CHIMNEY DESIGN CALCULATIONCODE : I.S. 6533 PAGE 1 OF 14

CUSTOMER : FIRST CARBON TECHNOLOGIES PVT LTD,INDIACHIMNEY DIAMETER-TOP D1(IN cm) : 132CHIMNEY DIA BOTTOM BD (IN cm) : 220CHIMNEY HEIGHT TOTAL H( IN cm) : 4600CORROSION ALLOWANCE : MM 3

ALLOWABLE BEARING ON FOUNDATION Ff( IN KG/cm2) : 20ALLOWABLE BENDING STRESS-BEARING PLATE Fbp( IN KG/cm2) : 1650

DIA D1 DIA D1' D AVG SECTIONAL HEIGHT SHELL THICKNESS( IN cm) (IN cm) (IN cm) (IN cm) (IN MM) ( IN cm)

SEGMENT I 132 132 132 960 10 1.00SEGMENT II 132 132 132 960 12 1.20SEGMENT III 132 132 132 920 16 1.60SEGMENT IV 132 176 154 880 20 2.00SEGMENT V 176 220 198 880 22 2.20

DESIGN OF SEGMENT I

DESIGN WIND SPEED (Vz)= Vb X K1 X K2 X K3 ------ IS 875(3)- 1987

WHERE K1= PROBABILITY FACTOR= 1K2= TERRAIN FACTOR= 1.12K3= TOPOGRAPHY FACTOR = 1VB= BASIC WIND SPEED= 44 m/s

Vz = 49.28 METRES/SEC

DESIGN WIND PRESSURE PZ = 0.6xVzxVz NOTE: CONVERSION FACTORPZ = 1457.11104 N/M2 I N/M2 = 0.0000102 KG /cm2 98039.2157PZ = 0.014862532608 Kg/cm2

WIND FORCE FL = Cf x Ae x Pz x 1.1 (Pz= WIND PRESSURE)

WHERE Cf= FORCE COEFFICIENT 1.2Ae= EFFECTIVE AREA = AVG DIA x HEIGHTAe= 126720 cm2

1.1 = 10% INCREASED TO TAKE CARE OF WIND PRESSURE ON CAGE AND LADDER

WIND FORCE FL = 2486.0617744 Kg

PAGE 2 OF 14A) BENDING MOMENT

Mx = FL(H-Y)/2 where, H= HEIGHT OF CHIMNEY in cmY= SECTION HEIGHT in cm

Mx= 1193309.65168954 KG cmB) MODULUS OF SECTION

Z = .77T x D x D

WHERE T = SHELL THICKNESS W/O CORROSION ALLOWANCE(in cm) = 0.7

BOTTOM DIA(D) ( in cm)= 132

Z = 9391.536 cm^3

C) ACTUAL BENDING STRESS

FB= Mx/Z KG/cm^2= 127.062245376 KG/cm^2= 12457082.88 Pa= 12.45708288 Mpa

D) ACTUAL COMPRESSION STRESS

Fc= G / A

WHEREG= DEAD WEIGHT OF SEGMENT D1= 132 cm

D2= 130 cmG= 3099.85824 KGS

A= AREA OF SECTION BOTTOMW/O CORROSION ALLOWANCE

A= 288.597400000002 cm2

FC = 10.74111631 KG/cm2= 1053050.619 Pa

= 1.053050619 Mpa

E) TOTAL COMBINED STRESS PAGE 3 OF 14

Sc = Fb+ Fc= 13.5101334985719 Mpa

REFER TABLE 3 : I.S. 6533

he/D< 20 D/t<140

MAXIMUM PERMISSIBLE COMBINED STRESS Mpa 126WITH TEMPERATURE CORRECTION FACTORALLOWABLE COMBINED STRESS a= 94.5

STABILITY CHECK

1.6 (Fb+ Fc) - 0.9 xFc < 1.8 x a

20.66846804 < 170.1 Mpa(CALCULATED) (ALLOWABLE)

