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Structure
14.1 Introduction
Objectives
14.2 Types of Steel Chimney
14.2.1 Self-supporting Steel Chimneys
14.2.2 Guyed Steel Chimneys
14.3 Factors
14.4 Design of Steel Plates for Self-supporting Steel Chimneys
14.5 Design of Joints for Self-supporting Steel Chimneys
14.6 Design of Flue Openings for Self-supporting Steel Chimneys
14.7 Fvrces Acting on Steel Chimney
14.7.1 Vertical Forces
14.7.2 Horizontal Forces
14.8 Bending Moment on Self-supporting Steel Chimneys
14.9 Bending Stress on Steel Chimney Due to Wind
14.10 Permissible Stresses
14.1 1 Design of Base Plate
14.12 Design of Anchor Bolts
14.13 Design of Foundation
14.14 Lining for Chimney
14.15 Stability of Steel Chimney
14.16 Design Problems
14.17 Summary
14.18 Answers to SAQs
14.1 INTRODUCTION
Steel Chimneys are frequently known as steel Stacks. The steel chimneys are made
of steel plants and supported on foundation. The steel chimneys are cylindrical in
shape. To provide larger base and greater stability, and to allow for easy entrance
of flue gases, the lower portion of the steel chimney is widened or flared out. The
widened section of the chimney at the base reduces the unit stresses in the steel at
the base of the chimney. The steel chimneys are constructed for the emission of
flue gases to such a height that the gases do not contaminate the surrounding
atmosphere. The cross-sectional area of the steel chimney is kept large enough to
allow the passage of burnt gases. The cross-sectional area of the steel chimneys
depends on the type and quantity of fuels to be used in plant, available draft for
carrying the burnt gases up the chimney. The height of the steel chimney is kept to
provide the required draft. "The draft is defined as the difference between the
absolute gas pressure at any point in the steel chimney and the ambient atmosphere
pressure." The draft depends on the height of the steel chimney above sea level,
the type of fuel to be burnt, the type of furnace and the temperature of the burnt
gases.
When the gases in a steel chimney are heated, then the gases expand. The hot
gases occupy larger volume than before. The weight of the gases per cubic metre
becomes less. As a result of this, the unit pressure at the bottom of chimney due to
weight of hot gases also becomes less than the unit pressure due to weight of cold
air outside the chimney. The difference between two pressures results in the flow
of the burnt gases up the chimney. For the purpose of structural design of steel
Steel Structures chimney, the height and the diameter of chimney at the top are known. The loads
acting on the steel chimney are transferred to the foundation easily by the widened
section. The base of the chimney may be made conical or bell-mouthed. But the
fabrication of bell-mouthed base does not have any advantage over the conical base
and the fabrication is costly. So, generally the conical base is provided.
The recommended height od flared portion of the chimney is 113rd of the height of
the chimney. The ratio of the diameter of the base of the flare to the diameter of
the cylindrical portion varies from 514 to 312. The plates in the conical flare should
not be thinner than the thickness of the lowest course in the cylindrical portion.
Objectives
After studying this unit, you should be able to
distinguish between various types of steel chimneys,
evaluate the forces acting on a steel chimney,
effect of bending moment and bending stress on self-supporting steel
chimneys,
design of flue openings, points and foundations,
obtain expression$ for bending moment, stresses and thickness of plates,
and
understand the stability concept of steel chimney
tCylip
n odrrt i ocna l
a (I((I
Breech
or
F l u e opening
14.3 FACTORS
A choice between self-supporting steel chimney and guyed steel chimney is made
by considering some of the important factors : Number of units, type of equipment,
and type of fuel to be used are considered. In case the chimney to be used for
boilers, the surface area, output efficiency, draft requirements etc. are taken into
account. The mode of operation of the equipment shall also be considered.
The type of lining is decided knowing the composition of the flue gases. The
temperature of the flue gases before entering the chimney and its likely variation
are studied. The local statutory regulations, relating to height, dispersion of ash,
Steel Structures provision for earthing aviation warning lamps. The quantity of dust and data about
the aggressiveness of the flve gases etc. are the factors which should be considered
for selecting a type of steel chimney.
- - - - -
The leeward side of the $tee1 chimney is subjected to maximum compressive stress
due to the combined effect of wind, weight of steel chimney and weight of lining.
The maximum total compressive stress on leeward side.
Design of Steel Chimneys
The thickness of the steel plates at various horizontal sections are found. The
thickness of steel plates o f the flared portion should not be less than the thickness
of steel plates in the cylindrical portion. The thickness of steel plates of chimney is
kept in excess than what is necessary (in order to protect them from corrosion) by
allowance for corrosion, which depends upon the design life of the steel chimney.
The spacing of the rivets along the caulked edges of plates shall not be greater
than 10 times the thickness of plates. The spacing of the rivets shall not be less
than 2.5 times the diameter of rivet.
