Aug 2013

MACHINE FOUNDATION
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
2

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

Possible options of foundations

Possible options of foundations

STRUCTURAL DRAWING OF TG
BUILDING

Schematic diagram of machine

foundation system

MODELLING OPTIONS FOR

FOUNDATION-SOLID
SHELL,PLATE

10

MODELLING OPTIONS FOR

SOIL-SPRINGS,CONTINUM

11

12

ISOLATION PRINCIPLE and

TRANSMISSIBILTY

13

14

REAL PROBLEM-TABLE TOP

FOUNDATION-TG FOUNDATIONNAGAI PROJECT

15

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

16

DOCUMENTS WE RECEIVE,CODES NEED

TO REFERRED Project Reference Drawings / Documents
1

Design Basis Report for Civil, Structural and Architectural Works

Machine Manufacturers Drawings

2
3
4
5

2165-T-1-VVG-C-501

Turbine Foundation Loads

2165-T-1-VVG-C-502

Turbogenerator Acoustic Enclosure Foundation Loads

2165-T-1-UMP-C-501

Turbogenerator Foundation Drawing Plan View & Sections

2165-T-1-VVB-M-501

Turbogenerator General Outline Plan View & Sections

CODES FOR DESIGN OF BASE RAFT

DIN 4024 (Part1)

Machine Foundations - Flexible structures which supports

machines with rotating elements

DIN ISO 1940-1

Balance Quality Requirements for Rotors in a constant (rigid) State

IS 2974 (Part 3)

Design and Construction of Machine Foundations Foundations For Rotary Type Machines (Medium and
High Frequency)

17

MATERIAL DETAILS
Material

Concrete, C40

Property

Value

Units

Density

25

kN/ cum

Characteristic
Strength

40

N/ Sq mm

Modulus of Elasticity

32500 (Dynamic)

Remarks

IS-456 (2000)

N/ sq mm

IS-2974 (Part 3)

18

LOADS WE RECEIVE FROM

MECHANICAL PEOPLE

19

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
.

20

SOLID MODEL-ANSYS

21

MESHED SOLID MODELANSYS

22

SUPPORT CONDITIONS

23

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.

24


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
25
of applied mass is participated..

TUNING OF MASS AND

STIFFNESS

26

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
FREQ. (Hz)

MACHIN
E FREQ.
(Hz)

FREQ.
SAPARATION
(%)

XTRANS
YTRANS
ZTRANS
ROT-X
ROT-Y
ROT-Z

2.85863

50

94.28274

17.6915

50

64.617

3.58554

50

92.82892

4
1
4

17.6915
2.85863
17.6915

50
50
50

64.617
94.28274
64.617

27

MODE 1

28

MODE 2

29

MODE 3

30

MODE 4

31

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.
32

33

BEARING

#1
#2
#3
#4

UNBALANCED FORCE AT RATED

SPEED (50 Hz)
(Kips)
(KN)
8.2
8.2
8.2
8.2

36.3
36.3
36.6
36.6

LOCATION

TURBINE
TURBINE
GENERATOR
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

BEARIN
2% DAMPING
Condition
G
LOCATI
ON

NODE

UX
(m)

UY
(m)

UZ
(m)

1750

2.2283
59
2.1000
78
1.4559
65
2.1000
78
0.4765
84
0.9830
78
1.0681

2.0949
875
1.8002
342
0.6442
127
1.8002
342
0.7991
964
2.4001
657
1.4327
693
0.5894
506
-

0.7163
144
0.8717
515
1.5667
955
0.8717
515
0.7032
227
0.5480
38
0.7475
793
1.0218
484
-

2.4001

1793
2

1560
1524

4459
4468

4607
4760

UX,
MAX
UY, MAX

1750
4468

1.2016
05
2.2283
59
-

35

From the above table it can be seen that the vibration amplitudes in both
directions are very less and well within the manufacturers 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 m Rating: Good
(2% Damping)
Hence, the foundation system adopted is classified as Good for normal
operating conditions.

36

Vibration Amplitude in Y direction for node 4468

37

38

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

Static Spring
4Gv Rv
Kv
Constants
1

Dynamic
Impedance

Horizontal

Rocking

8Gh Rh
Kh
2

8Gr Rr
Kr
31

K v k v ia 0 cv K h k h ia 0 ch

K r k r ia 0 c r

Torsion
16Gt Rt
Kt
3

K t k t ia 0 ct

DYNAMIC PROPERTIES
The classic single lumped mass machinefoundation-soil system with circular foundation on
elastic half-space summarized by Richart, Woods,
HallMotion
(1970): Spring Constant
Reference
Vertical

Horizontal
Rocking
Torsion

Ky

4G R
1

32(1 )GR
7 8
8GR 3
K rz
31
16
K ry
G R3
3
Kx

Timoshenko & Goodier (1951)

Bycroft (1956)
Borowicka (1943)
Reissner & Sagoci (1944)

A Frequency Independent Model,

Applied for 0 < a <1.0
0

a : Dimensionless frequency.

DYNAMIC PROPERTIES
Dimensionless frequency, a0

R
a0
Vs
Where:
: 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 . 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

44