DESIGN ANALYSIS

OF
ID 1700MM SIZE, 34.7 M HEIGHT FURNACE
STACK

Customer:

Multifacet Technical Center Pvt. Ltd. (MTCPL)

#F810, Vivekadhama, Bharthnagar
Off Magadi road, Bangalore 91
Ph: 080-32946374 fax: 080-23588044
Email: Multifacet@dataone.in, mtc.bng@multifacet.net & mtc.bng@gmail.com
Web: www.multifacet.net

Prepared by RN
P.O No. Report No. Date:
Checked by BVN
ATECH-00585/08 0801.20B 23/12/2008
Approved by BVN

Document Change Note: Total pages: 54+12 Any previous copies of this
document issued to the
customer, must be destroyed if
Rev. No By Description Appvd Date not of this current revision.
Title: Design analysis of id 1700 mm size, 34.7 m height furnace stack for Jindal, Orissa
Report No.: 0801.20B
Rev. No.: 0

Disclaimer:

The information contained is specific to the technical data

mentioned in this report.
No document will be provided to customer in any editable format.
MTCPL is not responsible for any changes made to the report by
any means and any consequences arising as a result of
manipulation of data.
Interpretation of the information contained herein should be
based on complete report and not on parts thereof.
This report is a property of MTCPL and should not be copied
either directly or indirectly without a written consent from the
company.
Disputes, if any, will be within the Jurisdiction of Bangalore only.

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Title: Design analysis of id 1700 mm size, 34.7 m height furnace stack for Jindal, Orissa
Report No.: 0801.20B
Rev. No.: 0

ABSTRACT

This report summarises the design analysis carried out on 1700 mm furnace stack. The
analysis is carried out based on procedures outlined in IS: 6533 (Part2): 1989, IS: 1893
(Part 4): 2005 and Finite Element Modeling for the stack. The Stack is analyzed for self-
weight, imposed load, wind and seismic loads. All the results have been summarized in
the form of tabulations, resultant displacement and stress contours. After studying the
stresses and deflections, comparison was made with the permissible values. It has
been demonstrated that the design meets all the engineering design criteria as per IS:
6533 (Part2): 1989, IS: 1893 (Part 4): 2005 and IS: 800 - 1984. Foundation load
calculations have also been provided.

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Title: Design analysis of id 1700 mm size, 34.7 m height furnace stack for Jindal, Orissa
Report No.: 0801.20B
Rev. No.: 0

TABLE OF CONTENTS
Contents Page No.

LIST OF FIGURES ...................................................................................................................... 5

