer diameter of the chimney at top with corrosion,
dc1 = di1 + ( 2 x tc) = 757 mm
Outer diameter of the chimney at bottom with corrosion,
dc2 = di2 + ( 2 x tc) = 924 mm

Mean Diameter without corrosion at bottom dm = d2 + t

= 906 + 9 = 915 mm
Total Height from top, h6 = 30000 mm = 30 m
pi
Cross sectional area of chimney = Af6 = ---- x (dc22 – d22)
4
= 0.7854 x (92.4 2 – 90.6 2)
= 258.71 cm2
Total Wight of section 2 (with corrosion allowance), W = 1348.5 kg.
( 10 % Extra weight considered for ladder)
W6 = 3326 + 1348.5 = 4674.5 kg

Exposed area to wind = 4.2025 m2

Area = 12.1625 + 4.2025 = 16.365 m2.

Wind Force WF6 = 16.365 x 150 = 2454.7 kg.

H6
Bending Moment BM6 = WF6 x ------
2
3000
= 2454.7 x ------
2
= 3682125 kg.cm

pi ( dc24 – d24)
Section Modulus, Z6 = ------ x -------------------
32 dc2

pi(( 92.4) 4 – (90.6)4)

= ------ x -------------------------
32 92.4

= 5860.75 cm3.
 W6 BM6
Total Stress = ----------- + ----------
Af6 Z6

4674.65 3682125
= ----------- + ----------
258.71 5860.75

= 646.34 kg/cm2.

h4 30000 dm 915
---- = --------- = 32.79 , -------- = -------- = 101.67
dm 915 t 9

As per IS 6533, allowable stress is , fas1= 102.5 MPa

Temperature Factor for 300 C, Kt= 0.67
Allowable stress = 102.5 x 0.67 = 68.675 Mpa = 700.29 kg/cm2.

Actual total stress is less than allowable stress. Hence the thickness ( 9 + 3 ) 12
mm is sufficient.
 HOLDING DOWN BOLTS:

4 x BM6 Wt.
P1 = --------------- - -------- Material of Construction : IS -225
n. D1 n P1 = Max. force in one bolt
BM6 = Bending moment at base
N = No. of bolts
D1 = Dia. of bolt ring
Wt. = Wt. Of chimney.

4 x 3682125 4674.6
P1 = --------------------- - ------------ Cosidering 12 nos. of bolts at
12 x 120 12 120 cm PCD.

= 9838.571 kg.

P1
BOLT STRESS = --------
AC/S Dia. Of bolt = 36 mm

9838.571
= ------------------ AC/S = 10.17 * 0.8
8.14 = 8.14 cm2

= 1208 kg/cm2.
Allowable max. tensile stress in bolt is 1260 kg/cm2. Hence design is OK.

BASE PLATE THICKNESS:

Compressive force/unit length of base plate 4 x 3682125 4674.6

Circumferentially = -------------------- + -----------
Pi x (92.4)2 pi x 120

= 561.5 kg/cm

Width of plate = 30 cm
561.5
= -------------
30
= 18.7 kg/cm2.
Normal allowable bearing stress on concrete is 40 kg/cm2.
Hence Design is OK.
PLATE THICKNESS :
b 3 x Fc
t= ---
2 Fs

b = Width of plate = 30 cm
Fc= Bearing stress on the foundation.
Fs= Allowable bending stress in plate = 1650 kg/cm2
30 3 x 18.7
t= ---
2 1650

= 2.76 cm.

Hence required base plate thickness is 28 mm.

Provided base plate thickness is 30 mm. Hence OK.

ANCHOR BOLT LENGTH:

Force per bolt
Bolt Length = ------------------------
10 x periphery of bolt
9838
= ---------------------
10 x 3.6 x pi

= 87 cm. = 870 mm.

Maximum embedded length of bolt = 40 x Dia. of bolt

= 40 x 36
= 1440 mm.

Provided in contract is 1500 mm. Hence safe.

DEFLECTION OF CHIMNEY:

W L3
STACK : Ymax. = ------------- I = Z x D /2
8 EI
(0.424 x 15 x 150) x (1500)3 I = 1192.07 x 42.4/2
= ---------------------------- I = 25271.8 cm4
8 x 2.1x106 x 25271.8
= 7.58 cm

BOTTOM CONE :
W L3
Ymax. = ------------- I = Z x D /2
8 EI
(0.924 x 15 x 150) x (1500)3 I = 5860.75 x 92.4/2
= ---------------------------- I = 270766.6 cm4
8 x 2.1x106 x 270766.6
= 1.54 cm

Total Deflection = Stack + Bottom cone

= 7.58 + 1.54
= 9.12 cm
= 91.2 mm

Allowable deflection should not exceed as per code H/200

= 30000/ 200
= 150 mm

Hence safe.