CHIMNEY DESIGN CALCULATION

CODE : I.S. 6533 PAGE 1 OF 14

CUSTOMER : FIRST CARBON TECHNOLOGIES PVT LTD,INDIA
CHIMNEY DIAMETER-TOP D1(IN cm) : 132
CHIMNEY DIA BOTTOM BD (IN cm) : 220
CHIMNEY HEIGHT TOTAL H( IN cm) : 4600
CORROSION ALLOWANCE : MM 3
ALLOWABLE BEARING ON FOUNDATION Ff( IN KG/cm2) : 20
ALLOWABLE BENDING STRESS-BEARING PLATE Fbp( IN KG/cm2) : 1650

DIA D1 DIA D1' D AVG SECTIONAL HEIGHT SHELL THICKNESS

( IN cm) (IN cm) (IN cm) (IN cm) (IN MM) ( IN cm)
SEGMENT I 132 132 132 960 10 1.00
SEGMENT II 132 132 132 960 12 1.20
SEGMENT III 132 132 132 920 16 1.60
SEGMENT IV 132 176 154 880 20 2.00
SEGMENT V 176 220 198 880 22 2.20

DESIGN OF SEGMENT I

DESIGN WIND SPEED (Vz)= Vb X K1 X K2 X K3 ------ IS 875(3)- 1987

WHERE K1= PROBABILITY FACTOR= 1

K2= TERRAIN FACTOR= 1.12
K3= TOPOGRAPHY FACTOR = 1
VB= BASIC WIND SPEED= 44 m/s

Vz = 49.28 METRES/SEC

DESIGN WIND PRESSURE PZ = 0.6xVzxVz NOTE: CONVERSION FACTOR

PZ = 1457.11104 N/M2 I N/M2 = 0.0000102 KG /cm2 98039.2157
PZ = 0.0148625326 Kg/cm2

WIND FORCE FL = Cf x Ae x Pz x 1.1 (Pz= WIND PRESSURE)

WHERE Cf= FORCE COEFFICIENT 1.2

Ae= EFFECTIVE AREA = AVG DIA x HEIGHT
Ae= 126720 cm2

1.1 = 10% INCREASED TO TAKE CARE OF WIND PRESSURE ON CAGE AND LADDER
WIND FORCE FL = 2486.0617744 Kg

PAGE 2 OF 14
A) BENDING MOMENT

Mx = FL(H-Y)/2 where, H= HEIGHT OF CHIMNEY in cm

Y= SECTION HEIGHT in cm
Mx= 1193309.65168954 KG cm
B) MODULUS OF SECTION

Z= .77T x D x D

WHERE T= SHELL THICKNESS W/O CORROSION ALLOWANCE(in cm) = 0.7

BOTTOM DIA(D) ( in cm)= 132

Z= 9391.536 cm^3

C) ACTUAL BENDING STRESS

FB= Mx/Z KG/cm^2

= 127.062245376 KG/cm^2
= 12457082.88 Pa
= 12.45708288 Mpa

D) ACTUAL COMPRESSION STRESS

Fc= G/A

WHERE
G= DEAD WEIGHT OF SEGMENT D1= 132 cm
D2= 130 cm
G= 3099.85824 KGS

A= AREA OF SECTION BOTTOM

W/O CORROSION ALLOWANCE

A= 288.5974 cm2

FC = 10.74111631 KG/cm2
= 1053050.619 Pa
 = 1.053050619 Mpa

E) TOTAL COMBINED STRESS

PAGE 3 OF 14
Sc = Fb+ Fc
= 13.5101334986 Mpa

REFER TABLE 3 : I.S. 6533

he/D< 20 D/t<140

MAXIMUM PERMISSIBLE COMBINED STRESS Mpa 126

WITH TEMPERATURE CORRECTION FACTOR
ALLOWABLE COMBINED STRESS a= 94.5

STABILITY CHECK

1.6 (Fb+ Fc) - 0.9 xFc < 1.8 x a

20.66846804 < 170.1 Mpa

(CALCULATED) (ALLOWABLE)

