ANALYSIS AND DESIGN OF FRAMED FOUNDATIONS

FOR TURBO GENERATOR – IN TRIPPLEARM INDIA

PRIVATE LIMITED (TIPL)

AN INTERNSHIP REPORT
  
Submitted By

DHANUKSHA K P
2019102010

In partial fulfilment for the award of the degree of

BACHELOR OF ENGINEEERING
In
CIVIL ENGINEERING

DEPARTMENT OF CIVIL ENGINEERING

COLLEGE OF ENGINEERING, GUINDY
ANNA UNIVERSITY, CHENNAI 600 025.

NOVEMBER 2022
 ACKNOWLEDGEMENT

The satisfaction that accompanies the successful completion of any task

would be incomplete without mentioning of the people who made it
possible.

I would like to express my sincere thanks to DR.K.P.JAYA, Professor

and head of the department, Department of Civil Engineering, for her
encouragement during the course of work.

Also, I’m very thankful to Dr.K.SOUNDARANAYAKI, Assistant

professor, Centre for Environmental Studies for her guidance for the
completion of the task.

I would like to express my sincere thanks to Mr. Y.VAIDEGI, Director

of TRIPPLEARM INDIA PRIVATE LIMITED, for hiring me as an
intern in her company.

I wish to extend my gratitude to her for guiding me throughout the one

month of training period, teaching me the design principles and for
providing me an excellent opportunity of learning.
 TABLE OF CONTENTS

CHAPTER                                        TITLE                                    PAGE NO

LIST OF FIGURES

                                                LIST OF TABLES

            LIST OF FLOWCHARTS
INTRODUCTION:

HIGH SPEED MACHINES such as turbo-generators are generally

mounted on framed – type foundations. The turbo – generator
foundation is a vital and expensive part in a power plant complex. It is
therefore, essential that the foundation is designed adequately for all
possible combinations of static and dynamic loads. While the
mechanical engineers usually furnish the layout diagram – showing the
broad outlines of the foundation and clearances required for piping,
linkages, etc.., and also the loading diagram—it is the task of the
structural engineer to check the adequacy of the foundation under static
and dynamic conditions. At times, it may be the machine manufacturers
so as to satisfy the design requirements such that they could alter the
dimensions. It is therefore desirable to have a close combination
between the foundation designers and the erection staff (electrical and
mechanical) from the early planning stage until the foundation is
completed and the machine is installed.

In the early stages of development, turbo generators were mounted on

the so-called “wall type foundation” consisting of a pair of walls on
which were seated the turbine and generator. With the increase in the
size and output of the machinery, more sophisticated types of foundation
had to be devised for functional reasons. Framed foundations are now
popular for supporting high – speed machinery , on account of their
many advantages, such as    saving in space, saving in materials, easy
accessibility to all machine parts for inspection and less liability to
cracking due to settlement and temperature changes. The common
materials of construction used for these foundation are reinforced
concrete and steel. However, RCC foundations are common both in
India and abroad.

1.1 TURBO – GENERATOR:

The turbo-generator forms the heart of a power plant. It is the most vital
and expensive equipment of a power plant complex and is generally
housed inside a turbo-generator building. A turbo-generator consists of a
turbine, generator and other auxiliaries like condenser, pipelines carrying
superheated steam etc. Turbo-generator falls under high speed rotary
type machines and its capacity varies from 2 MW to 2000MW. The
turbo-generator foundation consists of turbo-generator and its auxiliaries
mounted on a table top foundation. The foundation can be either made of
steel or RCC.A RCC table top type (fig.1) foundation are commonly
adopted. The top deck, column and bottom raft together constitute the
turbo-generator foundation.
2. DESIGN CRITERIA

2.1 BASIC PRINCIPLE OF TURBO – GENERATOR DESIGN

The basic principal of TG foundation remains same compared to other

machine foundation.ie,

 No resonance should occur and hence the natural frequency of

foundation system should not coincide with the operating
frequency of the machine. The foundation is high tuned when its
fundamental frequency is greater than the operating speed or low
tuned when its fundamental frequency is lower than the operating
speed.

