550 TPD SAP WITH PRODUCT MIX &

50 TPD SO2 PLANT Document No:-

M/s SEYA INDUSTRIES LTD.
SITE:- TARAPUR, MAHARASHTRA Rev
Document Title :
FFIL JOB NO:- 201712 Date

DESIGN OF SELF SUPPORTING STACK

Self standing tail gas stack 98m high having bade diameter of 4000mm & top diameter of 1300mm

Shell Corroded Avg. Outer

Zone Level Weight
Thickne Thickness Diameter
mm mm m m kg

25 8 5 1.3 98 - 96 510
24 8 5 1.3 96 - 92 1020
23 8 5 1.3 92 - 88 1020
22 12 9 1.3 88 - 84 1524
21 12 9 1.3 84 - 80 1524
20 12 9 1.3 80 - 76 1524
19 12 9 1.3 76 - 72 1524
18 12 9 2 72 - 68 2353
17 12 9 2.7 68 - 66 1591
16 12 9 2.7 66 - 62 3181
15 12 9 2.7 62 - 58 3181
14 12 9 2.7 58 - 54 3181
13 16 13 2.7 54 - 50 4235
12 16 13 2.7 50 - 46 4235
11 16 13 2.7 46 - 43 3176
10 16 13 3.35 43 - 41 2630
9 16 13 4 41 - 38 4714
8 16 13 4 38 - 34 6285
7 16 13 4 34 - 30 6285
6 16 13 4 30 - 25 7857
5 20 17 4 25 - 20 9811
4 20 17 4 20 - 15 9811
3 25 22 4 15 - 10 12248
2 25 22 4 10 - 5 12248
1 25 22 4 5-0 12248

Sample calculation for Zone 7

Diameter at top = 4.000 m Diameter at bottom = 4.000 m

Avg Outer Dimeter = 4.000 m Shell Thickness = 0.016 m
Avg Inner Dimeter = 3.968 m Zone Height = 4.000 m

2 2
Weight of Zone = π *( 4.000 + 3.968 ) * 7850 * 4.000 = 6285 kg
4

Page 1 of 16
 550 TPD SAP WITH PRODUCT MIX &
50 TPD SO2 PLANT Document No:-
M/s SEYA INDUSTRIES LTD.
SITE:- TARAPUR, MAHARASHTRA Rev
Document Title :
FFIL JOB NO:- 201712 Date

Load Calculations.

Dead Weight
Self weight of the chimmney shell os taken by staad as per uncorroded thickness & a factor of 1.2
has been applied to self weight to account for the loads due to service platforms,ladders, flueducts etc

Live load
Live load on the service platform = 300 kg/sqm
Considering 1m width of the platform.The live load is calculated and applied as a joint load in the
staad file at level 7.5m, 15m, 22.5m, 30m, 37.5m, 45m, 49.3m

OD of OD of Platform LL on
LVL chimmney Platform area platform
m m m m2 kg Sample calculation
82.5 1.3 3.3 7.222 2166 For Lvl 45m
75 1.3 3.3 7.222 2166 OD platform = 5.5 m
67.5 2.7 4.7 11.618 3485 OD chimmney = 3.5 m
60 2.7 4.7 11.618 3485 Area = 3.14 x ( 5.5^2 -3.5^2 ) / 4
52.5 2.7 4.7 11.618 3485 = 14.1 m2
45 2.7 4.7 11.618 3485 Platform LL = 300 x 14.13
37.5 4 6 15.7 4710 = 4239 kg
30 4 6 15.7 4710
22.5 4 6 15.7 4710
15 4 6 15.7 4710
7.5 4 6 15.7 4710

Wind Load

Wind loads have been calculated in accordence with IS:875-2015 (Part 3) and IS:6533-1989 (Part2)

Basic wind speed as per design basis,Vb = 44 m/s

Design wind velocity,Vz = Vb k1 k2 k3 k4

Wind Pressure at height z,pz = 0.6 Vz2

and, Design wind Pressure pd = K d K a K c pz

Page 2 of 16
 550 TPD SAP WITH PRODUCT MIX &
50 TPD SO2 PLANT Document No:-
M/s SEYA INDUSTRIES LTD.
SITE:- TARAPUR, MAHARASHTRA Rev
Document Title :
FFIL JOB NO:- 201712 Date