DESIGN OF SEGMENT II

DESIGN WIND SPEED (Vz)= Vb X K1 X K2 X K3 ------ IS 875(3)- 1987

WHERE K1= PROBABILITY FACTOR= 1

K2= TERRAIN FACTOR= 1.11
K3= TOPOGRAPHY FACTOR = 1
VB= BASIC WIND SPEED= 44 m/s

Vz = 48.84 METRES/SEC

DESIGN WIND PRESSURE PZ = 0.6xVzxVz NOTE: CONVERSION FACTOR

PZ = 1431.20736 N/M2 I N/M2 = 0.0000102 KG /cm2
PZ = 0.0145983151 Kg/cm2

WIND FORCE F = Cf x Ae x Pz x 1.1 (Pz= WIND PRESSURE)

WHERE Cf= FORCE COEFFICIENT 1.2

Ae= EFFECTIVE AREA = AVG DIA x HEIGHT
Ae= 253440 cm2
 1.1 = 10% INCREASED TO TAKE CARE OF WIND PRESSURE ON CAGE AND LADDER

WIND FORCE FL = 4883.7320028 Kg

A) BENDING MOMENT PAGE 4 OF 14

Mx = FL(H-Y)/2 where, H= HEIGHT OF CHIMNEY in cm

Y= SECTION HEIGHT in cm
Mx= 4688382.72272538 KG cm
B) MODULUS OF SECTION

Z= .77T x D x D

WHERE T= SHELL THICKNESS W/O CORROSIONALLOWANCE(in cm) = 0.9

BOTTOM DIA(D) ( IN cm)= 132.00

Z= 12074.832 cm3

C) ACTUAL BENDING STRESS

FB= Mx/Z KG/cm2

= 388.2772632137 KG/cm2
= 38066398.3542857 Pa
= 38.0663983543 Mpa

D) ACTUAL COMPRESSION STRESS

Fc= G/A

WHERE
G= DEAD WEIGHT OF SEGMENT D1= 132 cm
D2= 129.6 cm
G= 6814.0089984 KGS
 A= AREA OF SECTION BOTTOM PAGE 5 OF 14
W/O CORROSION ALLOWANCE

A= 370.4886 cm2
370.4886

FC = 18.39195322 KG/cm2
= 1803132.668 Pa
= 1.803132668 Mpa

E) TOTAL COMBINED STRESS

Sc = Fb+ Fc
= 39.8695310226 Mpa

REFER TABLE 3 : I.S. 6533

he/D< 20 D/t<140

MAXIMUM PERMISSIBLE COMBINED STRESS Mpa 108

WITH TEMPERATURE CORRECTION FACTOR
ALLOWABLE COMBINED STRESS a= 81

STABILITY CHECK

1.6 (Fb+ Fc) - 0.9 xFc < 1.8 x a

62.16843023 < 145.8 Mpa

(CALCULATED) (ALLOWABLE)
DESIGN OF SEGMENT III

DESIGN WIND SPEED (Vz)= Vb X K1 X K2 X K3 ------ IS 875(3)- 1987

WHERE K1= PROBABILITY FACTOR= 1

K2= TERRAIN FACTOR= 1.09
K3= TOPOGRAPHY FACTOR = 1
VB= BASIC WIND SPEED= 44 m/s

Vz = 47.96 METRES/SEC
DESIGN WIND PRESSURE PZ = 0.6xVzxVz NOTE: CONVERSION FACTOR PAGE 6 OF 14
PZ = 1380.09696 N/M2 I N/M2 = 0.0000102 KG /cm2
PZ = 0.014076989 Kg/cm2

WIND FORCE F = Cf x Ae x Pz x 1.1 (Pz= WIND PRESSURE)