1.0 INTRODUCTION ................................................................................................................... 6
1.1 Assumptions: .................................................................................................................. 6
1.2 Customer specifications:................................................................................................. 6
1.3 Drawings referred: .......................................................................................................... 7
1.4 Materials of construction: ................................................................................................ 7
1.5 Codes referred: ............................................................................................................... 7
1.6 Allowable stress: ............................................................................................................. 8
1.7 Allowable deformations:.................................................................................................. 9
2.0 METHODOLOGY:................................................................................................................ 10
2.1 Analysis types considered: ........................................................................................... 10
2.2 Load cases: As per IS: 6533 (Part 2): 1989.................................................................. 10
3.0 WIND AND SEISMIC LOAD CALCULATIONS:................................................................... 11
3.1 Wind load: ..................................................................................................................... 11
3.1.1 Ovalling oscillations: [BS: 4076]............................................................................ 12
3.1.2 Strouhal Critical Velocity ....................................................................................... 12
3.2 Seismic load calculations:............................................................................................. 12
3.2.1 Horizontal seismic force co-efficient...................................................................... 13
3.2.2 Design base shear force ....................................................................................... 13
4.0 EIGEN VALUE (MODAL) ANALYSIS: ................................................................................. 15
4.1 Results of Eigen value (Modal) analysis: Table 2 ........................................................ 16
4.2 Static analysis: .............................................................................................................. 16
4.3 Results of static analysis:.............................................................................................. 16
4.4 Calculation of permissible stresses in beams, columns and bracings of supporting
structure ........................................................................................................................ 36
4.4.1 Calculations of permissible compressive stresses for bottom portion of the
supporting structure .............................................................................................. 38
4.4.2 Calculations of permissible compressive stresses for top portion of the supporting
structure ................................................................................................................ 39
4.5 Summary of results: ...................................................................................................... 40
5.0 FOUNDATION BOLT LOAD CALCULATIONS: .................................................................. 42
5.1 For Supporting structure ............................................................................................... 42
5.1.1 Calculation of Uplift force: ..................................................................................... 44
5.1.2 Calculation of shear force: .................................................................................... 44
5.1.3 Bending stress in the base plate of the column of supporting structure................ 45
5.1.4 Embedded length required for foundation bolt: ..................................................... 46
5.2 For stack ....................................................................................................................... 48
5.2.1 Calculation of tensile stress: ................................................................................. 50
5.2.2 Calculation of shear stress:................................................................................... 50
5.2.3 Calculation of bending stress: ............................................................................... 50
5.2.4 Checks as per IS 800 ............................................................................................ 51
5.2.5 Embedded length required for foundation bolt:.......................................................... 52
6.0 CONCLUSIONS:.................................................................................................................. 53
7.0 LIST OF REFERENCES:..................................................................................................... 54
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Title: Design analysis of id 1700 mm size, 34.7 m height furnace stack for Jindal, Orissa
Report No.: 0801.20B
Rev. No.: 0

LIST OF FIGURES

Contents Page No.

Fig. 1 Finite element model of the stack and supporting structure ............................................ 17

Fig. 2 Meshed model of stack and supporting structure ............................................................ 18

Fig. 3 Finite element model of supporting structure................................................................... 19

Fig. 4 Finite element model of access platform for sampling port.............................................. 20

Fig. 5 Boundary conditions and applied forces .......................................................................... 21

Fig. 6 Resultant displacement in the stack for load case1 ......................................................... 22

Fig. 7 Deformed shape of the supporting structure for load case1 ............................................ 23

Fig. 8 Von-Mises stresses in the stack for load case1 ............................................................... 24

Fig. 9 Compressive stresses in the stack for load case 1 .......................................................... 25

Fig. 10 Von-Mises stresses in the supporting elements of access platform for load case 1...... 26

Fig. 11 Von-Mises stresses in the supporting structure for load case1 ..................................... 27

Fig. 12 Axial stress in the supporting structure for load case1 .................................................. 28

Fig. 13 Resultant displacement in the stack for load case 2 ...................................................... 29

Fig. 14 Deformed shape of the supporting structure for load case 2 ......................................... 30

Fig. 15 Von-Mises stresses in the stack for load case 2 ............................................................ 31

Fig. 16 Compressive stresses in the stack for load case 2 ........................................................ 32

Fig. 17 Von-Mises stresses in the supporting elements of access platform for load case 2...... 33

Fig. 18 Von-Misses stresses in the supporting structure for load case 2................................... 34

Fig. 19 Axial stresses in the supporting structure for load case2............................................... 35

Fig. 20 Front view of supporting structure (bottom portion) ....................................................... 36

Fig. 21 Front view of supporting structure (top portion) ............................................................. 37

Fig. 22 Plan view of the column of supporting structure ............................................................ 42

Fig. 23 Key plan of supporting structure (stack stand)............................................................... 43

Fig. 24 Plane view of the base plate of stack............................................................................. 50

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Title: Design analysis of id 1700 mm size, 34.7 m height furnace stack for Jindal, Orissa
Report No.: 0801.20B
Rev. No.: 0

1.0 INTRODUCTION

The waste gases produced from the combustion of natural gas with excess of air is led
out to atmosphere through the stack (34.7M height). The stack is supported with a
supporting structure of height of 15984mm. It has a platform at a height of 27340 mm.
The sampling port is situated at a height of 28340 mm.

