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HINDUSTAN PETROLEUM CORPORATION LTD.

MUMBAI

DIESEL HYDROTREATER PROJECT

TITLE:

STANDARD SPECIFICATION FOR STEEL STACKS

DOCUMENT NO : 44LK-5100-00-V.02-0211-A4

Rev
No.

Issue Date

Pages

09.09.2008

Description

Prepared
By

Checked
By

Approved
By

Issued as standard specification

SNK

CR

HSC

-1-

Jacobs
HPCL, MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

STEEL STACKS

Doc No.: 44LK-5100-00-V.02-0211-A4

CONTENTS

1.0

GENERAL

2.0

CODES AND STANDARDS

3.0

TECHNICAL REQUIREMENTS

4.0

INSPECTION AND TESTING

5.0

PROTECION AND PAINTING

B.4.4_Std spec for Steel stacks

Page 2 of 6

Jacobs
HPCL, MUMBAI

Page 3 of 6

STANDARD SPECIFICATION FOR

44LK-5100

STEEL STACKS

Doc No.: 44LK-5100-00-V.02-0211-A4

1.0

GENERAL
Steel Chimneys are required in process, power, refineries, furnaces, boilers, etc. to let
out flue gases into the atmosphere. The diameter and their heights are decided by
functional requirements and environmental considerations. These stacks could be
ground supported or installed at higher elevations like boiler mounted depending upon
how the flue gases are passed through them. Depending upon their usage, these
stacks could be unlined or lined with a suitable refractory system. The stacks are
structurally tall hence important aspects is the design of self-supporting stacks are wind
/seismic loading, wind excited oscillations, limitations of deflection. Very tall stack could
be designed supported by superimposed structure around the stack covering the entire
height like in flare stacks. Stack design using guy wire ropes are not to be considered.
Apart from following various codal requirements for design, certain statutory
requirements like provincial building by laws and the civil aviation requirements
pertaining to such structures are also to be taken care during design. Jacobs shall
review the design documents produced by the vendor.

This specification covers only general design guidelines. Vendor is supposed to be

acquainted with the design of steel chimneys and is expected to cover all aspects of
design of this type of structures including its statutory and functional requirements.
Approval of his design documents shall not relieve the vendor from his contractual
obligations towards design and construction of the stack.

2.0

CODES AND STANDARDS

IS 6533(Part 1): 1989

Design and construction of steel chimney Code of

Practice Part 1 Mechanical aspects.

IS 6533(Part 2)

Code of Practice for design and construction of steel

chimney Part 2 Structural aspects.

IS 6

Specification for the

refractories, Group A.

IS 8

Specification for high heat duty fire clay refractories, Group

B.

IS 2042

Specification for insulating bricks.

IS 1363

Hexagonal head bolts, screws and nuts and product Grade

C.

IS 1364

Hexagonal head bolts, screws and nuts of product Grades

A & B.

IS 875 /Site data

For wind load consideration

IS 1893/site data

For seismic design consideration

IS 2062:1999

Steel for general structural purposes.

BS 4076:1978

Specifications for steel chimneys

B.4.4_Std spec for Steel stacks

moderate

heat

duty fire

clay

Jacobs
HPCL, MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

Page 4 of 6

STEEL STACKS

Doc No.: 44LK-5100-00-V.02-0211-A4

3.0

TECHNICAL REQUIREMENTS

3.1

General
The basic dimensions o the chimney (stack), namely clear diameter, height , etc. are
decided on consideration of temperature, composition of flue gases, Adjacent structures,
Pollution control, draft requirements However, certain recommended proportion should
be maintained for the strength and its stability.
Proportions of the basis dimensions of a self supporting chimney shall conform to the
following:

3.2

(i)

Minimum height of flare be equal to one third the height of the chimney.

(ii)

Minimum outside diameter or unlined chimney shell at top be equal to one

twentieth of the height of cylindrical portion of chimney and for lined chimney it
shall be one twenty fifth of the height or the cylindrical portion.

(iii)

Minimum outside diameter of flared chimney at base be equal to 1.6 times the
outside diameter of shell at top.