DESIGN OF SEGMENT II

DESIGN WIND SPEED (Vz)= Vb X K1 X K2 X K3 ------ IS 875(3)- 1987

WHERE K1= PROBABILITY FACTOR= 1K2= TERRAIN FACTOR= 1.11K3= TOPOGRAPHY FACTOR = 1VB= BASIC WIND SPEED= 44 m/s

Vz = 48.84 METRES/SEC

DESIGN WIND PRESSURE PZ = 0.6xVzxVz NOTE: CONVERSION FACTORPZ = 1431.20736 N/M2 I N/M2 = 0.0000102 KG /cm2PZ = 0.014598315072 Kg/cm2

WIND FORCE F = Cf x Ae x Pz x 1.1 (Pz= WIND PRESSURE)

WHERE Cf= FORCE COEFFICIENT 1.2Ae= EFFECTIVE AREA = AVG DIA x HEIGHTAe= 253440 cm2

1.1 = 10% INCREASED TO TAKE CARE OF WIND PRESSURE ON CAGE AND LADDER

WIND FORCE FL = 4883.7320028 Kg

A) BENDING MOMENT PAGE 4 OF 14

Mx = FL(H-Y)/2 where, H= HEIGHT OF CHIMNEY in cmY= SECTION HEIGHT in cm

Mx= 4688382.72272538 KG cmB) MODULUS OF SECTION

Z = .77T x D x D

WHERE T = SHELL THICKNESS W/O CORROSIONALLOWANCE(in cm) = 0.9

BOTTOM DIA(D) ( IN cm)= 132.00

Z = 12074.832 cm3

C) ACTUAL BENDING STRESS

FB= Mx/Z KG/cm2= 388.277263213714 KG/cm2= 38066398.3542857 Pa= 38.0663983542857 Mpa

D) ACTUAL COMPRESSION STRESS

Fc= G / A

WHEREG= DEAD WEIGHT OF SEGMENT D1= 132 cm

D2= 129.6 cmG= 6814.0089984 KGS

A= AREA OF SECTION BOTTOM PAGE 5 OF 14W/O CORROSION ALLOWANCE

A= 370.488600000002 cm2370.488600000002

FC = 18.39195322 KG/cm2= 1803132.668 Pa= 1.803132668 Mpa

E) TOTAL COMBINED STRESS

Sc = Fb+ Fc= 39.8695310225577 Mpa

REFER TABLE 3 : I.S. 6533

he/D< 20 D/t<140

MAXIMUM PERMISSIBLE COMBINED STRESS Mpa 108WITH TEMPERATURE CORRECTION FACTORALLOWABLE COMBINED STRESS a= 81

STABILITY CHECK

1.6 (Fb+ Fc) - 0.9 xFc < 1.8 x a

62.16843023 < 145.8 Mpa(CALCULATED) (ALLOWABLE)

DESIGN OF SEGMENT III

DESIGN WIND SPEED (Vz)= Vb X K1 X K2 X K3 ------ IS 875(3)- 1987

WHERE K1= PROBABILITY FACTOR= 1K2= TERRAIN FACTOR= 1.09K3= TOPOGRAPHY FACTOR = 1VB= BASIC WIND SPEED= 44 m/s

Vz = 47.96 METRES/SEC

DESIGN WIND PRESSURE PZ = 0.6xVzxVz NOTE: CONVERSION FACTOR PAGE 6 OF 14PZ = 1380.09696 N/M2 I N/M2 = 0.0000102 KG /cm2PZ = 0.014076988992 Kg/cm2

WIND FORCE F = Cf x Ae x Pz x 1.1 (Pz= WIND PRESSURE)

WHERE Cf= FORCE COEFFICIENT 1.2Ae= EFFECTIVE AREA = AVG DIA x HEIGHTAe= 374880 cm2

1.1 = 10% INCREASED TO TAKE CARE OF WIND PRESSURE ON CAGE AND LADDER

WIND FORCE FL = 6965.879756 Kg

A) BENDING MOMENT

Mx = FL(H-Y)/2 where, H= HEIGHT OF CHIMNEY in cmY= SECTION HEIGHT in cm

Mx= 12259948.3705313 KG cmB) MODULUS OF SECTION

Z = .77T x D x D

WHERE T = SHELL THICKNESS W/O CORROSION ALLOWANCE(in cm) = 1.3

BOTTOM DIA(D) ( IN cm)= 132

Z = 17441.424 cm3

C) ACTUAL BENDING STRESS

FB= Mx/Z KG/cm2= 702.921296479649 KG/cm2= 68913852.596044 Pa= 68.913852596044 Mpa