 The amplitudes of motion at operating frequencies should not

exceed the limiting amplitudes, which are generally specified by
machine manufacturers.

 An eccentricity of 3% of base dimension along which the centre of

gravity gets displaced may be allowed. The reason to limit
eccentricities is to minimize secondary moments that could
significantly influence the natural frequencies of the foundation.

2.2 INFORMATION NEEDED FOR DESIGN

The following data needs to be provided by machine manufacturer to the

designer for the design of TG foundation.
  Loading diagram showing magnitude and location of static and
dynamic loads exerted by machine on its foundation.

 Speed of turbine and generator

 Critical speeds of the machine Critical speed. The angular speed at

which the rotating shaft undergoes dynamic instability with
increase in lateral amplitude. This develops when the angular
speed is in resonance with natural frequency of lateral vibration of
shaft. The critical speed concept helps to identify the operational
region of rotar bearing system, probable mode shapes and
approximate location of peak amplitude.

 Mass moment of inertia of machine components

 Drawings showing the embedded parts, openings, grooves for

foundation bolts, etc.

 Piping layout, ducting etc.

 Temperature.

 Allowable amplitude.

2.3 SOIL DATA

 Soil profile and characteristics of soil up to at least thrice the width

of the turbine foundation or till hard strata are reached.
  The relative portion of the ground water table in different seasons
of the year.

2.4 POINTS TO BE CONSIDERED WHILE DESIGNING

 The total mass of the frame plus the raft shall not be less than three
times the mass of the machine

 The mass of the top deck plus mass of half the length of the
column shall not be less than the mass of the supported turbine and
its auxiliaries on the top deck.

 A minimum gap of 25 mm shall be maintained between top deck of

turbo generator foundation and floor of turbine building to avoid
transfer of vibration to the floor

 The clear distance in any direction between adjacent foundations

and turbo generator foundation shall be large enough to avoid
transmission of detrimental vibration amplitudes through the
surrounding. Foundation spacing is intended to ensure that the soil
response of adjacent foundations is independent as far as possible.

 A spacing of 2.5 times the width of the smallest foundation is

recommended, because the volumes of soil under stress from
adjacent foundations will not overlap in that case. In such cases
vibration isolation pads are to be installed on the adjacent sides of
the foundations to avoid transfer of vibration
  The stress in the soil due to turbo generator foundation depends not
only on the maximum displacement characterizing the vibration,
the settlement caused by vibration increases with pressure.
Therefore the pressure permitted must be smaller than that
permitted for static load. Hence, the stress induced in soil shall not
exceed 50% of the allowable bearing capacity of the soil.

3. CODAL PROVISIONS
 TABLE 1: DESIGN CRITERIA IN CODAL PROVISIONS

4. SPECIAL CONSIDERATIONS IN PLANNING

 The foundation should be completely separated from the main

building or other neighbouring foundations by providing a clear
gap all around. This avoids transfer of vibrations to the
surroundings.

 All the beams and columns should be provided with adequate

launches to ensure rigidity of joints and to avoid large
concentration of stresses.

 As far as possible, it is desirable to avoid overhanging cantilevered

projections. Where they are unavoidable, they should be so
designed as to ensure adequate rigidity against vibrations.

 The base slab should be rigid to prevent non – uniform settlement

of the soil. According to the prevailing standards, the effective
thickness of the slab should be at least one tenth of its length of the
minimum width of the column, whichever is more. Further, the
weight of the base slab should not be less than the total weight of
the machine plus the weight of the foundation including the base
slab. The minimum thickness of the base slab should be 2m.
  As far as possible, the transverse frames should be located directly
under the bearings and the eccentric loadings on the transverse
girders should be avoided.

 As far as possible, the foundation should be so dimensioned that

the resultant force due to weight of the machine and foundation
including the top deck, intermediate slab if any , the base slab and
the column passes through the centre of gravity of the base area in
contact with the soil.