Minimum Thickness
The minimum thickness of stack shall be 6.0mm but shall not be less than calculated as
per following formula:
Wall Thickness = Dia. + 2.5 + Corrosion allowance
1000

3.3

Corrosion Allowance
The total allowance of corrosion shall be sum of the external and internal allowance and
shall be selected in line with IS 6533 recommendation unless specified otherwise.

3.4

Allowable Deflection
The maximum deflection at the top of the steel chimney produced by the wind load
without taking into account the dynamic factors, calculated a acting on the circular cross
section shall not be greater than h/200 where h is the unsupported height of the
chimney. Effect of cage ladder, platform and other pretensions shall be taken care
during calculation of wind deflection.

3.5

Maximum Permissible Stresses:

3.5.1

Allowable stresses is axial tension, sheer and bearing shall be as specified in IS 800. To
control buckling, the compressive stresses caused by the extreme fibre stresses due to
bending and direct load for the following load combinations shall be within safe limits
after considering temperature effects and allowance for large opening in shell:

B.4.4_Std spec for Steel stacks

Jacobs
HPCL, MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

Page 5 of 6

STEEL STACKS

Doc No.: 44LK-5100-00-V.02-0211-A4

3.5.2

3.5.3

For design of chimney and its foundation, any of the following load combinations which
produce maximum forces and effects and consequently maximum stresses shall be
chosen.
I.

Dead load + wind load

II.

Dead load + Earthquake load

III.

Dead load + load due to lining + imposed load on service platform + wind load or

IV.

Dead load + load due to lining + imposed load on service platforms +

earthquake loads.

Check for Resonance

In case of self supporting chimney, checking for resonance shall be carried out if the
critical velocity for as determined from Annexure A of IS 6533 Part 2.

0.5 to 0.8 times the design wind velocity for lined chimney
0.33 to 0.8 time the design wind velocity for unlined chimney.
For lined chimneys, checking for resonance shall be carried out for both the cases, that
is with or without lining. Chimney which have high diameter/thickness ratio may be
subjected to wind generated ovalling oscillating due to circumferentially varying and
fluctuating pressure. There shall be suitably taken care as per IS 6533 like providing
strake vanes, providing circumferential stiffeners for chimneys having high diameter to
thickness to avoid ovalling oscillations due to circumferentially varying and fluctuating
pressure etc. Design forces, bending moments and for first mode of oscillation
deflection shall be calculated as per IS 6533 Part 2.

3.6

Supporting
The chimney shall be structurally stable on its foundation. Allowable stress for
foundation bolts, its base plate, gussets, stool etc. shall be as per IS 800.

3.7

Chimney Top
The chimney top shall be provided with a rain hood at the top. This hood shall allow free
passage to the flue gases but save the top opening from rain water entering into it.

3.8

Ladder platforms, Painters trolley, Warning lamps, Lightening protections:

Approach ladder and platforms for servicing of warning lamps, inspection etc. shall be
provided as necessary As a general rule one interlanding platform after every 5m and
full platform wherever service demands is to be provided. Projection of platform shall be
1.0m upto 1m dia. Chimney and 1.2m for chimney >1.2m from chimney insulation
service. Caged ladder and platform shall be ell protected and properly attached for
safety reasons. Weight of cages ladder shall be taken as 35 kg/m and that of platform
2
170 kg/m . Platforms and ladders shall be galvanised.

B.4.4_Std spec for Steel stacks

Jacobs
HPCL, MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

Page 6 of 6

STEEL STACKS

Doc No.: 44LK-5100-00-V.02-0211-A4

4.0

INSPECTION AND TESTING

All the materials used for fabricating the stack shall be new and as per specified material
of construction.
Welding shall be carried out by qualified welders and inspection shall proceed on he
basis of approved Quality Assurance Plan prepared by the vendor. However, following
minimum stages are anticipated.
a) Identification of major raw materials
b) Set up and its alignment
c) DP and any other specified NDT.
d) Final dimensional checks
e) Transportation scheme.

5.0

PROTECTION AND PAINTING

Consideration shall be given to the surface preparation and protective treatment of both
the exterior and interior surface of chimney shells in order to prolong the life and improve
the appearance of chimney. Pre-treatment and painting shall be in line with Jacob std
In case of very tall supported/unsupported chimney with aviation light arrangement the
chimney shall / its support structure shall be painted as per suitable aviation painting
system requirements.

B.4.4_Std spec for Steel stacks