Risk Factor k1 = 1

Terrain Category = Terrain category-3

Topography Factor k3 = 1

Cyclone Factor k4 = 1

Wind directionality Factor kd = 1

Area averaging Factor ka = 0.8

Combination Factor kc = 1

The design wind pressure at different zones are tabulated below

Zone Height k2 Vz Pz Pd Sample calculation fo Zone 7

m m m kN/m2 kN/m2
25 98 - 96 1.1968 52.66 1.67 1.34 Height of Zone = 34
24 96 - 92 1.1936 52.52 1.66 1.33
23 92 - 88 1.1872 52.24 1.64 1.32 k3 = 1.07
22 88 - 84 1.1808 51.96 1.62 1.3
21 84 - 80 1.1744 51.68 1.61 1.29 Vz = 44 x 1 x 1.072 x 1 x 1
20 80 - 76 1.168 51.4 1.59 1.28 = 47.17 m/s
19 76 - 72 1.1616 51.12 1.57 1.26
18 72 - 68 1.1552 50.83 1.56 1.25 Pz = 0.6 x 47.17 x 47.17
2
17 68 - 66 1.1488 50.55 1.54 1.24 = 1.34 kN/m
16 66 - 62 1.1456 50.41 1.53 1.23
15 62 - 58 1.1392 50.13 1.51 1.21 Pd = 1.34 x 1 x 0.8 x 1
2
14 58 - 54 1.1328 49.85 1.5 1.2 = 1.08 kN/m
13 54 - 50 1.1264 49.57 1.48 1.19
12 50 - 46 1.12 49.28 1.46 1.17
11 46 - 43 1.108 48.76 1.43 1.15
10 43 - 41 1.099 48.36 1.41 1.13
9 41 - 38 1.093 48.1 1.39 1.12
8 38 - 34 1.084 47.7 1.37 1.1
7 34 - 30 1.072 47.17 1.34 1.08
6 30 - 25 1.06 46.64 1.31 1.05
5 25 - 20 1.035 45.54 1.25 1
4 20 - 15 1.01 44.44 1.19 0.96

Page 3 of 16
 550 TPD SAP WITH PRODUCT MIX &
50 TPD SO2 PLANT Document No:-
M/s SEYA INDUSTRIES LTD.
SITE:- TARAPUR, MAHARASHTRA Rev
Document Title :
FFIL JOB NO:- 201712 Date
3 15 - 10 0.97 42.68 1.1 0.88
2 10 - 5 0.91 40.04 0.97 0.78
1 5-0 0.91 40.04 0.97 0.78

The chimmney is divided into parts of 5m,4.5 & 3.5m. The wind load calculated is applied
as a concentrated load at mid point of each part

Calculation of static wind force: Clause 8.2.3 of IS:6533-1989 (Part2)

The static wind force acting at mid point of kth zone is calculated as follows:

Pst,k = c q k hk dk

Where,
c = Shape factor for the chimmney for circular section = 0.7
qk = Static wind pressure at the midpoint of kth zone
hk = height of kth zone strip(m)
dk = external diameter of chimmney (m)

The wind load is increased by 10% to account for platform & ladders and additional 10% for top 10m
portion to account for streaks

Zone lvl c Pz dk hk Pst.k Pst.k

(m) (kN/m2) (m) (m) (kN) 10/20%incr

25 98 - 96 0.7 1.34 1.3 2 2.44 2.927

24 96 - 92 0.7 1.33 1.3 4 4.84 5.809
23 92 - 88 0.7 1.32 1.3 4 4.80 5.766
22 88 - 84 0.7 1.3 1.3 4 4.73 5.678
21 84 - 80 0.7 1.29 1.3 4 4.70 5.635
20 80 - 76 0.7 1.28 1.3 4 4.66 5.591
19 76 - 72 0.7 1.26 1.3 4 4.59 5.504
18 72 - 68 0.7 1.25 2 4 7.00 8.400

Page 4 of 16
 550 TPD SAP WITH PRODUCT MIX &
50 TPD SO2 PLANT Document No:-
M/s SEYA INDUSTRIES LTD.
SITE:- TARAPUR, MAHARASHTRA Rev
Document Title :
FFIL JOB NO:- 201712 Date
17 68 - 66 0.7 1.24 2.7 2 4.69 5.625
16 66 - 62 0.7 1.23 2.7 4 9.30 10.229
15 62 - 58 0.7 1.21 2.7 4 9.15 10.062
14 58 - 54 0.7 1.2 2.7 4 9.07 9.979
13 54 - 50 0.7 1.19 2.7 4 9.00 9.896
12 50 - 46 0.7 1.17 2.7 4 8.85 9.730
11 46 - 43 0.7 1.15 2.7 3 6.52 7.173
10 43 - 41 0.7 1.13 3.35 2 5.30 5.830
9 41 - 38 0.7 1.12 4 3 9.41 10.349
8 38 - 34 0.7 1.1 4 4 12.32 13.552
7 34 - 30 0.7 1.08 4 4 12.10 13.306
6 30 - 25 0.7 1.05 4 5 14.70 16.170
5 25 - 20 0.7 1 4 5 14.00 15.400
4 20 - 15 0.7 0.96 4 5 13.44 14.784
3 15 - 10 0.7 0.88 4 5 12.32 13.552
2 10 - 5 0.7 0.78 4 5 10.92 12.012
1 5-0 0.7 0.78 4 5 10.92 12.012