5. PRINCIPLE DESIGN CRITERIA

 From a point of view of vibration, the natural frequencies of the

foundation system should be far away from the operating machine
as well as the critical speeds of the rotor. A clear separating
margins of at least 20 % should be ensured in the design.

 The amplitudes of the vibration should be within the permissible

limits. The permissible limits specified at the bearing level of the
machine are started as under :

 For machines with operating speeds of 3000 rpm or more :

 Vertical vibrations            0.02 mm

 Horizontal vibrations      0.04 mm

 For machines with operating speed less than 3000 rpm :

 Vertical vibrations            0.04 mm

  Horizontal vibrations        0.07 mm

 The static calculation should be carried out separately for each

loading case. The bending moments obtained for each loading case
should be considered for design. The effect of vertical and
horizontal dynamic forces should not be added since they do not
occur simultaneously.

 The soil stress below the base slab of the foundation should not
exceed the allowable bearing pressure on the soil. For computation
of the total load on the soil, only half the vertical dynamic force
need be considered.

 The torsional moments in frame girders caused by eccentric

loading of the machine should be accounted for in structural
design.

6. ANALYSIS OF FRAMED FOUNDATION FOR         TURBO-

GENERATORS

For design of turbo-generator foundation both static and dynamic

analysis are carried out.

6.1 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.

6.1.1 Free Vibration analysis

A free system vibrates under forces inherent 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.

6.1.1.1 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.

6.1.1.2 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.

6.1.1.3 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.

6.1.1 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. The flowchart for dynamic
analysis is shown.

6.2 STATIC ANALYSIS

Static loads are principally a function of the weights of the machine and
all its auxiliary equipment. The static analysis of foundation, i.e.,
analysis of forces, moments and displacement of the foundation system
shall be based on load combination that will be discussed below

 DL+OL+NUL+TLF

 DL+OL+NUL+TLF+SCF

 DL+OL+TLF+LBL/BFL
  DL+OL+NUL+TLF+SL

Design of individual component of the foundation shall be designed as

per IS456:2000.

7. PRIMARY LOAD AND LOAD COMBINATION FOR STATIC

ANALYSIS

7.1 Primary loads

7.1.1 Dead load (DL):

Dead load includes self-weight of the foundation and dead weight of

machine and its auxiliaries. The weight of machine component are
supplied by machine manufacturer.

7.1.2 Operation load (OL):

The operation loads supplied by machine manufacturer includes friction

forces, torque loads, thermal elongation, vacuum in condenser, piping
forces etc

a) Torque loads :

Forces due to steam in turbine section impose a torque on the

stationary turbine casing in the direction opposite to the direction
of rotation of rotar. The turbine manufacturer provides this data.
b) Vacuum in condenser:

In a thermal power plant the mode of cooling the steam in the

turbine is done either by air cooled condenser or water cooled
condenser. Water cooled contender are mounted on the base raft.
Whereas the air cooled condenser also called ACC is a separate
unit outside the T.G building to which the steam is taken through a
separate pipe. In case of turbine mounted on TG raft, load due to
vacuum in condenser needs to be considered. The pressure on the
turbine casing is atmospheric and the pressure in the condenser is
below atmospheric pressure. The differential pressure between the
turbine casing and the condenser results in a suction or a vacuum
load transferred to the deck slab through turbine base plates. The
magnitude of the vacuum load is significantly large and may be
several times the weight of condenser.

c) Frictional load :
 The heat emitted by pipes carrying superheated steam, circulation
of steam through turbine casing itself give rise to temperature
gradients between foundation components causing additional stress
on them. Heat build-up in turbine casing and bed plates induces
thermal loading on the foundation. The expansion of casing and
base plate of the machine relative to the concrete deck results in
frictional loads on the slab.

