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ID 1700MM SIZE, 34.7 M HEIGHT FURNACE
STACK
Customer:
P.O No.
ATECH-00585/08
Report No.
0801.20B
Rev. No
By
Date:
23/12/2008
Prepared by
RN
Checked by
BVN
Approved by
BVN
Description
Appvd
Date
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.
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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 selfweight, 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.
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
Height
Site
Type
Material
Fluid Handled
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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
Cylindrical Shell
Platforms, Ladders
Foundation Bolts
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
(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)
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
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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
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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
Permissible deflection at
the top of stack
231
165
138.6
123.8
Load Case
No.
Compressive stresses in
Kgf/mm2 (MPa)
Allowable stress
Induced
Allowable
stress
Induced
10.8 (106)
8.579 (84.2)
17.12 (168)
7.413 (72.7)
10.8 (106)
5.577 (54.7)
17.12 (168)
5.690 (55.8)
Von-Mises stresses in
Kgf/mm2 (MPa)
Compressive stress in
Kgf/mm2 (MPa)
Beam
Column
Bracing
Beam
Column
Bracing
Allowable stress
in Kgf/mm2
(MPa)
18.66
(183)
18.66
(183)
18.66
(183)
19.9
(195.3)
20.16
(197.8)
17.12
(168)
17.66
(173.2)
8.876
(87.07)
8.846
(86.7)
0.782
(7.7)
6.732
(66)
6.147
(60.3)
17.71
(173.2)
8.869
(87)
2.556
(25.17)
0.668
(6.5)
6.304
(61.8)
7.24
(71)
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