TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE

TCE.M1-ME-266-101
BASIC STUDY GUIDE FOR STACKS SHEET i OF iii

BASIC STUDY GUIDE FOR

STACKS

REV.NO. R0 R1 ISSUE

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD.BY PAT Sd/- PAT

CHD.BY APW Sd/- TSR R1

APD.BY RL Sd/- RL

DATE 00.01.13 02.02.22

TCE FORM NO. 020R2

 TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE
TCE.M1-ME-266-101
BASIC STUDY GUIDE FOR STACKS SHEET i OF iii

FLOPPY NO. : TCE.00000-ME-FP-108

FILE NAME : M1ME101R1.DOC

REV.NO. R0 R1 ISSUE

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD.BY PAT Sd/- PAT

CHD.BY APW Sd/- TSR R1

APD.BY RL Sd/- RL

DATE 00.01.13 02.02.22

TCE FORM NO. 020R2

 TCE CONSULTING ENGINEERS LIMITED SECTION: CONTENTS
TCE.M1-ME-266-101 SHEET ii OF iii
BASIC STUDY GUIDE FOR STACKS

CONTENTS
SL. NO. TITLE SH. NO.

1.0 SCOPE 1

2.0 INPUT DATA 1

3.0 STACK CONSTRUCTION 1

4.0 TYPE OF STACK 2

5.0 STACK HEIGHT BASED ON EMISSION 2

REGULATIONS
6.0 STACK DIAMETER AND HEIGHT BASED ON 2
DRAFT LOSS CALCULATIONS

7.0 SALIENT FEATURES OF STACK 4

8.0 PAINTING VERSUS ALUMINISING OF 4

STEEL STACKS
FIGURES

1. RECOMMENDED STACK DIAMETER 7

2. STACK HEIGHT VERSUS STACK DRAFT 8

3. STACK EXIT GAS TEMPERATURE VERSUS 9

STACK DIMENSIONS

4. FRICTION FACTOR VERSUS REYNOLD’S 10

NUMBER

ISSUE
R1

TCE FORM NO. 120 R1

 TCE CONSULTING ENGINEERS LIMITED SECTION: REV. STATUS
TCE.M1-ME-266-101 SHEET iii OF iii
BASIC STUDY GUIDE FOR STACKS

REVISION STATUS

REV. NO. DATE DESCRIPTION

R0 00.01.13 ----

R1 02.02.22 Generally revised.

ISSUE
R1

TCE FORM NO. 120 R1

 TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M1-ME-266-101 SHEET 1 OF 10
BASIC STUDY GUIDE FOR STACKS

1.0 SCOPE

This document gives guidelines for carrying out a basic study for stacks. For format,
structure and other guidelines for preparation of a basic study refer TCE.M9-PCS-
25.

2.0 INPUT DATA

2.1 STEAM GENERATOR (SG), HOT WATER BOILER AND THERMIC FLUID
HEATER (TFH)

2.1.1 Fuel firing rate for worst fuel at 100% Maximum Continuous Rating (MCR)

2.1.2 Flue gas flow rate at 100% MCR for the design fuel considering leakage in air pre-
heater (if applicable) for SG, hot water boiler or TFH

2.1.3 Flue gas temperature at stack inlet at 100% MCR for design fuel considering
leakage in air pre-heater (if applicable) for SG, hot water boiler or TFH

2.2 DIESEL ENGINE, DIESEL GENERATOR (DG) AND HEAT RECOVERY

STEAM GENERATOR (HRSG)

2.2.1 Fuel consumption at rated capacity. For HRSG this is applicable only if
supplementary firing is provided.

2.2.2 Flue gas flow rate at rated capacity

2.2.3 Flue gas temperature at stack inlet at rated capacity

2.3 GENERAL

2.3.1 Maximum ambient air temperature

2.3.2 Barometric pressure

2.3.3 Sulphur content in fuel

2.3.4 Flue gas density at stack inlet

2.3.5 Centre-line elevations of flue gas inlets

3.0 STACK CONSTRUCTION

ISSUE
R1

TCE FORM NO. 120 R1

 TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M1-ME-266-101 SHEET 2 OF 10
BASIC STUDY GUIDE FOR STACKS

The stack may be either of steel or RCC. Generally, consider steel stacks for
heights upto 65 M and RCC stacks for heights above 65 M. Refer IS 6533 and
consult civil engineer for general design considerations.
4.0 TYPE OF STACK

For installation having more than one SG, hot water boiler, TFH or HRSG, the
stack may be any of the following types :
(a) Individual stack for each of the units

(b) Common stack for all the units

(c) Multiflue stack for all the units

Type of stack shall be decided based on economic comparison of the three types of
stacks. For diesel engines and DGs, manufacturers normally recommend only
individual stacks. Decide on the type of stack in consultation with the manufacturers.

