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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

Description

Prepared By

Checked By

Approved By

09.09.2008

Issued as standard specification

SNK

CR

HSC

-1-

Jacobs
HPCL, MUMBAI 44LK-5100 STANDARD SPECIFICATION FOR STEEL STACKS Page 2 of 6

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

Jacobs
HPCL, MUMBAI 44LK-5100 STANDARD SPECIFICATION FOR STEEL STACKS Page 3 of 6

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 IS 6533(Part 2) IS 6 IS 8 IS 2042 IS 1363 IS 1364 IS 875 /Site data IS 1893/site data IS 2062:1999 BS 4076:1978 : : : : : : : : : : : Design and construction of steel chimney Code of Practice Part 1 Mechanical aspects. Code of Practice for design and construction of steel chimney Part 2 Structural aspects. Specification for the refractories, Group A. moderate heat duty fire clay

Specification for high heat duty fire clay refractories, Group B. Specification for insulating bricks. Hexagonal head bolts, screws and nuts and product Grade C. Hexagonal head bolts, screws and nuts of product Grades A & B. For wind load consideration For seismic design consideration Steel for general structural purposes. Specifications for steel chimneys

B.4.4_Std spec for Steel stacks

Jacobs
HPCL, MUMBAI 44LK-5100 STANDARD SPECIFICATION FOR STEEL STACKS Page 4 of 6

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

3.0
3.1

TECHNICAL REQUIREMENTS
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: (i) (ii) Minimum height of flare be equal to one third the height of the chimney. 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. Minimum outside diameter of flared chimney at base be equal to 1.6 times the outside diameter of shell at top.

(iii)

3.2

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 3.5.1

Maximum Permissible Stresses: 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 44LK-5100 STANDARD SPECIFICATION FOR STEEL STACKS Page 5 of 6

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


3.5.2 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. II. III. IV. 3.5.3 Dead load + wind load Dead load + Earthquake load Dead load + load due to lining + imposed load on service platform + wind load or 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 44LK-5100 STANDARD SPECIFICATION FOR STEEL STACKS Page 6 of 6

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

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