D) ACTUAL COMPRESSION STRESS

Fc= G / A

WHERE PAGE 7 OF 14G= DEAD WEIGHT OF SEGMENT D1= 132 cm

D2= 128.8 cmG= 11545.3549696 KGS

0A= AREA OF SECTION BOTTOM

W/O CORROSION ALLOWANCE

A= 533.5174 cm2

FC = 21.64007204 KG/cm2= 2121575.69 Pa= 2.12157569 Mpa

E) TOTAL COMBINED STRESS

Sc = Fb+ Fc= 71.0354282860575 Mpa

REFER TABLE 3 : I.S. 6533

he/D< 20 D/t<140

MAXIMUM PERMISSIBLE COMBINED STRESS Mpa 124WITH TEMPERATURE CORRECTION FACTORALLOWABLE COMBINED STRESS a= 93

STABILITY CHECK

1.6 (Fb+ Fc) - 0.9 xFc < 1.8 x a

111.7472671 < 167.4 Mpa(CALCULATED) (ALLOWABLE)

DESIGN OF SEGMENT IV

DESIGN WIND SPEED (Vz)= Vb X K1 X K2 X K3 ------ IS 875(3)- 1987

WHERE K1= PROBABILITY FACTOR= 1K2= TERRAIN FACTOR= 1.06K3= TOPOGRAPHY FACTOR = 1

VB= BASIC WIND SPEED= 44 m/s

Vz = 46.64 METRES/SEC PAGE 8 OF 14

DESIGN WIND PRESSURE PZ = 0.6xVzxVz NOTE: CONVERSION FACTORPZ = 1305.17376 N/M2 I N/M2 = 0.0000102 KG /cm2PZ = 0.013312772352 Kg/cm2

WIND FORCE F = Cf x Ae x Pz x 1.1 (Pz= WIND PRESSURE)

WHERE Cf= FORCE COEFFICIENT 1.2Ae= EFFECTIVE AREA = AVG DIA x HEIGHTAe= 510400 cm2

1.1 = 10% INCREASED TO TAKE CARE OF WIND PRESSURE ON CAGE AND LADDER

WIND FORCE F = 8969.1874912 Kg

A) BENDING MOMENT

Mx = FL(H-Y)/2 where, H= HEIGHT OF CHIMNEY in cmY= SECTION HEIGHT in cm

Mx= 21517080.7913127 KG cmB) MODULUS OF SECTION

Z = .77T x D x D

WHERE T = SHELL THICKNESS W/O CORROSION ALLOWANCE(in cm) = 1.7

BOTTOM DIA(D) ( IN cm)= 176

Z = 40547.584 cm3

C) ACTUAL BENDING STRESS

FB= Mx/Z KG/cm2= 530.662462930286 KG/cm2= 52025731.6598319 Pa= 52.0257316598319 Mpa

D) ACTUAL COMPRESSION STRESS

Fc= G / A

WHERE PAGE 9 OF 14G= DEAD WEIGHT OF SEGMENT D1= 154 cm

D2= 150 cmG= 18139.4554496 KGS

A= AREA OF SECTION BOTTOMW/O CORROSION ALLOWANCE

A= 812.977400000002 cm2

FC = 22.31237357 KG/cm2= 2187487.605 Pa= 2.187487605 Mpa

E) TOTAL COMBINED STRESS

Sc = Fb+ Fc= 54.2132192643519 Mpa

REFER TABLE 3 : I.S. 6533

he/D< 30 D/t<140

MAXIMUM PERMISSBLE COMBINED STRESS Mpa 108WITH TEMPERATURE CORRECTION FACTORALLOWABLE COMBINED STRESS a= 81

STABILITY CHECK

1.6 (Fb+ Fc) - 0.9 xFc < 1.8 x a

84.77241198 < 145.8 Mpa(CALCULATED) (ALLOWABLE)

