MACHINE FOUNDATION

Aug 2013

ANALYSIS-ONLY PRACTICAL VIEW

A.PAVAN KUMAR
AGENDA :-

• Objective of machine foundation analysis

• Types of machine foundation
• Codes available –DIN 1024,IS 2974,VDI
Guidelines,ACI 351
• Machine foundation analysis
• Modelling options –Solid element,Shell
Element
• Softwares Available –ANSYS,SAP 2000, etc
• Real Problem -2*125MW Turbo Generator
Foundation

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DESIGN OVERVIEW
• Design Criteria:

The basic goal in

the design of a
machine
foundation is to
limit its motion to
amplitudes that
neither endanger
the satisfactory
operation of the
machine nor
disturb people
working in the
immediate vicinity.
(Gazetas 1983)
Performance Criteria

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Possible options of foundations

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Possible options of foundations

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STRUCTURAL DRAWING OF TG
BUILDING

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Schematic diagram of machine
foundation system

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MODELLING OPTIONS FOR
FOUNDATION-SOLID
SHELL,PLATE

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MODELLING OPTIONS FOR
SOIL-SPRINGS,CONTINUM

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ISOLATION PRINCIPLE and
TRANSMISSIBILTY

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REAL PROBLEM-TABLE TOP
FOUNDATION-TG FOUNDATION-
NAGAI PROJECT

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SCOPE
The objective is to study the dynamic behavior of Turbine Generator
(TG) pedestal under normal operating conditions and also emergency
conditions for 2X150 MW Nagai Thermal Power Plant located at
Nagapattinam (Dist), Near Okku & Venkidanathangal Villages,
Tamilnadu State, India.

The following checks with relevant structural analysis have been carried
out to accomplish the above object.
Natural Frequency check – Modal analysis is carried out in ANSYS
software to elicit the natural frequencies of machine-foundation system
for all significant modes of vibration. The natural frequencies are
checked with relevant provisions of DIN 4024 Part1.
Vibration amplitude check – The absolute maximum amplitudes are
obtained by performing steady state harmonic analysis of STG
foundation in ANSYS and checked according to VDI-guideline 2056,
Machine group ‘T’

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 DOCUMENTS WE RECEIVE,CODES NEED
TO REFERRED Project Reference Drawings / Documents
1
Design Basis Report for Civil, Structural and Architectural Works

Machine Manufacturer’s Drawings

2
2165-T-1-VVG-C-501 Turbine Foundation Loads

3
2165-T-1-VVG-C-502 Turbogenerator Acoustic Enclosure Foundation Loads

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2165-T-1-UMP-C-501 Turbogenerator Foundation Drawing Plan View & Sections

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2165-T-1-VVB-M-501 Turbogenerator General Outline Plan View & Sections

CODES FOR DESIGN OF BASE RAFT

Machine Foundations - Flexible structures which supports

DIN 4024 (Part1)
machines with rotating elements

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DIN ISO 1940-1 Balance Quality Requirements for Rotors in a constant (rigid) State

Design and Construction of Machine Foundations – Foundations For Rotary Type Machines (Medium and
IS 2974 (Part 3)
High Frequency)

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MATERIAL DETAILS
Material Property Value Units Remarks

Density 25 kN/ cum

Characteristic
40 N/ Sq mm IS-456 (2000)
Strength
Concrete, C40

Modulus of Elasticity 32500 (Dynamic) N/ sq mm IS-2974 (Part 3)

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LOADS WE RECEIVE FROM
MECHANICAL PEOPLE

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DESCRIPTION AND MODELING OF STRUCTURE
The geometry is considered as per foundation outline drawing. The
columns are assumed to be fixed on top of base raft at FL (–)4.05m. The
top deck level is considered as FL (+) 12.0m & FL(+) 11.2m for Turbine &
Generator respectively. It can be seen from the geometry that the TG
pedestal is built-up of large sections. Hence, the solid brick finite elements
are used to represent the geometry for dynamic analysis. The solid model
is built in ANSYS software based on this geometry and then the finite
element is created by mapped mesh using brick elements. The mapped
volume mesh contains only hexahedron elements.