* Top 10m increased by 20%

Sample calculation for Zone 25
Pst.k = 0.7 x 1.34 x 1.3 x 2 = 2.4388kg

= 2.4388 x 1.2 / 1000 = 2.927 Tonnes

Natural frequency of vibration for self weight = 0.706 cps (from STAAD output file)

Hence Time period = 1/0.706 = 1.416 sec

Since period for natural oscillation for the chimmney exceed 0.25 sec, the dynamic
effect of wind needs to be considered (cl.No.8.3.1 of IS:6533 (part2)-1989)

Calculation of Dynamic wind force: Clause 8.3 of IS:6533-1989 (Part2)

Dynamic loads on the structure is calculated for the first three modes of ossicilation for the structure.
The loads due to subsequent modes are assumed to be negligible.

Dynamic wind load acting at the centre of jth zone of the chimmney in the ith mode
of natural oscillation is determined as follows.

Pdyn.ij = Mj ξi ηij ν

Mj = Mass of the jth zone in kg

ξi = dynamic coefficent (for unlined chimmney)
nij = Deduced accelertation

Page 5 of 16
 550 TPD SAP WITH PRODUCT MIX &
50 TPD SO2 PLANT Document No:-
M/s SEYA INDUSTRIES LTD.
SITE:- TARAPUR, MAHARASHTRA Rev
Document Title :
FFIL JOB NO:- 201712 Date
ν = coefficient which take care of space correlation of wind pulsation speed according to
ht. & vicinity of building structures

Dynamic coeffcient ξi is determined from Table 5 of IS 6533 part 2 :1989 depending on parameter ξi'

Ti Vb
ξi'=
1200

Coefficient for space correlation of wind pulsation speed ν is determined from Table 7 of
IS 6533 part 2 :1989 based on parameter ξi'

The Chimney is designed as Unlined Chimney

1st Mode 2nd Mode 3rd Mode

Frequency 0.706 1.923 4.320
Time Period 1.416 0.520 0.231
ξi' 0.052 0.019 0.008
ξi 3.131 2.215 1.707
ν 0.650 1.000 1.000

Note: Value of ν for second and third mode are taken as 1 in accordance with clause 8.3.5

Sample Calculation for first mode:

Time Period T1 = 1.416

Basic Wind Speed Vb = 44
1.416 x 44
ξi' = = 0.052
1200

Therefore dynamic force coefficent ξ = 3.131 ( Table- 5)

ν for 98m height chimney = 0.650 (Table-7)

Deduced acceleration ηij, in m/s2 is determined according to formula:

Σ ϒik mk Pst.k
ηij = ϒij
Σ ϒik2 Mk

ϒik = relative ordinates of mode shape 'corresponding to the centres of jth

Page 6 of 16
 550 TPD SAP WITH PRODUCT MIX &
50 TPD SO2 PLANT Document No:-
M/s SEYA INDUSTRIES LTD.
SITE:- TARAPUR, MAHARASHTRA Rev
Document Title :
FFIL JOB NO:- 201712 Date
and kth zones in the ith mode of
mk = coefficient of pulsation of speed thrust from Table 6 of IS 6533 part 2 :1989
Pst.k = Static wind load on the kth zone

The different modes of oscillation for the structure has been determined with the help of
STAAD Pro software. The values obtained for the first three modes has been considered in design.

The type of location for the structure is taken as: Type B

Coefficent of pulsation of speed thrusts mk for Type B (Table - 6)

Ht mk
upto 10 0.83
upto 20 0.83
upto 40 0.75
upto 60 0.65
upto 100 0.60
upto 200 0.54

The mode shapes for the first three modes are tabulated below.