The steel plates more than 16 mm thick and not more than 22 mm thick are
sub-punched with a punch 5 mm smaller than the nominal diameter of rivet, and
reamed to a diameter of 1.5 mm larger than the rivet. The plates thicker than
22 mm are drilled.
Steel Structures
14.6 DESIGN OF FLUE OPENING FOR
SELF-SUPPORTING CHIMNEYS
The flue opening is also khown as breech opening. The flue opening is provided
for the entrance of flue gases. The flue gases come from furnaces of the boilers.
A flue opening or breech opening is provided in the steel chimney as shown in the
Figure 14.l(a). The area of the flue opening is kept about 20% larger than the
internal cross-sectional area of the chimney. The maximum width of the flue
opening should not be greater than two-thirds of the diameter. In order to
compensate the removed materials, the reinforcement should be provided all around
the flue opening. The vertical reinforcement provided should be 20% larger than
the material removed in the ratio of diameter to the long chord perpendicular to the
face of the opening.
Figure 14.2
The horizontal reinforcement provided at the top and bottom of the opening is kept
equal to the vertical reihforcement. The reinforcing material provides sufficient
vertical stiffness. In order to transfer and distribute the stress into the steel of the
chimney, the reinforcing material should be extended above and below the opening.
In the self-supporting steel chimney the flue opening is kept well above the flared
or conical base, so that it does not extend in the flared base.
The steel chimneys may have one or two breech openings, in the same direction,
two breech openings at right angles and three breech openings as shown in
Figure 14.2 (a), (b), (c), and (d), respectively. The number of flue openings may
be 1, 2, 3, or 4 depending upon the requirement. It is suggested that a maximum
of two flue-openings may be provided at one level so that the chimney remains
safe enough to resist the applied forces at the plane of the openings. However, it is
possible to provide thr$e openings in one plane. This is done only when the
number of the openings is three only. The width of openings does not exceed
one-third of the diameter of the chimney at that plane. A clean-out door as shown
by dotted lines in Figure 14.1 is provided preferably on the opposite side of the Deslgn of Steel Chimneys
breech opening near the base. The minimum size of clean-out door shall be
300 mm x 800 mm clear. The clean-out door serves the purpose of removal of ash
and for the inspection of inside of steel chimney clean-out doors are also properly
reinforced.
The compressive stress in the steel plates at the section XX due to the
self-weight of chimney is given by
The compressive stress in the steel plates at the section XX, due to
weight of lining
Steel Structures
14.7.2 Horizontal Forces
1) Wind Pressure
The wind pressure acts horizontally. The wind pressure acting on the
structure depends on the shape of the structure, the width of the
structure, the height of the structure, the location of the structure, and
the climatic condition The wind pressure per unit area increases with the
height of the structure above the ground level. In order to simplify the
design, the steel chimney is divided into number of segments of equal
height. The height of each segment may be kept 10 m. The intensity of
wind pressure over each segment may be assumed as uniform. The
intensity of wind pressure corresponding to the mid-height of each
scgment may be noted from IS : 875-1984. The wind pressure on the
flared portion may be found by using average diameter. The wind
pressure is assumed to act at the mid-height of each segment and also in
the flared portion. It has also been practised to take uniform wind
pressure over the full height of chimney.
The wind pressure
P = K.P1 x (Project area of chimney)
...(ii)
/'
Sometimes the self-supporting steel chimney is erected between the constructed
buildings. A portion of the chimney extends over the roof of the building as shown
in Figure 14.3. The remaining portion of the chimney remains protected from the
wind. The bending moment for the part of chimney above the roof is calculated in
accordance with the expression (ii) above, the bending moment of chimney below
the roof (protected from the wind) shall be determined as follows:
When the chimney is not fixed at the roof
F 7
Figure 14.3
..(i)
It is to note that these expressions are applicable for thickness of the plane less Design of Steel Chimneys
than 0.015d.
I
I
1
I Figure 14.4: Self-supporting Chimney
stress
Axial h , = 2L
I Bending h , = L
where, h , = effective height of chimney
The allowable stress in axial compression and in pending for circular steel chimney
are as per IS 6533-1971 ('Code of practice for design and construction of steel
chimneys). The combined stress shall comply with the requirements of IS:800-1984.
The member of the steel chimney reasonably exposed to adverse temperature shall
be considered. The allowable stresses are obtained by multiplying the basic stresses
the appropriate temperature coefficient, k,.The value of k, may be noted from
Table 14.2 as specified in IS:6533-1971.