Steel stacks may be either self supported or structurally supported or supported by

guy wires. Decide the type of supporting arrangement in consultation with civil
engineer.

5.0 STACK HEIGHT BASED ON EMISSION REGULATIONS

List the prevalent emission regulations in the basic study. These are given in the
relevant publications of the Ministry of Environment and Forests (MOEF) and State
Pollution Control Board (PCB). Calculate height of stack based on applicable
regulations.

6.0 STACK DIAMETER AND HEIGHT BASED ON DRAFT LOSS

CALCULATIONS

Step-by-step procedure for determination of stack diameter and height is given

below:
(a) Consider a design margin of 10% on the flue gas flow rate and from figure
1, obtain recommended stack diameter for natural draft.
(b) Assume stack exit gas temperature and calculate average stack gas
temperature. Consider a stack draft of one (1) inch of Water Column(WC)
and increase it to 1.1 inches for safety margin.

(c) From figure 2, obtain approximate stack height above flue gas entrance for
stack draft of 1.1 inches of WC and average stack gas temperature. This is
ISSUE
R1

TCE FORM NO. 120 R1

 TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M1-ME-266-101 SHEET 3 OF 10
BASIC STUDY GUIDE FOR STACKS

the tentative stack height excluding height from foundation to flue gas
entrance.

(d) From figure 3, obtain stack exit gas temperature for the tentative stack
height obtained at (c), recommended stack diameter obtained at (a) and
stack inlet gas temperature which is the input data.

(e) Compare the “Obtained Stack Exit Gas Temperature” with “Assumed
Stack Exit Gas Temperature”.

(f) Determine revised average stack gas temperature with the “Obtained Stack
Exit Gas Temperature” and repeat the steps (c) to (e) till obtained value is
within + 5% of assumed value.

(g) Based on exit gas temperature arrived, final required stack height is
obtained. This represents the active height to which the height of any inactive
section from foundation to stack flue gas entrance shall be added.

(h) The stack flow loss shall be checked by using values for diameter, height,
average gas temperature and gas flow in equation below:

ISSUE
R1

TCE FORM NO. 120 R1

 TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M1-ME-266-101 SHEET 4 OF 10
BASIC STUDY GUIDE FOR STACKS

Stack flow loss = (2.76/B) f Tg(L/Df5) (W/105)2+ (2.76/B)

(Tg/De4)(W/105)2 (Source : See N-1)

where stack flow loss is in inches of WC

W = mass flow rate of gas, lb/hr

Df = average internal stack diameter, ft

De = internal exit stack diameter, ft

L = stack height above gas entrance, ft

f = Moody friction factor from figure 4, dimensionless

Tg = average absolute gas temperature, R

B = barometric pressure, inches of Hg

(i) Theoretical stack draft is calculated using the equation:

Stack draft (inches of WC) = 7.57L (1/Ta – 1/0.965Tg)(B/30), where Ta =

absolute ambient temperature(R), (Source : See N1)

(j) Net available draft or available induced draft at the stack entrance is the
difference between theoretical stack draft and stack flow losses. It shall be
ensured that theoretical stack draft is 10% more than stack flow losses.
While arriving at net available draft, check whether entry losses are already
considered by SG, hot water boiler, diesel engine, DG, HRSG or TFH
vendor.

(k) Height arrived at using above method shall be checked with MOEF
regulations. If height calculated using above method is less than height
calculated based on MOEF regulations, height as per latter method shall be
followed. Civil aviation authorities regulations shall also be considered
before finalising the stack height. Generally, MOEF recommended height is
more than the height as per draft calculations.

(l) Steel stacks may be in cylindrical sections of varying diameters. Number of

sections and diameters shall be decided by the civil engineer. For RCC
stacks, consult civil engineer for determining the slope.