In the present stack, 14382 mm from the top of the stack is exposed to wind, while the
remaining height is enclosed in a building. The material of construction for stack body
and platforms is carbon steel (IS 2062 Gr. B), while for supporting structure it is St 42.

1.1 Assumptions:

1. The stack structure is considered as a thin shell. D/t Ratio (107.25) is greater
than 10. Therefore, thin shell elements 3D general shell element has been
employed.
2. The platform structure essentially consists of angle sections, flats and pipes.
These have been modeled as 3D beam elements.
3. Foundation bolt stresses have been provided for the worst combination of loads.
4. Theory of linear superposition has been applied for calculating stresses and
deflections from load combinations.
5. If any welds are to be done at site, the weld proportions are to be increased by
20% to take care of reduction in strength.
6. Wind speed within the building is assumed to be 5 m/s.
7. IS: 800 permits induced stresses to be exceeded by 33.3% on permissible
values for the case of wind load or earthquake load. As the state of stress in the
stack and supporting structure are within the limits, by Hooks law, we expect a
corresponding increase in the limits for deflections would be possible.

1.2 Customer specifications:

Design data:
Size : 1700mm (inner diameter)
Height : 34.7 M
Site :
Type : Supported by structure
Material : carbon steel (IS 2062 Gr. B)
Fluid Handled : The waste gases produced from the combustion of
natural gas
Gas flow rate : 65000 m3/hr.
Gas Temperature : 350C (max)
Seismic Zone : zone - III
Basic wind Speed : 50 m/s
Corrosion Allowance : 2 mm

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Title: Design analysis of id 1700 mm size, 34.7 m height furnace stack for Jindal, Orissa
Report No.: 0801.20B
Rev. No.: 0

1.3 Drawings referred:

1. 2802-0015 RC

1.4 Materials of construction:

Cylindrical Shell : Carbon Steel (IS: 2062 Gr. B)

Platforms, Ladders : Carbon Steel (IS: 2062 Gr. B)
Foundation Bolts : Carbon steel, IS: 1364 Gr. 8.8

1.5 Codes referred:

Code of Practice for design and construction of steel chimney IS: 6533 (Part2)-
1989 (reaffirmed 2003)

Code of Practice for design loads (other than earthquake) for buildings and
Structures - Part 3 Wind loads IS: 875 1987 (reaffirmed 2003)

Criteria for earthquake resistant design of structures IS: 1893 (Part1 (2002) &
Part 4) 2005

Code of Practice for general construction in steel IS: 800 1984 (re-affirmed in
1998)

IS: 456- 2000 Code of practice for plain & reinforced concrete

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Title: Design analysis of id 1700 mm size, 34.7 m height furnace stack for Jindal, Orissa
Report No.: 0801.20B
Rev. No.: 0

1.6 Allowable stress:

1. Allowable Stress in compression : 17.12 kgf/mm2 (168 MPa) (Ref. 1)

Allowable stress is found out from table 3, IS: 6533 (Part 2)
he/D = 34.7/1.716 =20.22 and D/t = 1.716/.016 = 107.25
Where, he = effective height of stack = 34.76 m
D = mean diameter = 1.7016 m
t = thickness of the plate = 0.016 m (16 mm)
From Table 3, stress corresponding to he/D(20.22) and D/t(107.25) allowable stress
is 12.84 kgf/mm2 (126 MPa)

As per IS 800, when wind load or seismic load is considered, the permissible stress
can be exceeded by 33.33%. Hence the allowable stress in compression is 12.84 *
1.3333 = 17.12 Kgf/mm2 (168 MPa)

2. Allowable stress for carbon steel (IS: 2062 Gr. B) :

Ultimate Tensile strength : 410 MPa
Yield Strength : 240 MPa
Allowable Stress at 350C : 79.46 MPa (8.1 kgf/mm2) (Ref. 11)

As per IS 800, when wind load or seismic load is considered, the permissible stress
can be exceeded by 33.33%. Hence the allowable stress is 79.46 * 1.3333 = 106
MPa (10.8 Kgf/mm2)