Coefficient, kt
hlk (dlt)
Ratio Ratio
100 125 150 175 200 225 250 300 350 400 450 500 550 600
and less
0 125.0 125.0
10 125.0
20 125.0
30 125.0 125.0 *
40 125.0 125.0 125.01125.0
50 125.0 125.0 125.0 125.0 125.0 125.0 125.0
In case, the increase in stresses is solely due to wind forces, the allowable stresses
may be exceeded by 25%. However, the thickness of steel plates shall not be less
than that needed if the wind forces were neglected.
Similarly, when the effect of seismic load is considered, the allowable stresses may
be exceeded by 25 percent. The thickness of steel plate shall not be less than that
required if the seismic forces were not taken in to account. The permissible
stresses in rivets are adopted as per IS : 800-1984.
where, d l = diameter of the steel chimney at the base of the flared portion.
The maximum compressive stress per unit circumferential length at the base plate
on the leeward side of the chimney.
where, obcr
= permissible bearing stress on the foundations.
In case the anchor bolts are provided on inside and outside of the steel chimney,
c / l of
anchor
bolts
1.X
b =width of base plate
I_ b = widk of base plate 4
( aI (b)
Figure 14.5
then the base plate may be kept symmetrical with chimney, as shown in
Figure 14.5(a). The unsuppor'ted length of the base plate 1, measured from the
extreme edge upto the critical section XX, are equal. In case the anchor bolts are
provided on the outside only, then the unsupported length I, would be kept more
than the inner unsupported length. The critical section is marked under the root of
angle section. The thickness bf base plate is found as under :
The maximum bending moment at the critical section XX
The moment of resistance of unit length of base plate at the critical section
The thickness of the base plate found by deducting the thickness of the angle
section from the total thickness obtained as per Eq. 14.18. The critical section may
be checked for shear stress. It is to note that the total thickness of the base plate a,
has been found by using permissible bearing stress on the foundation instead of
actual bearing stress. This provides comparatively more thickness in case the
unforseen wind pressure increases.
I
I
14.12 DESIGN OF ANCHOR BOLTS
The anchor bolts (holding down bolts) are provided to resist the uplift pressure due
to the overturning effect of the wind on the windward side of the stress chimney.
The uplift pressure is found by considering the combined effect of wind pressure
and the weight of chimney only. The weight of lining is omitted. It is assumed that
all the anchor bolts are drawn up tight. Further it is assumed that the line of
rotation is perpendicular to the direction of wind and passes through the centre of
the horizontal base section of the steel chimney as shown in Figure 14.1. The
initial tension in the anchor bolt, if any, is neglected.
The maximum tensile stress at the base plate on the windward side of the chimney
The maximum tensile stress per unit circumferential length at the base plate on the
windward side of the chimney
F2 = ofx ( t x 1) kN/m ...(14.20)
The maximum uplift force in one anchor bolt
= F , . g = o , x ( t x 1)xg kN
Figure 14.6
Then, the resisting moment due to weight of foundation is equal to the overturning
moment due to wind. Therefore
The width of foundation is then revised by considering the weight of steel chimney
and weight of lining.
The intensity of soil pressure is determind. It is given by
1
Steel Structures where, A and Z are the area and section modulus, respectively for the foundation
slab. If the radius of the circle of the circumscribing octagon is R, then the area of
foundation is 3.3 12 R and Z = 0.81 R~ as per (IS: 6533-197 1). The successive
trials are made for R to utilize fully. The soil pressure should not exceed the
allowable bearing capacity of the soil.
( a ) Foundation plan
L( b) Foundatron thickness
Figure 14.7
D = Diameter of footing = 2R
P = vertical load.
e = M/P
M = overturning moment
F = P/A
A = Area of circular footing
F,,, = Maximum unit bearing pressure including overturning moment.
The full utilisation of the bearing of soil may lead to situations where only the
part of foundation is in compression (Figure 14.7). In such a situation the footing
is designed as a circle, though it is constructed as octagonal.
The eccentricity e =
w,+ w,+W F
and thereby e/b valves are determined. The values of zero stress and the ratio Design of Steel Chimneys
f, lf are found from Figure 14.7 as per IS : (6533-1971) and thus the value of
f,,, is calculated. It is recommended in code IS : 6533-1971 that the elb valve
should not exceed 0.255 and K,lb not be less than 0.6.
Figure 14.8 : Maximum Soil Pressure and Neutral Axis for Circular Footing
e,
The lining may be made of radial fire brick, common concrete brick, cement gunite
or vibrobestos acid resisting bricks etc. The materials used for lining should be
capable of withstanding high temperature up to 2000°F. The lining is required from
below the flue opening to the height, where the heat of gases does not damage the
chimney. The height of lining should not be less than.10 times the diameter or 113
of height above the flue opening. The self-supporting steel chimneys are usually
lined throughout the full height of chimney. The lined chimneys are inspeted every
alternate year. In addition to the checking of thickness of chimney plates, the
condition of lining and insulation is also checked.