WHERE Cf= FORCE COEFFICIENT 1.2

Ae= EFFECTIVE AREA = AVG DIA x HEIGHT
Ae= 374880 cm2

1.1 = 10% INCREASED TO TAKE CARE OF WIND PRESSURE ON CAGE AND LADDER

WIND FORCE FL = 6965.879756 Kg

A) BENDING MOMENT

Mx = FL(H-Y)/2 where, H= HEIGHT OF CHIMNEY in cm

Y= SECTION HEIGHT in cm
Mx= 12259948.3705313 KG cm
B) MODULUS OF SECTION

Z= .77T x D x D

WHERE T= SHELL THICKNESS W/O CORROSION ALLOWANCE(in cm) = 1.3

BOTTOM DIA(D) ( IN cm)= 132

Z= 17441.424 cm3

C) ACTUAL BENDING STRESS

FB= Mx/Z KG/cm2

= 702.9212964796 KG/cm2
= 68913852.596044 Pa
= 68.913852596 Mpa

D) ACTUAL COMPRESSION STRESS

Fc= G/A
 WHERE PAGE 7 OF 14
G= DEAD WEIGHT OF SEGMENT D1= 132 cm
D2= 128.8 cm
G= 11545.3549696 KGS

0
A= AREA OF SECTION BOTTOM
W/O CORROSION ALLOWANCE

A= 533.5174 cm2

FC = 21.64007204 KG/cm2
= 2121575.69 Pa
= 2.12157569 Mpa

E) TOTAL COMBINED STRESS

Sc = Fb+ Fc
= 71.0354282861 Mpa

REFER TABLE 3 : I.S. 6533

he/D< 20 D/t<140

MAXIMUM PERMISSIBLE COMBINED STRESS Mpa 124

WITH TEMPERATURE CORRECTION FACTOR
ALLOWABLE COMBINED STRESS a= 93

STABILITY CHECK

1.6 (Fb+ Fc) - 0.9 xFc < 1.8 x a

111.7472671 < 167.4 Mpa

(CALCULATED) (ALLOWABLE)

DESIGN OF SEGMENT IV

DESIGN WIND SPEED (Vz)= Vb X K1 X K2 X K3 ------ IS 875(3)- 1987

WHERE K1= PROBABILITY FACTOR= 1

K2= TERRAIN FACTOR= 1.06
K3= TOPOGRAPHY FACTOR = 1
VB= BASIC WIND SPEED= 44 m/s
 Vz = 46.64 METRES/SEC PAGE 8 OF 14

DESIGN WIND PRESSURE PZ = 0.6xVzxVz NOTE: CONVERSION FACTOR

PZ = 1305.17376 N/M2 I N/M2 = 0.0000102 KG /cm2
PZ = 0.0133127724 Kg/cm2

WIND FORCE F = Cf x Ae x Pz x 1.1 (Pz= WIND PRESSURE)

WHERE Cf= FORCE COEFFICIENT 1.2

Ae= EFFECTIVE AREA = AVG DIA x HEIGHT
Ae= 510400 cm2

1.1 = 10% INCREASED TO TAKE CARE OF WIND PRESSURE ON CAGE AND LADDER

WIND FORCE F = 8969.1874912 Kg

A) BENDING MOMENT

Mx = FL(H-Y)/2 where, H= HEIGHT OF CHIMNEY in cm

Y= SECTION HEIGHT in cm
Mx= 21517080.7913126 KG cm
B) MODULUS OF SECTION

Z= .77T x D x D

WHERE T= SHELL THICKNESS W/O CORROSION ALLOWANCE(in cm) = 1.7

BOTTOM DIA(D) ( IN cm)= 176

Z= 40547.584 cm3

C) ACTUAL BENDING STRESS

FB= Mx/Z KG/cm2

= 530.6624629303 KG/cm2
= 52025731.6598319 Pa
= 52.0257316598 Mpa

D) ACTUAL COMPRESSION STRESS

Fc= G/A
 WHERE PAGE 9 OF 14
G= DEAD WEIGHT OF SEGMENT D1= 154 cm
D2= 150 cm
G= 18139.4554496 KGS

A= AREA OF SECTION BOTTOM

W/O CORROSION ALLOWANCE

A= 812.9774 cm2

FC = 22.31237357 KG/cm2
= 2187487.605 Pa
= 2.187487605 Mpa

E) TOTAL COMBINED STRESS

Sc = Fb+ Fc
= 54.2132192644 Mpa

REFER TABLE 3 : I.S. 6533

he/D< 30 D/t<140

MAXIMUM PERMISSBLE COMBINED STRESS Mpa 108

WITH TEMPERATURE CORRECTION FACTOR
ALLOWABLE COMBINED STRESS a= 81

STABILITY CHECK

1.6 (Fb+ Fc) - 0.9 xFc < 1.8 x a

84.77241198 < 145.8 Mpa

(CALCULATED) (ALLOWABLE)