7.1.3 Normal machine unbalance force (NUL):

Imbalance in rotating machinery is the common source of harmonic

excitation. The cause of this defect may be due to material imperfection,
tolerances etc of the rotar leading to centrifugal force in the system and
the vibration force is imparted to the bearings as a result of centrifugal
forces. Due to unsatisfactory balancing of rotating parts in practice the
mass centroid of rotating part does not coincide with center of
rotation(refer figure 4).In the course of operation the initial defective
balancing may be increased at an alarming rate in consequence of the
loosening, corrosion or breakage of the turbine blades. With generators
the warming up of the rotar, a displacement of the coils or variation in
the material of the rotar my upset the balance. Also the defects of the
lubrication system, deficiency of the packing and uneven warming up
rotating parts may cause expansion resulting in vibrations which do not
follow simple harmonic motion. But undergo complicated changes just
like the centrifugal forces produced by them. This fact is however
neglected and all mechanical forces are considered as centrifugal ones.
For the computation of dynamic effect the data of weight of rotating
parts & their point of application is necessary.
7.1.4 Temperature loads in foundation (TLF):

 Uniform temperature

 Temperature gradient across members.

Load due to temperature changes are generally taken into account by

assuming differential temperature between upper and lower slabs and
between inner and outer faces of the deck slab. The deck slab is
considered as horizontal frame and induced moment due to differential
temperature are accounted for. In absence of any rigorous calculation the
moment due to variation in temperature and shrinkage may be calculated
by considering the modulus of elasticity reduced to half and moment of
inertia of cracked reinforced concrete to about half to one third of full
section
 5)

7.1.5 Short circuit forces (SCF):

Short circuit induces a severe loading condition on the turbo-generator

foundation. A fault of this type occurs when any two of three generator
phase terminal are shorted. The short moment affects the foundation via
the generator casing in the form of opposite pairs of vertical forces, the
moment vector being parallel to shaft axis. The value of short circuit
forces is supplied by manufacturer

7.1.6 Loss of blade unbalance (LBL)/Bearing failure load (BFL):

 LBL

During operation it may happen that one or more blade of the turbine
rotar may break. This may increase the unbalance force on the TG
foundation. Since the turbo generator is tripped in such a condition and
this force occurs for a short time it is sufficient to check the TG
foundation from strength criteria. The machine manufacturer provides
this data.

 BFL

Bending of rotar induces larger unbalance force due to increase in

eccentricity. This may be due to differential temperatures, rotar fixed too
tightly at both end bearings and improper operation of machine

7.1.7 Seismic loads (SL):

Turbo generator foundations located in zone of high seismicity are

analysed for seismic loads. Seismic analysis shall be carried out as per
IS 1893(part 4)-2005 which classifies turbo generator foundation in
category 2 with importance factor 1.75.

7.1.8 Wind Load (WL):

This is usually not considered in the analysis of turbo generator

foundations for in most of the cases the TG foundation is placed inside a
turbine building where a wind load is transferred to the ground through
the structure itself.

7.2 Load Combinations:

IS 2974 gives the following load combination to be considered for

design
  DL+OL+NUL+TLF

 DL+OL+NUL+TLF+SCF

 DL+OL+TLF+LBL/BFL

 DL+OL+NUL+TLF+SL

8. STRUCTURAL DESIGN:

8.1 STATIC ANALYSIS OF LOADS:

    Having calculated the equivalent static loads occurring during the

operation of the machine, (dynamic case), then the structural design
would be at the static case. The design consists of calculating the
bending moments, shears, etc.., in the frame members considering the
worst combination of the various loading cases to be considered as
shown in the previous heading.

8.2 DESIGN OF CROSS FRAMES:

The bending moments, shears, etc.., in the frame members are

evaluated separately for each of the loading cases. The worst
combination of the effects of various loading cases is considered for the
design. The bending moments and the shear in the cross –frames may be
evaluated by the use of expressions given by Kleinlogel.
Where haunches are provided at the beam-column joint, the effective
spans (l) and height (h) are calculated from,

    Fig 7: a typical cross frame a) with haunches b) without haunches

Where X and Z are marked in the figure and α is a factor to be

determined from the figure 8. It may be found that the sections of the
foundation members as given in the drawings supplied by the
manufacturers are too massive for the induced moments and shears in
these members. According to the standard codes on the subject, at least
50 kg of steel per m3 of concrete section should be provided in all
foundation members.
Fig 9: graph for determination of coefficient α for haunched frames.