Basic geometric dimensions are:

Top deck thickness at E.L.11.2 = 1700mm

Sizes of columns = 1600X1600, 2540X1600, 2500X1600 mm
Thickness of deck at E.L.+12.0 = 2500mm
.

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SOLID MODEL-ANSYS

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MESHED SOLID MODEL-
ANSYS

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SUPPORT CONDITIONS

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MODAL ANALYSIS – NATURAL FREQUENCIES
The Mode-Frequency analysis for natural frequency and mode
shape determination is carried out in ANSYS. The assumptions
made in this analysis are
•The structure has no time varying forces, displacements,
pressures, or temperatures applied, which means that this is
free vibration analysis.
•There is no damping in the structural system.
•The structure has constant stiffness and mass effects.
3D MASS 21 element (from ANSYS element library) is used to
represent machine mass application points on top of deck.
The natural frequencies are obtained for first seventy five
modes of vibration.

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1. First order natural frequency, f1  1.25*fm or
f1  0.8*fm , fm = Machine operating
frequency, 50 Hz
 
f1 = 2.8586 Hz  0.8*50 = 40 Hz Hence condition 1 is o.k.
 
2) Higher order natural frequencies
 
Higher order natural frequencies that approach the service frequency:
 
fn  0.9*fm and
 
fn+1  1.1*fm
 
This condition is not met
 
If condition 2a) is not met, it shall suffice that fn is less than fm where n
is equal to 10 or 6.
 
f10 = 27.3487  50 Hz
 
Hence clause 2b) is satisfied.
 
From the above frequency table, it can be seen that the fundamental
structural frequencies are within 30 Hz where the predominant portion
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of applied mass is participated..
TUNING OF MASS AND
STIFFNESS

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FREQUENCY SEPARATION
CRITERIA
Estimation according to IS 2974 Part 3:
From the above Table it is clear that the Frequecy saparation in any mode is atleast
20% which meets the criterion specified in IS 2974 Part 3.

MODE MODE NATURAL MACHIN FREQ.

FREQ. (Hz) E FREQ. SAPARATION
(Hz) (%)

X- 1 2.85863 50 94.28274
TRANS
Y- 4 17.6915 50 64.617
TRANS
Z- 2 3.58554 50 92.82892
TRANS
ROT-X 4 17.6915 50 64.617
ROT-Y 1 2.85863 50 94.28274
ROT-Z 4 17.6915 50 64.617

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MODE 1

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MODE 2

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MODE 3

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MODE 4

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HARMONIC ANALYSIS – VIBRATION AMPLITUDES

The harmonic response analysis for obtaining forced vibration amplitudes.

This analysis solves the time-dependent equations of motion for TG
foundation undergoing steady-state vibration. The assumptions made in
this analysis are

The entire structure has constant stiffness, damping, and mass effects. The
structure damping of 2% is considered in the harmonic analysis for normal
operating condition in accordance with Cl. 9.1.1 f) of IS 2974 Part-3.
All loads and displacements vary sinusoidal at the same known frequency
(50 Hz in present analysis case).

The harmonic load is specified in ANSYS with three pieces of information

the amplitude, the phase angle, and the forcing frequency range . The
amplitude is the maximum value of the load. The phase angle is a measure
of the time by which the load lags (or leads) a frame of reference. The
phase angle is required only if multiple loads are present that are out of
phase with each other.
The bearing locations are shown indicatively below.
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 BEARING UNBALANCED FORCE AT RATED LOCATION
SPEED (50 Hz)
  (Kips) (KN)

#1 8.2 36.3 TURBINE

#2 8.2 36.3 TURBINE
#3 8.2 36.6 GENERATOR
#4 8.2 36.6 GENERATOR
Unbalanced forces at bearings Bg-1 to Bg-4 are distributed on the
foundation top as per the given Drawing. The excitation forces applied in
the analysis are listed in below table.
.
The unbalanced force can be acting at all the bearings simultaneously,
with random distribution of the relative phase angles.
 
The peak vibration amplitudes are calculated by performing harmonic
response analysis by applying unbalance forces at all bearing points in
both horizontal and vertical directions. 90o phase difference is
considered between horizontal and vertical directions.
 