1st Mode 2nd Mode 3rd Mode

Joint No. ϒ1k ϒ1k ϒ1k

26 -1.000 -1.000 -1.000
25 -0.955 -0.884 -0.792
24 -0.864 -0.654 -0.386
23 -0.775 -0.433 -0.022
22 -0.688 -0.229 0.268
21 -0.606 -0.053 0.463
20 -0.532 0.084 0.540
19 -0.467 0.168 0.497
18 -0.414 0.205 0.375
17 -0.388 0.218 0.308
16 -0.339 0.237 0.173
15 -0.292 0.246 0.044
14 -0.250 0.245 -0.070
13 -0.212 0.235 -0.159
12 -0.178 0.219 -0.221
11 -0.155 0.203 -0.244
10 -0.142 0.190 -0.250
9 -0.123 0.171 -0.251
8 -0.099 0.145 -0.243

Page 7 of 16
 550 TPD SAP WITH PRODUCT MIX &
50 TPD SO2 PLANT Document No:-
M/s SEYA INDUSTRIES LTD.
SITE:- TARAPUR, MAHARASHTRA Rev
Document Title :
FFIL JOB NO:- 201712 Date
7 -0.077 0.119 -0.222
6 -0.054 0.088 -0.184
5 -0.035 0.060 -0.136
4 -0.020 0.036 -0.087
3 -0.009 0.017 -0.044
2 -0.002 0.004 -0.012
1 0.000 0.000 0.000

Deduced Acceleration η1j for 1st mode

Zone Zone ϒ1j mk Pst.k ϒ1j mk Pst.k Mk ϒ1j2 Mk η1j

Height
25 97 -1.000 0.600 2.927 -1.756 0.612 0.612 4.000
24 94 -0.955 0.600 5.809 -3.329 1.224 1.116 3.820
23 90 -0.864 0.600 5.766 -2.989 1.224 0.914 3.456
22 86 -0.775 0.600 5.678 -2.640 1.829 1.098 3.100
21 82 -0.688 0.600 5.635 -2.326 1.829 0.866 2.752
20 78 -0.606 0.600 5.591 -2.033 1.829 0.672 2.424
19 74 -0.532 0.600 5.504 -1.757 1.829 0.518 2.128
18 70 -0.467 0.600 8.400 -2.354 2.824 0.616 1.868
17 67 -0.414 0.600 5.625 -1.397 1.909 0.327 1.656
16 64 -0.388 0.600 10.229 -2.381 3.817 0.575 1.552
15 60 -0.339 0.600 10.062 -2.047 3.817 0.439 1.356
14 56 -0.292 0.650 9.979 -1.894 3.817 0.325 1.168
13 52 -0.250 0.650 9.896 -1.608 5.082 0.318 1.000
12 48 -0.212 0.650 9.730 -1.341 5.082 0.228 0.848
11 44.5 -0.178 0.650 7.173 -0.830 3.811 0.121 0.712
10 42 -0.155 0.650 5.830 -0.587 3.156 0.076 0.620
9 39.5 -0.142 0.750 10.349 -1.102 5.657 0.114 0.568
8 36 -0.123 0.750 13.552 -1.250 7.542 0.114 0.492
7 32 -0.0990 0.750 13.306 -0.988 7.542 0.0739 0.3960
6 27.5 -0.0770 0.750 16.170 -0.934 9.428 0.0559 0.3080
5 22.5 -0.0540 0.750 15.400 -0.624 11.773 0.0343 0.2160
4 17.5 -0.0350 0.830 14.784 -0.429 11.773 0.0144 0.1400
3 12.5 -0.0200 0.830 13.552 -0.225 14.698 0.0059 0.0800
2 7.5 -0.0090 0.830 12.012 -0.090 14.698 0.0012 0.0360
1 2.5 -0.0020 0.830 12.012 -0.020 14.698 0.0001 0.0080

Σ ϒik mk Pst.k = -36.9306 Σ ϒik2 Mk = 9.2336

Sample Calculation for Zone 24

From above table, ϒ1j = -0.955 Σ ϒik mk Pst.k = -36.9306 Σ ϒik2 Mk = 9.2336

Therefore η1j = -0.955 x -36.9306 = 3.82

Page 8 of 16
 550 TPD SAP WITH PRODUCT MIX &
50 TPD SO2 PLANT Document No:-
M/s SEYA INDUSTRIES LTD.
SITE:- TARAPUR, MAHARASHTRA Rev
Document Title :
FFIL JOB NO:- 201712 Date
Therefore η1j = -0.955 x = 3.82
9.2336