8.3 DESIGN OF LONGITUDINAL FRAMES

      The analysis for the longitudinal frame is carried out by any of the
well-known methods for the various loading cases given below and the
reinforcement is provided accordingly.
 Static loads including the self-weight of longitudinal girders and
machine loads.
 Short circuit force as distributed load on generator support.
 Vacuum effect of condenser. If the condenser connection with the
turbine is rigid, this need not be considered.
 Construction loads considered as distributed loads on platforms
projecting from longitudinal girders. This may be generally taken
as 2000 kg/m2
 Vertical dynamic forces (if any) acting on the longitudinal girder.
 Half of the horizontal dynamic force which is considered to act
along the axis of longitudinal girders.
  Differential temperature of 20οC between the upper and the lower
foundation slabs.
 Shrinkage corresponding to a temperature fall of 10οC.
 Earthquake forces (only horizontal forces need be considered)
For considering the worst combination of the moments due to various
loads, the following points should be borne in mind.
 The construction or dead loads should not be considered to act
with the dynamic loads. The former only occur when the machine
is being assembled at rest.
 Vertical and horizontal dynamic loads should not be considered
simultaneously.
 Since the effects of temperature and shrinkage are mutually
opposite, they may not be considered together for evaluating.
 The effects of earthquake and the dynamic force from the
machinery may be considered together.
8.4 DESIGN OF FOUNDATION SLAB
 The basic area of foundation slab should be such that the
maximum bearing pressure on soil is not more than the
permissible bearing pressure.
 Having found the soil pressures and the load transmitted by
each column, the structural design for the foundation slab is
done as an ordinary raft
A practical design of an under-turned framed foundation for a 200
MW turbo-generator machine is done in TRIPPLEARM INDIA
PRIVATE LIMITED (TIPL)
9. DESIGN OF AN UNDER-TURNED FRAMED FOUNDATION
FOR A 200 MW TURBO-GENERATOR MACHINE:

11. REFERENCES
 Barkan, D.D. (1962). “Dynamics of Bases and Foundations”,
McGraw-Hill Book Company, New York, U.S.A
 .Major, A. (1980). “Dynamics in Civil Engineering-Analysis and
Design, Vols. I–IV”, Akadémiai Kiadó, Budapest, Hungary.
 Prakash, S. and Puri, V.K. (1988). “Foundations for Machines:
Analysis and Design”, John Wiley & Sons, New York, U.S.A.
 Arya, S. C., O’Neill, M. W., and Pincus, G., Design of Structures
and Foundations for Vibrating Machines, Gulf Publishing,
Houston, TX
 Jagmohan L. Humar. (1989), Dynamics of Structures: Second
Edition, Prentice Hall College Div
 Chowdhury Indrajit &Dasgupta P, Dynamics of structure and
foundation (2009) - CRC Press/Balkema
 BIS (1992). “IS 2974 (Part 3): 1992—Indian Standard Design and
Construction of Machine Foundations—Code of Practice, Part 3:
Foundations for Rotary Type Machines (Medium and High
Frequency) (Second Revision)”, Bureau of Indian Standards, New
Delhi
 DIN: 4024 (Part - 1), 1988: Machine foundations – Flexible
structures that support machines with rotating elements
 ACI 351.3R (04): Foundations for Dynamic Equipment
 ISO: 10816-2:2001(E): Mechanical vibrations – Evaluation of
machine vibration by measurements on non-rotating parts – Part 2:
Land-based steam turbines and generators in excess of 50MW with
normal operating speeds of 1500 r/min, 1800r/min, 3000 r/min and
3600 r/min.
 ISO: 1940-1:2003(E): Mechanical vibration – Balance quality
requirements for rotors in constant (rigid) state – Part 1:
Specification and verification of balance tolerances