The chimneys with riveted and bolted construction are checked near the flange
angles. The rivet heads on the interior surface are also checked. The interior surface
of lined chimney requires primary coat only. The exterior surfaces of the chimney is
painted as describer for unlined chimneys depending upon the service temperature.
- - - - --
1 4 . 1 6 ~ PROBLEMS
~ ~ 1 ~ ~
Example 14.1
A self-supportingl steel chimney is 80 m high and its diameter at the top is
3 metres. ~ e s i g breech
n (flue) opening. Adopt the wind force as per IS : 875.
The location of the place is such that the intensity of wind pressure up to
30 m height is 1 3 0 k ~ / m ~ .
Solution
The steel chimney is shown in Figure 14.9. The height of the chimney is
80 m and its diaineter at the top is 3 m.
Step 1
Flared portion
A conical flared portion is provided in the lower portion of the steel chimney.
The recommended height of flared portion
Design of Steel Chimneys
p5 .h5=0.7x1.72x3x5x2.5=45.15 kN-m
Total = 1698.90 kN-m
Steel Structures
I-w~nd pressure ( k ~ h n l l
- -80m
7 5m
---
--
hiyure 14.9 (b)
3000
Radius of gyration, K = 0.7 x -= 1050 mm
2
Effective height for axial stress
hl = 2 x 15 x 1000=30000mm
Ratio -
h1 = [ -
k
1
3 ~ : = 28.57
ratio = [ 3 x i 0 0 0 ) = 4 2 8
X=(o.ixi]=3000 1050
Area of cross-beetion
= n x 4350 x 12 - 2 x 2000 x 12 (for opening)
= IT5908 mm2
iii) Weight of chidnney
Weight of chidnney above X8 X8
= 472.507 kN
Design of Steel Chimneys
It is obtained as follows.
.The thickness of lining increases from top to bottom. The weight of the
chimney may be assumed as 0.64, 0.80, 0.96 and 1.28 kN/m2 per .metre
height of the chimney at the sections X2X2, X5 X5,X8X8 and XI XI
respectively.
At section X2x X2
n x 3 x 15 x 0.64 = 90.432 kN
Add 10% for stiffeness
= 1 . 1 0 90.432=99.475
~ kN
Area of cross-section
At Section X5X5
n x 3 x 15 x 0.64 = 90.432 kN
7~~3~15~0.80=113.04kN
203.472 kN
Add 10% for cross-section
= 1.10~
203.472kN
= 223.82 kN
Area of cross-section
n x 3 lOOO(8 - 4) = 37680 mm.
At section X8X8
n x 3 x 15 x 0.64 = 90.432 kN
nx3x15x0.80=113.040kN
n x 3 x 25 x 0.96 = 226.080kN
= 429.552 kN
Add 10% for stiffeners
1.10x 429.552 = 472.507 kN
The maximum compressive stress on the leeward side of the steel
chimney from Eq. 14.3
hi 60000
Ratio -= -- 57.14
k 1050
For bending stress
These stresses are increased by 25% for wind. The maximum tensile
stress on windward side from Eq. 14.1
Actual stress =
i934.238 x id 11587.15x 106
+
Radius of gyration, k
ratio = [ )
4.5 x loo0 = 375
12
SAQ
1) Design a self-supporting steel chimney of 100 m height. The diameter of
the cylindrical shell is 4 m. The chimney has a 100 m thick brick lining
supported on the shell.
2) A self-supporting steel chimney is 60 m high and has a diameter of 3 m
at the top. Design the foundation and the riveted points. The hoizontal
pressure may be assumed as 1.50 k ~ l m The~ . bearing stress in cement
concrete is 4.0 ~ / m m ~ .
14.17 SUMMARY
. *-
Let us conclude this unit by summarising what we have covered in it. In this unit
we have
1) Defined steel chimneys.
2) Described factors for selecting type of steel chimneys.
3) Studied the design of thickness of steel plates, joints, flue openings and
foundation.
4) Derived expressions for bending moment, stresses, thickness of plates.
5) Introduced the concept of lining for chimney.
6) Described the stability of steel chimney.
I
FURTHER READING
Design of Steel Structures - A.S. Arya & J. L. Ajmani
Steel Structures and Timber Structures, Vol. III - V.N. Vazirani & M.M. Ratwani
Design of Steel Structures - Vol. I & Vol. II - Dr. Ramchandia
Roofs and Bridges - M. Mprriman
Design of Steel Structures - M. Raghupati
Analysis, Design and DetaiYs of Structures- V. N . Vazirani & M.M. Ratvani
Design of Steel and Timber Structures - Ramamrutham
Structural Design in Steel - Sanvar Alum Raz
Desim o f Steel Structures 4Edwin H . Gaylord, Jr. & Charles N. Gavlard