DESIGN OF SEGMENT V

DESIGN WIND SPEED (Vz)= Vb X K1 X K2 X K3 ------ IS 875(3)- 1987

WHERE K1= PROBABILITY FACTOR= 1

K2= TERRAIN FACTOR= 1.02
K3= TOPOGRAPHY FACTOR = 1
 VB= BASIC WIND SPEED= 44 m/s

Vz = 44.88 METRES/SEC PAGE 10 OF 14

DESIGN WIND PRESSURE PZ = 0.6xVzxVz NOTE: CONVERSION FACTOR

PZ = 1208.52864 N/M2 I N/M2 = 0.0000102 KG /cm2
PZ = 0.0123269921 Kg/cm2

WIND FORCE F = Cf x Ae x Pz x 1.1 (Pz= WIND PRESSURE)

WHERE Cf= FORCE COEFFICIENT 1.2

Ae= EFFECTIVE AREA = AVG DIA x HEIGHT
Ae= 684640 cm2

1.1 = 10% INCREASED TO TAKE CARE OF WIND PRESSURE ON CAGE AND LADDER

WIND FORCE FL = 11140.208495 Kg

A) BENDING MOMENT

Mx = FL(H-Y)/2 where, H= HEIGHT OF CHIMNEY in cm

Y= SECTION HEIGHT in cm
Mx= 25622479.54 KG cm
MODULUS OF SECTION

Z= .77T x D x D

WHERE T= SHELL THICKNESS W/O CORROSION ALLOWANCE(in cm) = 1.9

BOTTOM DIA(D) ( IN cm)= 220

Z= 70809.2 cm3

C) ACTUAL BENDING STRESS

FB= Mx/Z KG/cm2

= 361.852408156 KG/cm2
= 35475726.2898045 Pa
= 35.4757262898 Mpa

D) ACTUAL COMPRESSION STRESS

Fc= G/A
 WHERE PAGE 11 OF 14
G= DEAD WEIGHT OF SEGMENT D1= 198 cm
D2= 193.6 cm
G= 27483.1223008 KGS

A= AREA OF SECTION BOTTOM

W/O CORROSION ALLOWANCE

A= 1169.9326 cm2

FC = 23.49120137 KG/cm2
= 2303058.958 Pa
= 2.303058958 Mpa

E) TOTAL COMBINED STRESS

Sc = Fb+ Fc
= 37.7787852481 Mpa

REFER TABLE 3 : I.S. 6533

he/D< 30 D/t<140

MAXIMUM PERMISSBLE COMBINED STRESS Mpa 108

WITH TEMPERATURE CORRECTION FACTOR
ALLOWABLE COMBINED STRESS a = 81

STABILITY CHECK

1.6 (Fb+ Fc) - 0.9 xFc < 1.8 x a

58.37330333 < 145.8 Mpa

(CALCULATED) (ALLOWABLE)

FOUNDATION BOLTS

MAXIMUM FORCE ON EACH BOLT P = (4M/nD1)-(Ws/n)

WHERE M = B.M AT THE BASE OF CHIMNEY x 100000.00

n = NUMBER OF BOLTS
Ws = WEIGHT OF THE CHIMNEY
 D1 = DIA OF BOLTCIRCLE pcd=

PAGE 12 OF 14
M= 25622479.54 Kg cm
BM= 256.22 (x 100000 Kg cm)
n= 32
Ws= 32000 KGS
D1= 250 cm

P= 11811.23977 KG

NET AREA OF BOLT = 14.764049712 cm2

SAY 15 cm2
NOW BOLT DIA D2 = 19.102196753 cm2
NOW BOLT DIA D = 4.3706059938 cm

USE M50 DIA BOLT

DESIGN OF BASE PLATE

COMPRESSIVE FORCE Cf = 1.27*M/D*D+(Ws+W1)/3.142 D1

WHERE D= EXTERNAL DIA OF CHIMNEY BASE
= 275 cm
W1 = WEIGHT OF THE CHIMNEY LINING
=
Cf = 471.03 Kg / Sq.Cm
Ff = 20
REQUIRED WIDTH OF BEARING PLATE B = Cf/Ff
= 23.5513 cm

WIDTH OF BEARING PLATE PROVIDED b = 27.5 cm WIDE BEARING PALTE

THK OF BEARING PLATE t' = b/2 * sqrt (3* Ff)/Fbp

((3*Ff)/Fbp) = 0.0363636364
0.1906925178
t' 2.62202 cm

HENCE THICKNESS OF THE PLATE t' = 3.2 cm