Deduced Acceleration η2j for 2nd mode

Zone Zone ϒ2j mk Pst.k ϒ2j mk Pst.k Mk ϒ2j2 Mk η2j

Height
25 97 -1.000 0.600 2.927 -1.756 0.612 0.612 -1.953
24 94 -0.884 0.600 5.809 -3.081 1.224 0.957 -1.726
23 90 -0.654 0.600 5.766 -2.262 1.224 0.524 -1.277
22 86 -0.433 0.600 5.678 -1.475 1.829 0.343 -0.846
21 82 -0.229 0.600 5.635 -0.774 1.829 0.096 -0.447
20 78 -0.053 0.600 5.591 -0.178 1.829 0.005 -0.104
19 74 0.084 0.600 5.504 0.277 1.829 0.013 0.164
18 70 0.168 0.600 8.400 0.847 2.824 0.080 0.328
17 67 0.205 0.600 5.625 0.692 1.909 0.080 0.400
16 64 0.218 0.600 10.229 1.338 3.817 0.181 0.426
15 60 0.237 0.600 10.062 1.431 3.817 0.214 0.463
14 56 0.246 0.650 9.979 1.596 3.817 0.231 0.480
13 52 0.245 0.650 9.896 1.576 5.082 0.305 0.478
12 48 0.235 0.650 9.730 1.486 5.082 0.281 0.459
11 44.5 0.219 0.650 7.173 1.021 3.811 0.183 0.428
10 42 0.203 0.650 5.830 0.769 3.156 0.130 0.396
9 39.5 0.190 0.750 10.349 1.475 5.657 0.204 0.371
8 36 0.171 0.750 13.552 1.738 7.542 0.221 0.334
7 32 0.145 0.750 13.306 1.447 7.542 0.159 0.283
6 27.5 0.119 0.750 16.170 1.443 9.428 0.134 0.232
5 22.5 0.088 0.750 15.400 1.016 11.773 0.091 0.172
4 17.5 0.060 0.830 14.784 0.736 11.773 0.042 0.117
3 12.5 0.036 0.830 13.552 0.405 14.698 0.019 0.070
2 7.5 0.017 0.830 12.012 0.169 14.698 0.004 0.033
1 2.5 0.004 0.830 12.012 0.040 14.698 0.000 0.008

Σ ϒik mk Pst.k = 9.9756 Σ ϒik2 Mk = 5.1081

Deduced Acceleration η3j for 3rd mode

Zone Zone ϒ3j mk Pst.k ϒ3j mk Pst.k Mk ϒ3j2 Mk η3j

Height
25 97 -1.000 0.600 2.927 -1.756 0.612 0.612 1.839
24 94 -0.792 0.600 5.809 -2.761 1.224 0.768 1.456
23 90 -0.386 0.600 5.766 -1.335 1.224 0.182 0.710
22 86 -0.022 0.600 5.678 -0.075 1.829 0.001 0.040
21 82 0.268 0.600 5.635 0.906 1.829 0.131 -0.493
20 78 0.463 0.600 5.591 1.553 1.829 0.392 -0.851

Page 9 of 16
 550 TPD SAP WITH PRODUCT MIX &
50 TPD SO2 PLANT Document No:-
M/s SEYA INDUSTRIES LTD.
SITE:- TARAPUR, MAHARASHTRA Rev
Document Title :
FFIL JOB NO:- 201712 Date
19 74 0.540 0.600 5.504 1.783 1.829 0.533 -0.993
18 70 0.497 0.600 8.400 2.505 2.824 0.697 -0.914
17 67 0.375 0.600 5.625 1.266 1.909 0.268 -0.690
16 64 0.308 0.600 10.229 1.890 3.817 0.362 -0.566
15 60 0.173 0.600 10.062 1.044 3.817 0.114 -0.318
14 56 0.044 0.650 9.979 0.285 3.817 0.007 -0.081
13 52 -0.070 0.650 9.896 -0.450 5.082 0.025 0.129
12 48 -0.159 0.650 9.730 -1.006 5.082 0.128 0.292
11 44.5 -0.221 0.650 7.173 -1.030 3.811 0.186 0.406
10 42 -0.244 0.650 5.830 -0.925 3.156 0.188 0.449
9 39.5 -0.250 0.750 10.349 -1.940 5.657 0.354 0.460
8 36 -0.251 0.750 13.552 -2.551 7.542 0.475 0.462
7 32 -0.243 0.750 13.306 -2.425 7.542 0.445 0.447
6 27.5 -0.222 0.750 16.170 -2.692 9.428 0.465 0.408
5 22.5 -0.184 0.750 15.400 -2.125 11.773 0.399 0.338
4 17.5 -0.136 0.830 14.784 -1.669 11.773 0.218 0.250
3 12.5 -0.087 0.830 13.552 -0.979 14.698 0.111 0.160
2 7.5 -0.044 0.830 12.012 -0.439 14.698 0.028 0.081
1 2.5 -0.012 0.830 12.012 -0.120 14.698 0.002 0.022

