Dynamic Analysis of Turbo Generator foundation on Olivine treated alluvial soil

J.Dhurai Rajiv Gandhi1 , E.Prasath1, G.Raja1, R.Gobinath2

1-PG student, Department of Soil Mechanics and Foundation Engineering, Karur College of
Engineering, Karur, Tamil Nadu.

2- Assistant Professor, Department of Civil Engineering, SR Engineering College, Warangal,

Telangana.

Email Id: dhurairajivgandhibe@gmail.com

Abstract:

Turbo-generators are power generation machinery used in the power plants. The
analysis and design of machine foundation requires more consideration since it includes the
static loads as well as the dynamic loads brought on by the working of machine. The
constraining sufficiency and working recurrence of a machine are the most critical parameters
to be considered in analysis of machine foundation. If the operating frequency of the machine
matches the frequency of the foundation, the foundation becomes unstable and completely
fails due to resonance. Considering the difficult natural parameters, enormity of the machines
and risk involved in terms of public outcry, analysis and designs of turbo-generator
foundations still remain one of the most difficult and challenging task in civil engineering
profession.

The presence of water in soil will affects the strength and other characteristics of soil.
Soil is a medium with widely distributed size of particles. The major disadvantage of soil
water contact is the pore water pressure. Major failure causes in soil is mainly due to excess
pore pressure in soil. Alluvial soil contains more amount of water than other soil. Density of
Alluvial soil has an importance in the strength of the soil. The distribution of soil particles
has also an influence in the soil strength. The shear strength and index properties of the
Alluvial soil are stabilized by using olivine sand. The objective of the dynamic analysis is to
check for resonance conditions and to ensure that the amplitude of vibrations is restricted
within the acceptable limits set by the machine manufacturer or code of practice. The
objective of the study is to analyse a Turbo- Generator machine foundation on olivine treated
alluvial soil by modelling the foundation using software PLAXIS and carrying out its
dynamic and static analysis.

Key words: Shear strength, PLAXIS, Static analysis and Dynamic analysis, IS 2974 part –III
(1992).

1. INTRODUCTION

Turbine generator machines form the heart of any power plant. The main source of this
energy is obviously electricity and this is what the turbine generators machines generate. The
turbine generator machine is one of the most important and complicated system in design,
manufacturing and testing. The turbine generator machine has a huge weight usually ranging
from 6000 kN to 17000 kN, which is imposed on a large massive concrete foundation
pedestal. The structural engineer plays an important role in the analysis and design of such
foundations and structures subjected to dynamic loads especially for the turbine foundation.
The analysis is considered a very complex problem because of the interaction of the structure,
the subsurface olivine treated alluvial soil, and the vibrating machine.

Fig.1 The typical layout of turbo generator mat

The Design of machine foundation is more complex than that of foundations which
underpins just static loads. In machine foundation, the originator must consider,
notwithstanding the static loads, the dynamic strengths brought on by working of the
machine. These dynamic powers are, thusly, transmitted to the foundation supporting the
machine. That the learning in this field has logged behind different branches of innovation is
incompletely because of the way that the obligation regarding satisfactory execution of a
machine is separated between the machine designer, who is normally a mechanical specialist,
and the foundation designer, whose assignment is to outline a reasonable foundation reliable
with the mechanical necessities and fulfilling the required resilience’s. It is, in this way,
attractive that the mechanical and structural specialists work in close coordination from the
arranging stage until the apparatus is introduced on the foundation. Until recently, the
practice in outline workplaces for the plan of machine foundation has been altogether in view
of experimental tenets, since next to no was thought about the conduct of foundation
subjected to dynamic loads. Which improvements in the fields of soil and auxiliary
progression, the outline rule were step by step set up without reliance on insignificant exact
techniques. The protest of this manual is to show these outline criteria in such a way, to the
point that the originator may discover them helpful for application to down to earth issues. .
The analysis and design of these foundations and structures became less complex after the
introduction of the finite element method and PLAXIS design software’s.