The unbalanced force at each bearing point is applied at two points on
top of foundation symmetrical to centerline of rotor. The lever arm effect
due to horizontal force acting at bearing point at higher elevation is
considered in form of push and pull on top of foundation on either side o
rotor. The harmonic analysis is carried out with different relative phase
angles and it is noted that the maximum displacement amplitude is
occurring for the case of same phase angle for unbalance forces applied
at all bearing points. The unbalanced forces at each bearing point are34
calculated and tabulated as below.
VIBRATION AMPLITUDES
The maximum displacement amplitudes obtained from the harmonic
analysis for 2% damping are tabulated below.The same results are
presented graphically.The vibration amplitudes are listed on top of deck
at corresponding bearing locations.

Vibration Amplitude Table for 2% Damping – Normal Operating

Condition BEARIN 2% DAMPING
G
LOCATI NODE UX UY UZ
ON (µm) (µm) (µm)

1 1750 2.2283 2.0949 0.7163

59 875 144
1793 2.1000 1.8002 0.8717
78 342 515
2 1560 1.4559 0.6442 1.5667
65 127 955
1524 2.1000 1.8002 0.8717
78 342 515
3 4459 0.4765 0.7991 0.7032
84 964 227
4468 0.9830 2.4001 0.5480
78 657 38
4 4607 1.0681 1.4327 0.7475
693 793
4760 1.2016 0.5894 1.0218
05 506 484
UX, 1750 2.2283 - -
MAX 59 35
UY, MAX 4468 - 2.4001 -
From the above table it can be seen that the vibration amplitudes in both
directions are very less and well within the manufacturer’s specified limits and
also VDI guideline. This is also obvious from the natural frequency table in Sec
3.0 that the contribution of vibration modes to amplitude response in
concentrated around lower modes only and its effect is tapered off towards
higher modes.
Rating according to VDI-guideline 2056, Machine group ‘T’ (Refer to chart in
next page)
At 50 Hz: Amplitudes < 12.5 µm ≡ Rating: “Good”
(2% Damping)
Hence, the foundation system adopted is classified as Good for normal
operating conditions.

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Vibration Amplitude in Y direction for node 4468

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DYNAMIC PROPERTIES

Dynamic Equilibrium Equation:

 M  X    C  X    K  X    F (t )
In Veletsos Model, the Dynamic Impedance
Expressed as:
I  K s   k d (a0 )  ia0 cd (a0 )

Mode Vertical Horizontal Rocking Torsion

Static Spring 4Gv Rv 8Gh Rh 8Gr Rr

3
3
Kv  Kh  Kr  16Gt Rt
Constants 31    Kt 
1  2 3
Dynamic
Impedance
K v  k v  ia 0 cv  K h  k h  ia 0 ch  K r  k r  ia 0 c r  K t  k t  ia 0 ct 
DYNAMIC PROPERTIES

• The classic single lumped mass machine-

K
foundation-soil system with circular foundation on
elastic half-space summarized by Richart, Woods,
HallMotion
(1970): Spring Constant Reference
4G R
Vertical Ky  Timoshenko & Goodier (1951)
1 
32(1   )GR
Horizontal Kx  Bycroft (1956)
7  8
8GR 3
Rocking K rz  Borowicka (1943)
31   
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Torsion K ry  G R3 Reissner & Sagoci (1944)
3

A Frequency Independent Model,

Applied for 0 < a <1.0 0

a : Dimensionless frequency.
DYNAMIC PROPERTIES
Dimensionless frequency, a0

R
a0 
Vs

Where:
ω: machine speed – equipment;
R: foundation radius – foundation;
Vs: shear wave speed – soil.
DYNAMIC PROPERTIES

Veletsos’ Model – Dynamic Stiffness and

Damping Coefficients:

b1 to b4 in expression above are dimensionless functions of μ. Given by

Veletsos for different type of soils.
 DYNAMIC PROPERTIES
• Veletsos Model, kx &
cx to Frequency
Relation in Horizontal
Mode:

• cx is independent of
a , or the frequency.
0

• kx in sandy soil is
kind of sensitive to
a , or the frequency.
0
THANQ

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