Σ ϒik mk Pst.k = -13.0444 Σ ϒik2 Mk = 7.0937

Deduced Acceleration η3j for 3rd mode

Zone Zone Mk η1j Pdyn,1j η2j Pdyn,2j η3j Pdyn,3j

Height
(m) (Tonnes) (m/s2) (kN) (m/s2) (kN) (m/s2) (kN)
25 97 0.612 4.000 4.981 -1.953 -2.648 1.839 1.921
24 94 1.224 3.820 9.514 -1.726 -4.681 1.456 3.042
23 90 1.224 3.456 8.607 -1.277 -3.463 0.710 1.483
22 86 1.829 3.100 11.536 -0.846 -3.426 0.040 0.126
21 82 1.829 2.752 10.241 -0.447 -1.812 -0.493 -1.538
20 78 1.829 2.424 9.020 -0.104 -0.419 -0.851 -2.657
19 74 1.829 2.128 7.919 0.164 0.665 -0.993 -3.099
18 70 2.824 1.868 10.732 0.328 2.052 -0.914 -4.404
17 67 1.909 1.656 6.433 0.400 1.693 -0.690 -2.247
16 64 3.817 1.552 12.055 0.426 3.600 -0.566 -3.690
15 60 3.817 1.356 10.532 0.463 3.914 -0.318 -2.072
14 56 3.817 1.168 9.072 0.480 4.062 -0.081 -0.527
13 52 5.082 1.000 10.341 0.478 5.386 0.129 1.116
12 48 5.082 0.848 8.769 0.459 5.167 0.292 2.536

Page 10 of 16
 550 TPD SAP WITH PRODUCT MIX &
50 TPD SO2 PLANT Document No:-
M/s SEYA INDUSTRIES LTD.
SITE:- TARAPUR, MAHARASHTRA Rev
Document Title :
FFIL JOB NO:- 201712 Date
11 44.5 3.811 0.712 5.521 0.428 3.611 0.406 2.643
10 42 3.156 0.620 3.981 0.396 2.772 0.449 2.417
9 39.5 5.657 0.568 6.538 0.371 4.650 0.460 4.438
8 36 7.542 0.492 7.550 0.334 5.579 0.462 5.941
7 32 7.542 0.396 6.077 0.283 4.731 0.447 5.751
6 27.5 9.428 0.308 5.909 0.232 4.854 0.408 6.568
5 22.5 11.773 0.216 5.174 0.172 4.482 0.338 6.798
4 17.5 11.773 0.140 3.354 0.117 3.056 0.250 5.025
3 12.5 14.698 0.080 2.392 0.070 2.289 0.160 4.013
2 7.5 14.698 0.036 1.077 0.033 1.081 0.081 2.029
1 2.5 14.698 0.008 0.239 0.008 0.254 0.022 0.553

Sample calculation for Zone 25 for 1st mode

ξi = 3.131
ν = 0.650
Mk = 0.612 Tonnes = 612.00 kg
2
η1j = 4.000 m/s
Therefore,
Pdyn,1j = 3.131 x 0.65 x 4 x 612
= 4982 N
= 4.982 kN

Check for Deflection:

Deflection of the chimmney due to DL+ static wind load as per staad out put = 100.252 mm

Allowable deflection = L/200 =98000 / 200 = 490 mm > 100.252 mm Hence safe

Thermal effects: (Table-4 IS:6533part 2-1989)

Since the temperature to which the stack is exposed is less than 80 o no reduction in
in permissible are required.

Design forces on the chimmney

The design wind forces has been combined in accordance with Cl.No.8.3.7 of IS:6533 (part2)-1989.
as follows

𝑃𝑘 = 𝑃𝑠𝑡.𝑘 + 𝑃𝑑𝑦𝑛.1𝑘 2 + 𝑃𝑑𝑦𝑛.2𝑘 2 + 𝑃𝑑𝑦𝑛.3𝑘 2

𝑀𝑘 = 𝑀𝑠𝑡.𝑘 + 𝑀𝑑𝑦𝑛.1𝑘 2 + 𝑀𝑑𝑦𝑛.2𝑘 2 + 𝑀𝑑𝑦𝑛.3𝑘 2

Page 11 of 16
 550 TPD SAP WITH PRODUCT MIX &
50 TPD SO2 PLANT Document No:-
M/s SEYA INDUSTRIES LTD.
SITE:- TARAPUR, MAHARASHTRA Rev
Document Title :
FFIL JOB NO:- 201712 Date

ϒ𝑘 = ϒ𝑠𝑡.𝑘 + ϒ𝑑𝑦𝑛.1𝑘 2 + ϒ𝑑𝑦𝑛.2𝑘 2 + ϒ𝑑𝑦𝑛.3𝑘 2

The design forces at the base of each zone is obtained from STAAD Pro. Software.

The design forces at the base of each zone and the corresponding stresses are computed below.