Turbo-Generator is a power generator apparatus, generating power put in power

plants. Turbo-generator foundation is an exceptionally complex building auxiliary part.
Diverse sorts of turbo- generator foundation are utilized for various machines relying upon
machines limit, geometrical sizes and constructional highlights. Dynamic conduct of the
foundation assumes a critical part in giving ordinary working conditions to the bolstered
turbo-generator. The foundation not exclusively ought to have an adequate bearing ability to
bolster the turbo-generator machine and its assistant gear, additionally be intended to
constrain the vibration amplitudes of the blades, the rotors and the course inside the worthy
level. RC turbo-generator floor involves best deck, supporting structure and a separated
foundation framework. All the gear of force plant including turbine, generator, and other
mechanical-electrical instruments are situated on top of the deck.

2. OBJECTIVES

The dynamic behaviour of the supporting structure along with the foundation, play an
important role in providing normal operating conditions for the supported turbo-generator.
The main source of dynamic forces in the turbo-generator is mass eccentricity, when the mass
center of rotating parts does not coincide with the center of rotation. Unbalanced masses of
the rotor produce centrifugal forces that lead to vibrations of the turbo-generator foundation.

The analysis of the turbine foundation is normally done in the following steps.

 Dynamic analysis to calculate the natural frequencies of the system to ensure that it is
out of tune to the operating frequency of the machine by ±20%.

 Calculation of the dynamic amplitude to check that the same are within the acceptable
limits as prescribed in the code or as pre-defined by the equipment supplier.

 Earthquake analysis if the same is perceived critical for the foundation.

 A pseudo–static analysis to obtain the design moment, shear and torsion induced in
the members and to check the stresses induced in the different structural elements like
beams, columns and slabs.

The objective of this study is to determine the dynamic response of the turbine foundation
where the effect of different parameters on the calculated response is evaluated. The paper
focuses on the first two steps of the analysis and accordingly details the various aspects
involved in the development of a realistic finite element model required for dynamic analysis.
The response of the foundation is then obtained through free vibration analysis (Eigen
analysis) and harmonic forced vibration analysis.
3. METHODOLOGY

In this paper following methodology will be followed:

a) Collect Input data for data analysis.

b) Apply loads and load combination calculations
c) Preliminary the sizing of foundation
d) Structural analysis
e) Prepare TG mat foundation on PLAXIS as per IS 2974 part 3 clause 9.1.1.

4. INPUT DATA

4.1 MACHINE DATA

The following data shall be made available to the designer by the machine
manufacturer

a) Loading diagram of the machine showing the location, magnitude and direction of
all loads including dynamic loads;
b) Speed of the machine;
c) Critical speeds of the machine;
d) Outline dimensions of the foundation;
e) Mass moment of inertia of the machine components;
f) Details of inserts and embedments;
g) Layout of piping, ducting, etc, and their supporting details;
h) Temperatures in various zones during operation; and
i) Allowable displacements at the machine bearing points during normal operation.

4.2 GEOTECHNICAL DATA

Investigation of the site where the foundation is to be located shall be done to evaluate
the following parameters:
a) Allowable bearing pressure/pile capacities.
b) In-site dynamic soil properties as per IS 5249 : 1992.

5 LOADING ON THE FOUNDATION

The following loads shall be considered for the foundation design:

a) Dead loads which include the self weight of the foundation and dead weight of the
machine;
b) Operation loads supplied by the machine manufacturer which include friction
forces, power torque, thermal elongation forces, vacuum in the condenser, piping
forces, etc;
 c) Unbalance forces during normal operation;
d) Temperature forces caused by uniform temperature change and gradient
temperature;
e) Short circuit breaker;
f)Loss of blade unbalance forces/bearing failure load;
g) Seismic forces; and
h) Erection loads.

