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CHIMNEY DESIGN CALCULATION : I.S.

6533 CUSTOMER : CHIMNEY DIAMETER-TOP D1(IN cm) CHIMNEY DIA BOTTOM BD (IN cm) CHIMNEY HEIGHT TOTAL H( IN cm) CORROSION ALLOWANCE ALLOWABLE BEARING ON FOUNDATION Ff( IN KG/cm2) ALLOWABLE BENDING STRESS-BEARING PLATE Fbp( IN KG/cm2) DIA D1 ( IN cm) 132 132 132 132 176 CODE PAGE FIRST CARBON TECHNOLOGIES PVT LTD,INDIA : 132 : 220 : 4600 : MM 3 : 20 : 1650 DIA D1' (IN cm) 132 132 132 176 220 D AVG (IN cm) 132 132 132 154 198 SECTIONAL HEIGHT (IN cm) 960 960 920 880 880 SHELL THICKNESS (IN MM) ( IN cm) 10 1.00 12 1.20 16 1.60 20 2.00 22 2.20 1 OF 14

SEGMENT I SEGMENT II SEGMENT III SEGMENT IV SEGMENT V

DESIGN OF SEGMENT I DESIGN WIND SPEED (Vz)= WHERE Vb X K1 X K2 X K3 K1= K2= K3= VB= PROBABILITY FACTOR= TERRAIN FACTOR= TOPOGRAPHY FACTOR = BASIC WIND SPEED= Vz = DESIGN WIND PRESSURE PZ = PZ = PZ = WIND FORCE WHERE FL 0.6xVzxVz 1457.11104 N/M2 0.014862533 Kg/cm2 = Cf= Ae= Ae= 1.1 = WIND FORCE FL = Cf x Ae x Pz x 1.1 FORCE COEFFICIENT EFFECTIVE AREA = 49.28 METRES/SEC NOTE: I N/M2 CONVERSION FACTOR = 0.0000102 KG /cm2 -----IS 875(3)1 1.12 1 44 m/s 1987

98039.2157

(Pz= WIND PRESSURE) 1.2 AVG DIA x HEIGHT 126720 cm2

10% INCREASED TO TAKE CARE OF WIND PRESSURE ON CAGE AND LADDER 2486.061774 Kg

PAGE A) BENDING MOMENT Mx = Mx= B) MODULUS OF SECTION Z= WHERE .77T x D x D T= SHELL THICKNESS W/O CORROSION ALLOWANCE(in cm) = 132 0.7 FL(H-Y)/2 1193309.652 KG cm where, H= Y= HEIGHT OF CHIMNEY in cm SECTION HEIGHT in cm

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BOTTOM DIA(D) ( in cm)=

Z= C) ACTUAL BENDING STRESS FB= = = = D) ACTUAL COMPRESSION STRESS Fc= WHERE G= G= G/A Mx/Z

9391.536 cm^3

127.0622454 12457082.88 12.45708288

KG/cm^2 KG/cm^2 Pa Mpa

DEAD WEIGHT OF SEGMENT 3099.85824 KGS

D1= D2=

132 cm 130 cm

A=

AREA OF SECTION BOTTOM W/O CORROSION ALLOWANCE 288.5974 cm2

A=

FC = = =

10.74111631 KG/cm2 1053050.619 Pa 1.053050619 Mpa

E) TOTAL COMBINED STRESS

PAGE Sc = = REFER TABLE 3 he/D< 20 D/t<140 126 94.5 Fb+ Fc 13.5101335 Mpa : I.S. 6533

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MAXIMUM PERMISSIBLE COMBINED STRESS Mpa WITH TEMPERATURE CORRECTION FACTOR ALLOWABLE COMBINED STRESS a= STABILITY CHECK 1.6 (Fb+ Fc) - 0.9 xFc < 1.8 x a 20.66846804 (CALCULATED) < 170.1 Mpa (ALLOWABLE)