OD at Corr. Section Axial Bending Maximum Maximum

Zone Area
base Thk. Modulus Force moment Comp. Tensile
Stress Stress
(m) (mm) (m2) (m3) (kN) (kNm) (N/mm2) (N/mm2)
25 1.3 5 0.020 0.007 6.001 8.905 1.653 1.063
24 1.3 5 0.020 0.007 18.002 78.114 12.798 11.027
23 1.3 5 0.020 0.007 30.004 211.100 33.670 30.718
22 1.3 9 0.036 0.012 47.950 408.701 36.263 33.635
21 1.3 9 0.036 0.012 65.897 671.551 59.232 55.620
20 1.3 9 0.036 0.012 83.843 992.745 87.191 82.594
19 1.3 9 0.036 0.012 101.790 1366.819 119.671 114.091
18 2.7 9 0.076 0.051 129.490 1802.064 37.044 33.638
17 2.7 9 0.076 0.051 148.217 2049.259 42.138 38.240
16 2.7 9 0.076 0.051 185.670 2609.665 53.620 48.737
15 2.7 9 0.076 0.051 223.124 3254.039 66.750 60.882
14 2.7 9 0.076 0.051 260.578 3977.042 81.421 74.568
13 2.7 13 0.110 0.073 310.441 4777.895 67.989 62.329
12 2.7 13 0.110 0.073 360.305 5655.582 80.413 73.844
11 2.7 13 0.110 0.073 397.703 6360.592 90.369 83.117
10 4 13 0.163 0.162 428.672 6853.117 45.017 39.749
9 4 13 0.163 0.162 484.185 7632.054 50.175 44.225
8 4 13 0.163 0.162 558.201 8747.353 57.528 50.668
7 4 13 0.163 0.162 632.217 9945.608 65.393 57.624
6 4 13 0.163 0.162 724.737 11551.349 75.892 66.986
5 4 17 0.213 0.211 840.270 13269.605 66.897 58.993
4 4 17 0.213 0.211 955.802 15091.254 76.081 67.090
3 4 22 0.275 0.272 1100.037 17004.756 66.568 58.562
2 4 22 0.275 0.272 1244.271 18996.791 74.422 65.366
1 4 22 0.275 0.272 1388.506 21056.215 82.524 72.418

The allowable stresses for the sections are calculated as per Cl.No.7.7.2 and ANNEX C
of IS:6533 (part2)-1989.

2
Yield Stress of Steel = 250 N/mm

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 550 TPD SAP WITH PRODUCT MIX &
50 TPD SO2 PLANT Document No:-
M/s SEYA INDUSTRIES LTD.
SITE:- TARAPUR, MAHARASHTRA Rev
Document Title :
FFIL JOB NO:- 201712 Date
Weld Efficiency = 0.8

OD at Corr. Eff. Max. Max Allowable. Allowable.

Zone Remark
base Thk. Height Comp. Tensile Comp. Tensile
Stress Stress Stress Stress
(m) (mm) (m) (N/mm2) (N/mm2) (N/mm2) (N/mm2)
25 1.300 5 2.000 1.653 1.063 96.357 120.000 SAFE
24 1.300 5 6.000 12.798 11.027 96.357 120.000 SAFE
23 1.300 5 10.000 33.670 30.718 96.357 120.000 SAFE
22 1.300 9 14.000 36.263 33.635 125.274 120.000 SAFE
21 1.300 9 18.000 59.232 55.620 125.274 120.000 SAFE
20 1.300 9 22.000 87.191 82.594 125.274 120.000 SAFE
19 1.300 9 26.000 119.671 114.091 125.274 120.000 SAFE
18 2.700 9 30.000 37.044 33.638 87.375 120.000 SAFE
17 2.700 9 32.000 42.138 38.240 87.375 120.000 SAFE
16 2.700 9 36.000 53.620 48.737 87.375 120.000 SAFE
15 2.700 9 40.000 66.750 60.882 87.375 120.000 SAFE
14 2.700 9 44.000 81.421 74.568 87.375 120.000 SAFE
13 2.700 13 48.000 67.989 62.329 110.079 120.000 SAFE
12 2.700 13 52.000 80.413 73.844 110.079 120.000 SAFE
11 2.700 13 55.000 90.369 83.117 110.079 120.000 SAFE
10 4.000 13 57.000 45.017 39.749 85.803 120.000 SAFE
9 4.000 13 60.000 50.175 44.225 85.803 120.000 SAFE
8 4.000 13 64.000 57.528 50.668 85.803 120.000 SAFE
7 4.000 13 68.000 65.393 57.624 85.803 120.000 SAFE
6 4.000 13 73.000 75.892 66.986 85.803 120.000 SAFE
5 4.000 17 78.000 66.897 58.993 102.594 120.000 SAFE
4 4.000 17 83.000 76.081 67.090 102.594 120.000 SAFE
3 4.000 22 88.000 66.568 58.562 93.181 120.000 SAFE
2 4.000 22 93.000 74.422 65.366 91.455 120.000 SAFE
1 4.000 22 98.000 82.524 72.418 89.791 120.000 SAFE