N-1: ‘Steam- Its Generation and Use’ (38th Edition) by Babcock and Wilcox

ISSUE
R1

TCE FORM NO. 120 R1

 TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M1-ME-266-101 SHEET 5 OF 10
BASIC STUDY GUIDE FOR STACKS

7.0 SALIENT FEATURES OF STACK

7.1 The basic study shall include briefly the civil construction aspects of the selected
stack configuration. Also include in the basic study, the salient features of the stack
with regard to provision of lining, insulation, if any, access door, clean out door, soot
hopper, exit nozzle, rain hood, stack monitoring system, sampling points, air vents,
cap, ladder, platforms, mounting arrangements, lighting, aviation beacons, earthing
and lightning protection etc. A data sheet shall be included as part of basic study.
For single flue stacks standard format TCE.M4-126-12 may be used.

7.2 Lining of stack may be required for one or more of the following purposes:

(a) To protect the stack shell from heat,

(b) To act as a protective covering thus reducing corrosion, and

(c) To maintain the temperature of the flue gases.

7.3 Lining details of stacks shall be decided by civil department.

8.0 PAINTING VERSUS ALUMINISING OF STEEL STACKS

8.1 PAINTING

8.1.1 Paints provide barrier protection by physically covering the metal with a film. Once
the paint film gets damaged barrier protection ceases and corrosion sets in. A
corrosion allowance of 5 mm is required to be provided to compensate for the
material loss due to corrosion. In case the flue gas is very corrosive SS lining or
gunniting is provided on the inside surface.

8.1.2 The internal surface of an unlined stack shall have two (2) coats of red oxide or zinc
chromate primer and external surface shall have one (1) coat of red oxide or zinc
chromate primer. Both internal and external surfaces shall then have two (2) coats of
heat resistant aluminium finish paint.

8.1.3 Painting also requires regular maintenance. Depending on the service temperature
and corrosive gas components, the frequency of maintenance of painting varies. For
conventional thermal power plants the stack surface is required to be repainted at
least once in 2 to 3 years. For high temperature applications, like stacks of DG
power plants and bypass stacks of Combined Cycle Power Plants (CCPP), the
frequency of maintenance painting is more compared to conventional power plants.
In case of chimney of captive power plant, located in fertiliser, petrochemical or in
chemical plants, having corrosive ambient atmosphere, painting may be required
even at an interval of 1 year.

ISSUE
R1

TCE FORM NO. 120 R1

 TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M1-ME-266-101 SHEET 6 OF 10
BASIC STUDY GUIDE FOR STACKS

8.2 ALUMINISING

8.2.1 Aluminising is a process of spraying aluminium to act as a protective coating on to

steel components to prevent heat oxidation, corrosion and scaling at high
temperatures upto 10000C. Before aluminising, the surface shall be thoroughly
cleaned by abrasive blasting equivalent to Swedish Standard SA2½ or SA3.
Aluminium coating is applied by means of metal spraying pistols fed with aluminium
powder or wire. The thickness of coating differs with respect to the service
temperature as per BS 2569, part-2. The sprayed metal coating for the protection
of iron and steel against corrosion at elevated temperatures are covered in BS 2569,
part-2. As per this code, the aluminising and subsequent tests for the uniformity and
adhesion of the coating have to be carried out. To enhance the appearance and to
have a smooth surface, sealing with one coat of painting (sealer coat) is
recommended on outside. Sealing is recommended on inside also to have a smooth
surface which would reduce the friction factor for flue gas flow.

8.2.2 The sprayed aluminium coating provides excellent oxidation resistance and
protection both against corrosion by industrial atmosphere and by hot gases.

8.2.3 Aluminium offers electro-chemical or sacrificial protection by being anodic to steel.

It sacrifices itself by cathodic action and thus prevents the underlying steel from
corroding.