6 SIZING OF THE FOUNDATION

The preliminary sizing of the various elements of the Turbo Generator foundation are to
be done to arrive at a foundation configuration which will need least changes after detailed
analysis and design. It is convenient and preferable to provide the same soffit level for all the
girders from the point of view of design and detailing.

The geometric layout of the foundation, the shape of the girder cross sections and
columns shall be arranged, as fast as possible, symmetrically with respect to the vertical plane
passing through the longitudinal axis of the machine.

6.1 SIZING OF THE TOP DECK

The proportioning of the deck is basically governed by the machine manufacturer’s

drawing giving the sole plate locations and opening details for the various parts of the
machine. While fixing the depth of the girders the following guidelines may generally be
used:

Girders Supporting the Turbine:

Clear span-to-depth ratio = ranging from 2 to 3
Depth to width ratio = ranging from 1 to 3

Girders Supporting the Generator:

Clear span-to-depth ratio = ranging from 2.5 to 3.5
Depth to width ratio = ranging from 1 to 1.5

6.2 SIZING OF COLUMNS

The following guidelines may be followed for column sizing:

a) As far as possible pairs of columns should be provided under each transverse girder;
b) Compressive stresses and elastic shortening should be kept uniform in all the columns
as far as possible; and
c) The first two natural frequencies of column with its top and bottom ends fixed shall be
away from the operating frequency of the turbo-generator by at least 20 percent.
6.3 SIZING OF BASE MAT

The base, mat shall be sufficiently rigid to preserve the shaft alignment. Following are
some guidelines for the base mat sizing:

a) The mass of the machine plus top deck,

b) The ratio of the bending stiffness of the base raft and largest columns in the transverse
direction should be at least two, and
c) The thickness of the base raft should not be less than 0’07 L4’j in which L is the
average of the two adjacent clear spans. This is applicable to rafts supported directly on
soil. This shall not be used for piled foundations.

As far as possible, the foundation shall be so dimensioned that the resultant force due to
the weight of the machine, the deck, intermediate slabs (if any)and the base mat together with
the weight of the columns passes through the centre of gravity of the base area in contact with
the base mat. In cases, where small eccentricities are unavoidable, an eccentricity of up to 3
percent of the base dimension along which the centre of gravity gets displaced may be
allowed.

7 METHODS OF ANALYSIS

For design of turbo generator foundation both static and dynamic analysis are carried
out.

1) STATIC ANALYSIS

Static loads are principally a function of the weights of the machine and all its
auxiliary equipment. The static analysis of foundation, ie, analysis of forces, moments and
displacement of the foundation system shall be based on load combination as discussed
above.
a) DL+OL+NUL+TLF
b) DL+OL+NUL+TLF+SCF
c) DL+OL+TLF+LBL/BFL
d)DL+OL+NUL+TLF+SL
Design of individual component of the foundation shall be designed as per IS456:2000.

2) DYNAMIC ANALYSIS

Dynamic loads, which occur during the operation of the machine, result from forces
generated by unbalance. The magnitude of these dynamic loads primarily depends upon the
machine’s operating speed and the type, size, weight, and arrangement (position) of moving
parts within the casing.

Vibration system falls in two major categories: forced and free.

 a) FREE VIBRATION ANALYSIS

A free system vibrates under forces in herient to the system. The natural frequency
(Eigen value) and mode shapes (Eigen vector) of a structure are the parameters that affect
response of the structure under dynamic loading. This type of system will vibrate at one or
more of its natural frequencies. In this process no external forcing function is involved, the
natural frequency and mode shapes are direct functions of the stiffness and mass distribution
of the structure.

FREQUENCY RATIO

The frequency ratio is a term that relates the operating speed of the equipment to the
natural frequencies of the foundation. Designer requires that the frequency of the foundation
shall differ from the operating speed of the equipment by certain margins so as to prevent
resonance conditions from developing within the foundation equipment. The margin can be
expressed in terms of fn/fm ratio (natural frequency to operating frequency) which requires
that the fn/fm < 0.8 or fn/fm> 0.8 or in other words the fundamental natural frequency shall
be at least 20 percent away from the machine operating speed. However 50% frequency
separation is preferred as IS 2974 (part 3).