DESIGN OF SEGMENT II DESIGN WIND SPEED (Vz)= WHERE Vb X K1 X K2 X K3 K1= K2= K3= VB= PROBABILITY FACTOR= TERRAIN FACTOR= TOPOGRAPHY FACTOR = BASIC WIND SPEED= Vz = DESIGN WIND PRESSURE PZ = PZ = PZ = WIND FORCE WHERE F 0.6xVzxVz 1431.20736 N/M2 0.014598315 Kg/cm2 = Cf= Ae= Ae= 1.1 = WIND FORCE FL = Cf x Ae x Pz x 1.1 FORCE COEFFICIENT EFFECTIVE AREA = 48.84 METRES/SEC NOTE: I N/M2 CONVERSION FACTOR = 0.0000102 KG /cm2 -----IS 875(3)1 1.11 1 44 m/s 1987

(Pz= WIND PRESSURE) 1.2 AVG DIA x HEIGHT 253440 cm2

10% INCREASED TO TAKE CARE OF WIND PRESSURE ON CAGE AND LADDER 4883.732003 Kg

A)

BENDING MOMENT Mx = FL(H-Y)/2 4688382.723 KG cm where, H= Y= HEIGHT OF CHIMNEY in cm SECTION HEIGHT in cm

PAGE

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Mx= B) MODULUS OF SECTION Z= WHERE .77T x D x D

T=

SHELL THICKNESS W/O CORROSIONALLOWANCE(in cm) = 132.00

0.9

BOTTOM DIA(D) ( IN cm)=

Z= C) ACTUAL BENDING STRESS FB= = = = D) ACTUAL COMPRESSION STRESS Fc= WHERE G= G= G/A Mx/Z

12074.832 cm3

388.2772632 38066398.35 38.06639835

KG/cm2 KG/cm2 Pa Mpa

DEAD WEIGHT OF SEGMENT 6814.008998 KGS

D1= D2=

132 cm 129.6 cm

A=

AREA OF SECTION BOTTOM W/O CORROSION ALLOWANCE 370.4886 cm2 370.4886

PAGE

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A=

FC = = =

18.39195322 KG/cm2 1803132.668 Pa 1.803132668 Mpa

E) TOTAL COMBINED STRESS Sc = = REFER TABLE 3 he/D< 20 D/t<140 108 81 Fb+ Fc 39.86953102 Mpa : I.S. 6533

MAXIMUM PERMISSIBLE COMBINED STRESS Mpa WITH TEMPERATURE CORRECTION FACTOR ALLOWABLE COMBINED STRESS a= STABILITY CHECK 1.6 (Fb+ Fc) - 0.9 xFc < 1.8 x a 62.16843023 (CALCULATED) DESIGN OF SEGMENT III DESIGN WIND SPEED (Vz)= WHERE Vb X K1 X K2 X K3 K1= K2= K3= VB= PROBABILITY FACTOR= TERRAIN FACTOR= TOPOGRAPHY FACTOR = BASIC WIND SPEED= Vz = -----< 145.8 Mpa (ALLOWABLE)

IS 875(3)1 1.09 1 44 m/s

1987

47.96 METRES/SEC

DESIGN WIND PRESSURE PZ = PZ = PZ = WIND FORCE WHERE F

0.6xVzxVz 1380.09696 N/M2 0.014076989 Kg/cm2 = Cf= Ae= Ae= 1.1 = Cf x Ae x Pz x 1.1 FORCE COEFFICIENT EFFECTIVE AREA =

NOTE: I N/M2

CONVERSION FACTOR = 0.0000102 KG /cm2

PAGE

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(Pz= WIND PRESSURE) 1.2 AVG DIA x HEIGHT 374880 cm2

10% INCREASED TO TAKE CARE OF WIND PRESSURE ON CAGE AND LADDER 6965.879756 Kg

WIND FORCE

FL

A)

BENDING MOMENT Mx = FL(H-Y)/2 12259948.37 KG cm where, H= Y= HEIGHT OF CHIMNEY in cm SECTION HEIGHT in cm