8.2.4 Aluminising is a long term maintenance free protection of steel stacks and this
reduces the plant outage time. As per BS 5493- 1977, Sec.2:
(a) Unsealed aluminium sprayed coating has a life of 20 years before first
maintenance for corrosive atmosphere and for high temperature surfaces.
(b) Sealed aluminium spraying coating has a life of 20 years before first
maintenance for corrosive atmosphere and for high temperature surfaces,
and it is recommended for stacks requiring aesthetic, colour, inert barrier
and abrasive resistance.
(c) Sealed aluminium sprayed coating with first maintenance painting after 20
years is recommended for a very long life of more than 20 years (more than
the life of the plant). The first maintenance coating thickness shall be
minimum 75 microns with a finish coat.
(d) Sealed aluminium sprayed coating with frequent maintenance painting (no
requirement of measurable overlay of sealer, one coat is sufficient) is
recommended for indefinite life period of the stacks.
8.2.5 The corrosion allowance of 5 mm which is normally provided for painted stacks
shall be eliminated if aluminising is carried out on both interior and exterior surfaces,
since possibility of corrosion attack on the metal surface is almost nil. Corrosion
allowance of 5 mm shall be provided if only exterior surface is aluminised.

ISSUE
R1

TCE FORM NO. 120 R1

 TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M1-ME-266-101 SHEET 7 OF 10
BASIC STUDY GUIDE FOR STACKS

8.2.6 Not much variation is expected in the time duration for aluminising and painting.
Approximately 150 M2 of surface area can be aluminised in a day. Hence,
aluminising is not expected to cause any delay in project implementation.
8.2.7 Following limitations are experienced in aluminising of steel stacks:
(a) Aluminising of entire internal surface of the stacks already erected has not
yet become viable. But the inside weldments at the joints can be aluminised
irrespective of the stack height.
(b) Aluminising of interior surface of the stacks of diameter less than 750 mm is
not possible even at ground level.
8.3 CONCLUSION

Aluminising is a better and economical process than painting to enhance the life of
stacks by preventing corrosion due to high temperature, acid gas and moist
environments. The cost of aluminising and maintenance painting once in 5 years is
cheaper than the cost of painting once in 2 to 3 years. For DG set exhaust gas
stacks and CCPP bypass stacks, due to the high temperature service, the frequency
of repainting may be still higher than that of conventional utility plants and hence
aluminising becomes more economical practice to enhance the life of stacks.
Aluminising of exterior surface only, shall be specified for the stacks of diameter less
than 750 mm and corrosion allowance of 5 mm shall be provided to take care of
inside corrosion.

ISSUE
R1

TCE FORM NO. 120 R1

 TCE CONSULTING ENGINEERS LIMITED SECTION: FIGURE
TCE.M1-ME-266-101 SHEET 7 OF 10
BASIC STUDY GUIDE FOR STACKS

FIGURE 1
RECOMMENDED STACK DIAMETER

SOURCE: ‘Steam- Its generation and Use’ 38th

Edition – by Babcock and Wilcox

ISSUE
R1

TCE FORM NO. 120 R1

 TCE CONSULTING ENGINEERS LIMITED SECTION: FIGURE
TCE.M1-ME-266-101 SHEET 8 OF 10
BASIC STUDY GUIDE FOR STACKS

FIGURE 2
STACK HEIGHT VERSUS STACK DRAFT

SOURCE: ‘Steam- Its generation and Use’ 38th

Edition– by Babcock and Wilcox

ISSUE
R1

TCE FORM NO. 120 R1

 TCE CONSULTING ENGINEERS LIMITED SECTION: FIGURE
TCE.M1-ME-266-101 SHEET 9 OF 10
BASIC STUDY GUIDE FOR STACKS

FIGURE 3
STACK EXIT GAS TEMPERATURE
VERSUS STACK DIMENSIONS

ISSUE
R1

TCE FORM NO. 120 R1

 TCE CONSULTING ENGINEERS LIMITED SECTION: FIGURE
TCE.M1-ME-266-101 SHEET 10 OF 10
BASIC STUDY GUIDE FOR STACKS

SOURCE: ‘Steam- Its generation and Use’(38th

Edition) by Babcock and Wilcox

FIGURE 4
FRICTION FACTOR VERSUS REYNOLD’S NUMBER

ISSUE
R1

TCE FORM NO. 120 R1

 TCE CONSULTING ENGINEERS LIMITED SECTION: FIGURE
TCE.M1-ME-266-101 SHEET 11 OF 10
BASIC STUDY GUIDE FOR STACKS

SOURCE: ‘Steam- Its generation and Use’ 38th Edition –

by Babcock and Wilcox

ISSUE
R1

TCE FORM NO. 120 R1