DESIGN OF SEGMENT V

DESIGN WIND SPEED (Vz)= Vb X K1 X K2 X K3 ------ IS 875(3)- 1987

WHERE K1= PROBABILITY FACTOR= 1K2= TERRAIN FACTOR= 1.02K3= TOPOGRAPHY FACTOR = 1

VB= BASIC WIND SPEED= 44 m/s

Vz = 44.88 METRES/SEC PAGE 10 OF 14

DESIGN WIND PRESSURE PZ = 0.6xVzxVz NOTE: CONVERSION FACTORPZ = 1208.52864 N/M2 I N/M2 = 0.0000102 KG /cm2PZ = 0.012326992128 Kg/cm2

WIND FORCE F = Cf x Ae x Pz x 1.1 (Pz= WIND PRESSURE)

WHERE Cf= FORCE COEFFICIENT 1.2Ae= EFFECTIVE AREA = AVG DIA x HEIGHTAe= 684640 cm2

1.1 = 10% INCREASED TO TAKE CARE OF WIND PRESSURE ON CAGE AND LADDER

WIND FORCE FL = 11140.208495 Kg

A) BENDING MOMENT

Mx = FL(H-Y)/2 where, H= HEIGHT OF CHIMNEY in cmY= SECTION HEIGHT in cm

Mx= 25622479.54 KG cmMODULUS OF SECTION

Z = .77T x D x D

WHERE T = SHELL THICKNESS W/O CORROSION ALLOWANCE(in cm) = 1.9

BOTTOM DIA(D) ( IN cm)= 220

Z = 70809.2 cm3

C) ACTUAL BENDING STRESS

FB= Mx/Z KG/cm2= 361.852408156006 KG/cm2= 35475726.2898045 Pa= 35.4757262898045 Mpa

D) ACTUAL COMPRESSION STRESS

Fc= G / A

WHERE PAGE 11 OF 14G= DEAD WEIGHT OF SEGMENT D1= 198 cm

D2= 193.6 cmG= 27483.1223008 KGS

A= AREA OF SECTION BOTTOMW/O CORROSION ALLOWANCE

A= 1169.93260000001 cm2

FC = 23.49120137 KG/cm2= 2303058.958 Pa= 2.303058958 Mpa

E) TOTAL COMBINED STRESS

Sc = Fb+ Fc= 37.7787852480559 Mpa

REFER TABLE 3 : I.S. 6533

he/D< 30 D/t<140

MAXIMUM PERMISSBLE COMBINED STRESS Mpa 108WITH TEMPERATURE CORRECTION FACTORALLOWABLE COMBINED STRESS a = 81

STABILITY CHECK

1.6 (Fb+ Fc) - 0.9 xFc < 1.8 x a

58.37330333 < 145.8 Mpa(CALCULATED) (ALLOWABLE)

FOUNDATION BOLTS

MAXIMUM FORCE ON EACH BOLT P = (4M/nD1)-(Ws/n)

WHERE M = B.M AT THE BASE OF CHIMNEY x 100000.00n = NUMBER OF BOLTSWs = WEIGHT OF THE CHIMNEY

D1 = DIA OF BOLTCIRCLE pcd=

PAGE 12 OF 14M= 25622479.54 Kg cmBM= 256.22 (x 100000 Kg cm)n= 32Ws= 32000 KGSD1= 250 cm

P= 11811.23977 KG

NET AREA OF BOLT = 14.764049712 cm2SAY 15 cm2= 19.102196753

NOW BOLT DIA D = 4.3706059938 cm

USE M50 DIA BOLTDESIGN OF BASE PLATE

COMPRESSIVE FORCE Cf = 1.27*M/D*D+(Ws+W1)/3.142 D1WHERE D= EXTERNAL DIA OF CHIMNEY BASE = 275 cm

W1 = WEIGHT OF THE CHIMNEY LINING =

Cf = 471.03 Kg / Sq.CmFf = 20

REQUIRED WIDTH OF BEARING PLATE B = Cf/Ff= 23.5513 cm

WIDTH OF BEARING PLATE PROVIDED b = 27.5 cm WIDE BEARING PALTE

THK OF BEARING PLATE t' = b/2 * sqrt (3* Ff)/Fbp((3*Ff)/Fbp) = 0.03636363636

0.19069251785t' 2.62202 cm

HENCE THICKNESS OF THE PLATE t' = 3.2 cm

NOW BOLT DIA D2 cm2