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Abstract: This paper reviews and analyzes history and present situation of turbine
generator foundation in China for last ten years. It states dynamic analysis, static
deflection analysis and model test technology. By analyzing project examples, this
paper introduces the development and application of this technology. In order to
advance China's technology of turbine-generator foundation designing, this paper
provides reference for designing of foundations of turbine generators.
Key words: Balanced quality grade, foundation of turbine-generator sets,
dynamic analysis, static deflection analysis, model test
Figure 3 Research on the layout of spring foundation combined with turbine house
2 Vibration analysis of foundation
The unbalanced force is input data for vibration analysis of foundation. Generally the
unbalanced force is determined by a constant balanced quality grade. Based on
vibration analysis of shaft system by Manufacturer recently, unbalanced forces are
resulted from bearing forces under rotor excitation. The following example briefly
describes the use of this kind of unbalanced force to calculate forced vibration.
2.1 Set and foundation
1000MW full speed machine has a high pressure turbine, an intermediate pressure
turbine, two low-pressure turbines and a generator. The bearing is supported on
transverse beam directly. The shaft system is composed by 6 rotors and 7 bearings,
which is called single shaft and single support point bearing.
1) The amplitude of vertical and horizontal unbalanced force is not the same;
2) Each bearing unbalanced force is unable to be determined by constant balanced
quality grade;
3) When the balanced quality grade is G2.5 and G6.3 for full speed machine, the
unbalanced force is 0.08 and 0.2 of weight of the rotor. The Table 2 shows that:
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during the shafting vibration analysis, the vertical unbalanced force in turbine
module is greater than G2.5 and less than G6.3. The horizontal unbalanced force
of bearing Brg_1 in turbine module is greater than G6.3.
(2) Under the unbalanced force of the shafting vibration analysis and constant
balance quality grade analysis, the differences between maximum vibration
amplitude analysis methods are summarized as follows.
Table 3 Analysis methods of maximum vibration amplitude of T-G foundation
Unbalanced force number The maximum
Num. Analysis load case number
of each load case value method
Determined by the total number of rotor and Take the
1 All bearings
vibration analysis of shafting system maximum
2 The total number of rotor is multiplied by 2 Single bearing SRSS
All unbalanced forces in the same or alternating
Take the
3 direction and vertical or horizontal direction, All bearings
maximum
A total of 4 load cases.
Note:
Num. 1:Unbalanced force of shaft vibration analysis;
Num. 2 and 3:Unbalanced force of constant balanced grade;
(3) The shafting vibration analysis of unbalanced force marks the progress of
technology. When manufacturers provide unbalanced force of shafting vibration
analysis, the forced vibration should be analyzed based on the unbalanced forces
provided by the manufacturer.
3 Static Deflection analysis of turbine-generator foundation
Along with the unit capacity becoming larger and the continuous updating of the
machine, T-G foundation static deflection analysis is attracting more and more
attention from foundation designers. With the updating of the new machines by every
manufacturer, strict rules have been made for the deflection limits of the foundation
shafting. Various methods for stipulating deflection limits and their advantages and
disadvantages are briefly reviewed as fol1ows.
3.1 Radius of Curvature Criteria
The radius of curvature is defined as the circle determined by any three points that lie
in one plane. This criterion generally requires that radius of curvature need to be
checked at each set of three adjacent transverse girders along both the vertical and
transverse directions. The acceptable limits of vertical and transverse radius that
describe the shaft curvature caused by static load in operating﹙hereinafter referred
to as the ‘operating loads’) subsequent to initial alignment vary from one machine to
another. One criterion is greater than 40km for a single bearing and 3000-r/min
machine. After calculating, the criterion is met for spring foundation of a 3000-r/min
and 1000mw machine.
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Figure 8 Procedure to calculate the Center point coordinates and the Radius
3.2Δα' Criteria
Δα' criteria consider the whole shaft-line project onto horizontal plane of the
foundation table , with all rotors represented by segments of line. Owing to
foundation deflection under operating loads, angles are generated at each coupling
between the various successive segments representative of the rotors. The limit of Δα'
is less than 5×10-5. After calculating, the criterion is met for spring foundation of a
1500-r/min and 1000mw machine.
According to Figure10,the radius of curvature and Δα' all are based upon the circle
determined by any three points. The formula (1) is expressed as relation between the
radius of curvature and Δα'. Suppose the distance between the first and third point is
10 (m),the radius of curvature R is 40 (km) and Δα' is 12.5×10-5, which exceeds the
5×10-5 of limit value. Indicating:Δα' criteria are stricter than the radius of curvature
criteria. When the distance between the three points is equal, arch height H = 0.313
(mm) which is the displacement difference of the adjacent bearings is more than 0.25
(mm).
A = 2Rsin 2 (1)
3.3 Differential radial displacement between adjacent bearings
Under operating loads, one new datum line is established respectively by drawing a
line connecting the rotor support points. The new datum lines can be sloped lines
which are established based on the condition that the distance between the line and
each point W1, W2, … is minimal (best line). In the under mentioned sketch, the
label ‘Datum Operating Load’ is used to identify these new datum lines. The
deflection of any rotor support points from the new datum line for operating loads
must not exceed ΔR/2=0.125mm. The differential displacement between adjacent
bearings must not exceed ΔR=0.25mm. After static deflection calculation for two
spring foundations of 900mw and 3000-r/min Siemens machine in operating, the
deflection of any rotor support point from the new datum line and the differential
displacement between adjacent bearings all exceed the limit. Compared with two
above-mentioned criteria of three point pattern, the criteria are difficult to meet. This
criteria is based upon the best line pattern of each bearing of the shaft system. When
this criteria is used to analyze the static deflection, it can be determined by consulting
with the manufacturer based on the comparison of the results between the new
foundation and the reference foundation.
Based on the static analysis of shaft system by Manufacturer, matrix [ΔR/R ]0.1mm is
obtained from a successive, arbitrary lowering 0.1mm of each journal bearing.
Based on the static analysis of foundation by foundation designer, matrix [δ] is
obtained from bearing displacement under normal operating loads.
Under operating loads, the loads on the rotor bearings in the rotor system are
calculated by formula follows.
The limit of ΔR/R vary from one machine to another. One limit is less than 10% and
20% in vertical and horizontal respectively for 1000mw and a 1500-r/min machine.
4 Model test
For new kind and the first design of T-G foundation, model test is an effective
method to verify and evaluating the foundation design and analysis of reasonable and
reliable, and is advanced technology that is different from the numerical analysis of
the dynamic characteristics and vibration response of the T-G foundation.
The first vibration and seismic model test of spring foundation has been done based
on T-G foundation of the 1000MW and half speed ALSTOM machine, date in 2009.
Test according to the proportion of 1:10 established the spring foundation of real
model, including the spring vibration isolation system simulation, seismic action
considering the deck and the equipment of gravity on the column pressure. The
substructure design under spring conclusion is according to the general structure
seismic requirements, can be used as the engineering design and technical support.
5 Conclusions
Promoting technological development depend on productivity, T-G foundation
design engineers are to make unremitting efforts to explore and master the technique
of T-G foundation, expecting to make greater contributions to the T-G foundation
design for large capacity and new type of machine.
Reference
[1] “Design of Large Steam Turbine-Generator Foundation.” Task Committee on
Turbine Foundations of the Fossil Power Committee and the Nuclear Energy
Division of ASCE(1987)