Mx= B) MODULUS OF SECTION Z= WHERE .77T x D x D

T=

SHELL THICKNESS W/O CORROSION ALLOWANCE(in cm) = 132

1.3

BOTTOM DIA(D) ( IN cm)=

Z= C) ACTUAL BENDING STRESS FB= = = = D) ACTUAL COMPRESSION STRESS Fc= G/A Mx/Z

17441.424 cm3

702.9212965 68913852.6 68.9138526

KG/cm2 KG/cm2 Pa Mpa

WHERE G= G=

PAGE DEAD WEIGHT OF SEGMENT 11545.35497 KGS 0 D1= D2= 132 cm 128.8 cm

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A=

AREA OF SECTION BOTTOM W/O CORROSION ALLOWANCE 533.5174 cm2

A=

FC = = =

21.64007204 KG/cm2 2121575.69 Pa 2.12157569 Mpa

E) TOTAL COMBINED STRESS Sc = = REFER TABLE 3 he/D< 20 D/t<140 124 93 Fb+ Fc 71.03542829 Mpa : I.S. 6533

MAXIMUM PERMISSIBLE COMBINED STRESS Mpa WITH TEMPERATURE CORRECTION FACTOR ALLOWABLE COMBINED STRESS a= STABILITY CHECK 1.6 (Fb+ Fc) - 0.9 xFc < 1.8 x a 111.7472671 (CALCULATED) DESIGN OF SEGMENT IV DESIGN WIND SPEED (Vz)= WHERE Vb X K1 X K2 X K3 K1= K2= K3= VB= PROBABILITY FACTOR= TERRAIN FACTOR= TOPOGRAPHY FACTOR = BASIC WIND SPEED= -----< 167.4 Mpa (ALLOWABLE)

IS 875(3)1 1.06 1 44 m/s

1987

Vz = DESIGN WIND PRESSURE PZ = PZ = PZ = WIND FORCE WHERE F 0.6xVzxVz 1305.17376 N/M2 0.013312772 Kg/cm2 = Cf= Ae= Ae= 1.1 = WIND FORCE F = Cf x Ae x Pz x 1.1 FORCE COEFFICIENT EFFECTIVE AREA =

46.64 METRES/SEC NOTE: I N/M2 CONVERSION FACTOR = 0.0000102 KG /cm2

PAGE

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(Pz= WIND PRESSURE) 1.2 AVG DIA x HEIGHT 510400 cm2

10% INCREASED TO TAKE CARE OF WIND PRESSURE ON CAGE AND LADDER 8969.187491 Kg

A)

BENDING MOMENT Mx = FL(H-Y)/2 21517080.79 KG cm where, H= Y= HEIGHT OF CHIMNEY in cm SECTION HEIGHT in cm

Mx= B) MODULUS OF SECTION Z= WHERE .77T x D x D

T=

SHELL THICKNESS W/O CORROSION ALLOWANCE(in cm) = 176

1.7

BOTTOM DIA(D) ( IN cm)=

Z= C) ACTUAL BENDING STRESS FB= = = = D) ACTUAL COMPRESSION STRESS Fc= G/A Mx/Z

40547.584 cm3

530.6624629 52025731.66 52.02573166

KG/cm2 KG/cm2 Pa Mpa

WHERE G= G=

PAGE DEAD WEIGHT OF SEGMENT 18139.45545 KGS D1= D2= 154 cm 150 cm

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A=

AREA OF SECTION BOTTOM W/O CORROSION ALLOWANCE 812.9774 cm2

A=

FC = = =

22.31237357 KG/cm2 2187487.605 Pa 2.187487605 Mpa

E) TOTAL COMBINED STRESS Sc = = REFER TABLE 3 he/D< 30 D/t<140 108 81 Fb+ Fc 54.21321926 Mpa : I.S. 6533

MAXIMUM PERMISSBLE COMBINED STRESS Mpa WITH TEMPERATURE CORRECTION FACTOR ALLOWABLE COMBINED STRESS a= STABILITY CHECK 1.6 (Fb+ Fc) - 0.9 xFc < 1.8 x a 84.77241198 (CALCULATED) DESIGN OF SEGMENT V DESIGN WIND SPEED (Vz)= WHERE Vb X K1 X K2 X K3 K1= K2= K3= VB= PROBABILITY FACTOR= TERRAIN FACTOR= TOPOGRAPHY FACTOR = BASIC WIND SPEED= -----< 145.8 Mpa (ALLOWABLE)