Sample Design calculation at base of Zone - 7

Shell thickness = 16 mm Outer Dia= 4000 mm

Corossion allowance = 3 mm Inner Dia = 3968 mm
Hence design thickness of plate = 13 mm
Considering corrosion allowance Inner Dia = 3974 mm
Hence Mean diameter (D) at the level considered = (4000 + 3974) / 2 = 3987 mm

Effective Height He = 68000 mm

He/D = 17 D/t = 308

Hence Permissible stress in compression = 0.5 x 250 x 1 x ( 270 / 307.7 x ( 1 - 67 / 307.7) )

Page 13 of 16
 550 TPD SAP WITH PRODUCT MIX &
50 TPD SO2 PLANT Document No:-
M/s SEYA INDUSTRIES LTD.
SITE:- TARAPUR, MAHARASHTRA Rev
Document Title :
FFIL JOB NO:- 201712 Date

= 85.8 N/mm2

Hence Permissible stress in compression = 0.6 x 250 x 0.8 = 120 N/mm2

Maximum bending moment, = 9946 kNm Axial Force = 632.217 kN

Moment of Inertia, I = 3.14 x ( 4000^4 - 3974^4 ) / 64 = 3.234E+11 mm4

Section Modulus, Z = 3.23E+11 = 1.62E+08 mm3

4000/2

Area, A = 3.14 x ( 4000^2 - 3974^2 ) / 4 = 1.63E+05 mm2

Stress due bending = 9946 x 10^6 = 61.51 < 85.8 N/mm2 Hence Safe
1.62E+08
Therefore 16 mm thick plate is OK

Stress due to Axial load = 632.217 x 10^3 = 3.88

1.63E+05

Total Stress in Compression = 61.51 + 3.88 = 65.39 < 85.8 N/mm2 Hence Safe

Total Stress in Tension = 61.51 - 3.88 = 57.63 < 120 N/mm2 Hence Safe

Design for foundation bolts

Design Forces at base: Virtical Force = 1388.5 kN

Shear Force = 422.1 kN
Moment = 21056.2 kNm

Diameter at base = 4000 mm = 4 m

4M
Tensile force to be resisted by bolts = - W
d

4 x 21056.2
= - 1388.5
4

Page 14 of 16
 550 TPD SAP WITH PRODUCT MIX &
50 TPD SO2 PLANT Document No:-
M/s SEYA INDUSTRIES LTD.
SITE:- TARAPUR, MAHARASHTRA Rev
Document Title :
FFIL JOB NO:- 201712 Date

= 19667.7 kN

No. of bolts provided = 100

Tension per bolt = 196.677 kN

Total Shear Force = 422.1 kN

Shear Force per bolt = 4.221 kN

Tensile Capacity of 4.6 Grade M48 Bolts = 0.6 x 240 x 3.14 x 48 x 48 / 4

= 260 kN > 196.677, Hence Safe in Tension

Shear Capacity of bolts = 0.6 x 1/√3 x 240 x 3.14 x 48 x 48 / 4

= 150 kN > 4.221, Hence Safe in Shear

Combined Interaction ratio = 196.677 4.221

+ = 0.785
260 150 < 1, Hence Safe

Design of Base Plate.

Maximum force per unit length = 4M W =

+
πd2 πd

4 x 21056.2 1388.5
+ = 2023.58 kN
3.14 x 4^2 3.14 x 4

Allowable bearing pressure = 0.25 x fck = 0.25 x 25 = 6.25 N/mm2

Width of base plate required = 2023.6 = 324 mm

6.25
Provided width of base plate = 400 mm

Therefore actual bearing stress,w = 2023.6 = 5.05895 N/mm2

400
Maximum cantilevered length of base plate, n = 250 mm

Allowable plate bending stress, fbs = 0.75 x fy = 0.75 x 240 = 180 N/mm2

Thickness of base plate required = 3𝑤𝑐 2 /𝑓𝑏𝑠 = 73 mm

Page 15 of 16
 550 TPD SAP WITH PRODUCT MIX &
50 TPD SO2 PLANT Document No:-
M/s SEYA INDUSTRIES LTD.
SITE:- TARAPUR, MAHARASHTRA Rev
Document Title :
FFIL JOB NO:- 201712 Date
Provided thickness of the base plate = 75 mm > 73 mm Hence safe

Page 16 of 16