If there is a potential for resonance, the designer should either adjust to the foundation
size or perform more refined calculations. The size and type of equipment play an important
role in this decision process.

High-Tuned System: A high-tuned system is a machine foundation system in which

the operating frequency (range) of the machinery is below all natural frequencies of the
System.

Low-Tuned System: A low-tuned system is a machine foundation system in which the

operating frequency (range) of the machinery is above all natural frequencies of the System.

b) FORCED VIBRATION ANALYSIS.

Forced vibration is vibration caused by external force being impressed on the body.
This type of vibration takes place at frequency of the exciting force, which is an arbitrary
quantity independent of the natural frequency of the system. When frequency of the exciting
force and the natural frequency coincide, a resonance condition is reached and dangerously
large amplitudes may result.

8 VIBRATION MEASUREMENT

AMPLITUDE
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 (Gazettes 1983). Allowable amplitudes depend on the
speed, location, and criticality or function of the machine.

The amplitude serves as an important parameter in computing the vibration

measurement. The vibration limits applicable to the machine are normally set by the
equipment manufacturer. The limits are usually predicated on either limiting damage to the
equipment or ensuring proper performance of the equipment. The normal criterion limits
vibration displacements or velocities at the bearings of the rotating shaft. Excessive
vibrations of the bearings increase maintenance requirements and lead to premature failure of
the bearings.

ACI 20351.3R (04) and DIN 4024 suggests that when the equipment manufacturer
does not establish vibration limits, ISO 10816-Part 2 may be referred.

DESIGN CHARTS FOR MACHINE FOUNDATIONS

To use of the solution presented in equations of machine foundation by the empirical

method, design charts are prepared to be a guide for the designer engineer. The selected
values used in these charts were limited based on the conditions considered in Table (4) as
well as the limitations considered in the limitations of machine foundation. The design charts
are selected based on three displacements which are acceptable for design of machine
foundations (Bowles, 1988).

Parameters Basic values Range of values Units

Weight of the machine (Wmach.) 1444.905 60-620 kN

Frequency (f) 585 50-1000 rpm

Unit weight of soil(ᵧ) 18.33 18-22 kN/m3

Shear modulus (G) 96365 25000-190000 kN/m2

Poisson ratio (ᶹ) 0.35 0.3-0.45 -

Depth (Di) 0.05 0.05-0.15 -

Length of foundation(Lf) 8.39 2-20 m

Breadth of foundation (Bf) 4.80 2-20 m
Height of foundation (h) 1.52 0.6-2.2 m
Weight of foundation (Wfou.) 1443.95 (3-5)Wmach kN
SOIL PARAMETERS FOR DESIGN

Properties Result Standard adopted

Specific gravity 2.85 IS 2720 (iii):1980
Uniformity coefficient (Cu) 3.26 IS 2720 (iv):1985
Coefficient of curvature (Cc) 1.64 IS 2720 (iv):1985
Liquid limit 20.8 % IS 2720 (v):1985
Plastic limit 7.27 % IS 2720 (v):1985
Plasticity index 13.53% IS 2720 (v):1985
Soil Classification CL, Green IS 1498 : 1970
Bulk Density 1.35 g/cm3 IS 2720 (v):1985
Fineness Modulus 5.5 IS 2720 (iv):1985
Maximum Dry density 2.45 g/cm3 IS 2720(vii):1980
OMC 13% IS 2720(vii):1980
Unconfined compressive strength (UCS) 118 K Pa IS 2720 (x):1973
Triaxial compression test 18.96 K Pa IS 2720(xi):1971
Consolidation 0.001cm2/sec IS 2720 (xv):1986
Permeability test-Falling head 0.091 mm/sec IS 2720(xvii):1986
Split tensile 9.74 K Pa ASTM D3967:16