IS 875(3)1 1.02 1 44 m/s

1987

Vz = DESIGN WIND PRESSURE PZ = PZ = PZ = WIND FORCE WHERE F 0.6xVzxVz 1208.52864 N/M2 0.012326992 Kg/cm2 = Cf= Ae= Ae= 1.1 = WIND FORCE FL = Cf x Ae x Pz x 1.1 FORCE COEFFICIENT EFFECTIVE AREA =

44.88 METRES/SEC NOTE: I N/M2 CONVERSION FACTOR = 0.0000102 KG /cm2

PAGE

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(Pz= WIND PRESSURE) 1.2 AVG DIA x HEIGHT 684640 cm2

10% INCREASED TO TAKE CARE OF WIND PRESSURE ON CAGE AND LADDER 11140.2085 Kg

A)

BENDING MOMENT Mx = Mx= FL(H-Y)/2 25622479.54 KG cm where, H= Y= HEIGHT OF CHIMNEY in cm SECTION HEIGHT in cm

MODULUS OF SECTION Z= WHERE .77T x D x D T= SHELL THICKNESS W/O CORROSION ALLOWANCE(in cm) = 220 1.9

BOTTOM DIA(D) ( IN cm)=

Z= C) ACTUAL BENDING STRESS FB= = = = D) ACTUAL COMPRESSION STRESS Fc= G/A Mx/Z

70809.2 cm3

361.8524082 35475726.29 35.47572629

KG/cm2 KG/cm2 Pa Mpa

WHERE G= G=

PAGE DEAD WEIGHT OF SEGMENT 27483.1223 KGS D1= D2= 198 cm 193.6 cm

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A=

AREA OF SECTION BOTTOM W/O CORROSION ALLOWANCE 1169.9326 cm2

A=

FC = = =

23.49120137 KG/cm2 2303058.958 Pa 2.303058958 Mpa

E) TOTAL COMBINED STRESS Sc = = REFER TABLE 3 he/D< 30 D/t<140 108 81 Fb+ Fc 37.77878525 Mpa : I.S. 6533

MAXIMUM PERMISSBLE COMBINED STRESS Mpa WITH TEMPERATURE CORRECTION FACTOR ALLOWABLE COMBINED STRESS a = STABILITY CHECK 1.6 (Fb+ Fc) - 0.9 xFc < 1.8 x a 58.37330333 (CALCULATED) FOUNDATION BOLTS MAXIMUM FORCE ON EACH BOLT WHERE P M n Ws D1 < 145.8 Mpa (ALLOWABLE)

= = = = =

(4M/nD1)-(Ws/n) B.M AT THE BASE OF CHIMNEY x NUMBER OF BOLTS WEIGHT OF THE CHIMNEY DIA OF BOLTCIRCLE pcd= 100000.00

PAGE M= BM= n= Ws= D1= P= NET AREA OF BOLT NOW BOLT DIA D2 NOW BOLT DIA D = SAY = = USE M50 DIA BOLT DESIGN OF BASE PLATE COMPRESSIVE FORCE Cf = WHERE D= = = = = = = = = 1.27*M/D*D+(Ws+W1)/3.142 D1 EXTERNAL DIA OF CHIMNEY BASE 275 cm WEIGHT OF THE CHIMNEY LINING 471.03 Kg / Sq.Cm 20 Cf/Ff 23.5513 cm 27.5 cm WIDE BEARING PALTE b/2 * sqrt (3* Ff)/Fbp = 0.036363636 0.190692518 2.62202 cm 3.2 cm 25622479.54 Kg cm 256.22 (x 100000 Kg cm) 32 32000 KGS 250 cm 11811.23977 KG 14.76404971 15 19.10219675 cm2 4.370605994 cm cm2 cm2

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W1 Cf Ff REQUIRED WIDTH OF BEARING PLATE B

WIDTH OF BEARING PLATE PROVIDED b THK OF BEARING PLATE t' =

((3*Ff)/Fbp) t' HENCE THICKNESS OF THE PLATE t' =