3. Allowable stress for foundation bolt : IS: 1364 Gr. 8.8

Ultimate Tensile strength : 785 MPa
Yield Strength : 628 MPa
Allowable Stress : 262 MPa (27 kgf/mm2)
: (Min of 1/3 of UTS or 2/3 of YS)
Allowable shear stress : 131 MPa(13.5 kgf/mm2)

As per IS 800, when wind load or seismic load is considered, the permissible bolt
stress can be exceeded by 25%. Hence the allowable stresses are:

a. Allowable stress in tension = 327.5 MPa (33.4 Kgf/mm2)

b. Allowable stress in shear = 163.75 MPa (16.69 Kgf/mm2)

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Title: Design analysis of id 1700 mm size, 34.7 m height furnace stack for Jindal, Orissa
Report No.: 0801.20B
Rev. No.: 0

2.0 METHODOLOGY:

Refer to Figs. 1, 2, 3 and 4 for finite element model of the stack. Using NISA
[Numerically Integrated Elements for System Analysis], the entire stack is modeled with
4-Noded plate elements while the supporting structure (stack stand) is made from 3D
beam elements. The FEM model consists of 6969 nodes and 7172 elements. Fig 2
shows finite element mesh pattern. The Stack and the supporting structure in FEM
model is considered fixed at their respective. The self-weight, wind loads and seismic
loads were applied to stack in the form of different load cases. Stress analysis was
carried out by Finite element software NISA. The Von-Mises stresses, maximum
compressive stress (Szz) and Resultant displacement were compared with the
allowable values for the given material of construction. Results were compared and
tabulated for all the load cases. Foundation load table and calculations were made for
the worst combination of loadings.

2.1 Analysis types considered:

1. Eigen Value (Modal) Analysis to determine natural frequencies of vibration.

2. Static Analysis considering the static wind effect, dead load and imposed load
3. Seismic Analysis

2.2 Load cases: As per IS: 6533 (Part 2): 1989

Load case 1: Dead load + Imposed load + Wind load

Load case 2: Dead load + Imposed load + Seismic load

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Title: Design analysis of id 1700 mm size, 34.7 m height furnace stack for Jindal, Orissa
Report No.: 0801.20B
Rev. No.: 0

Fig. 6 Resultant displacement in the stack for load case1

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Title: Design analysis of id 1700 mm size, 34.7 m height furnace stack for Jindal, Orissa
Report No.: 0801.20B
Rev. No.: 0

Fig. 8 Von-Mises stresses in the stack for load case1

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Title: Design analysis of id 1700 mm size, 34.7 m height furnace stack for Jindal, Orissa
Report No.: 0801.20B
Rev. No.: 0

4.5 Summary of results:

a. Deflection: Table 3
Permissible deflection at Actual deflection at the
Load case No.
the top of stack top of stack
1 231 165
2 138.6 123.8

b. Stresses in stack: Table 4

Von-Mises stresses in Kgf/mm2 Compressive stresses in

(MPa) Kgf/mm2 (MPa)
Load Case
No. Allowable
Allowable stress Induced Induced
stress

1 10.8 (106) 8.579 (84.2) 17.12 (168) 7.413 (72.7)

2 10.8 (106) 5.577 (54.7) 17.12 (168) 5.690 (55.8)

c. Stresses in the elements of supporting structure (Bottom portion): Table 5

Von-Mises stresses in Compressive stress in

Kgf/mm2 (MPa) Kgf/mm2 (MPa)
Load case No.
Beam Column Bracing Beam Column Bracing

Allowable stress
18.66 18.66 18.66 19.9 20.16 17.12
in Kgf/mm2
(183) (183) (183) (195.3) (197.8) (168)
(MPa)
17.66 8.876 8.846 0.782 6.732 6.147
1
(173.2) (87.07) (86.7) (7.7) (66) (60.3)
17.71 8.869 2.556 0.668 6.304 7.24
2
(173.2) (87) (25.17) (6.5) (61.8) (71)

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