Journal of Civil Engineering and Environmental Technology

Print ISSN: 2349-8404; Online ISSN: 2349-879X; Volume 1, Number 4; August, 2014 pp. 30 – 35
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Dynamic Analysis of Turbo-generator Machine

Foundations
Jayarajan P., Kouzer K.M.
M.Dasan Institute of Technology (M-DIT), Ulliyeri, Kozhikode -673620, Kerala
Civil Engineering
Govt.Engineering College
Kozhikode -673005, Kerala

Abstract : Turbo-generators are power generation machinery reach 4.0 m. Top of the deck slab is about 16-18 m above the
used in the power plants. It is the most vital and expensive base mat top.
equipment of a power plant complex and is generally placed
inside a power house. The turbo-generator foundation consists of
turbine, generator and its auxiliaries mounted on a reinforced
cement concrete (RCC) table top structure consisting of the top
deck, columns and bottom raft. Considering the difficult natural
parameters, enormity of the machines and risk involved in terms
of public outcry, analysis and design of turbo-generator
foundations still remain one of the most difficult and challenging
task in civil engineering profession. A key ingredient to the
successful foundation design for a turbo-generator is the careful
engineering analysis of the foundation response to the dynamic
loads from the anticipated operation of the machine.

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 Figure 1. Layout of a TG foundation
machine manufacturer or code of practice. This is achieved
through a free vibration analysis to accurately determine the Turbo-generators in power stations are often placed on
natural frequencies for various modes of vibration and then a foundation structures that are flexible over the running range
harmonic forced vibration analysis to determine the foundation of the machine and can therefore contribute to its dynamics.
response to loads due to machine unbalance. The paper presents Established methods of obtaining structural models for these
a detailed procedure for the finite element modelling of foundations, such as, finite element method have proved
foundation structure along with supporting soil and dynamic
successful because of the realistic approach used in the
analysis of turbo-generator foundations. To demonstrate the
analysis procedures, an example problem of a turbo-generator analysis considering all the complexities of the parameters.
foundation is also solved using SAP2000 software which provides Dynamic effects of the turbo-generators also play a major
an effective computational environment to perform all types of role on sizing of the foundation wherein conditions like
analyses. resonance is avoided by varying stiffness and mass of the
structure which leads to modifications in foundation sizes.
1. INTRODUCTION
2. OBJECTIVES
A Turbo-generator (TG) foundation consists of an RCC
top deck slab, a supporting structure of beams and columns The dynamic behaviour of the supporting structure
and a foundation system consisting rafts or piles resting on along with the foundation, play an important role in
soil (Figure 1). The top deck supports all the equipments providing normal operating conditions for the supported
including turbine, generator and other rotary equipments. turbo-generator. The main source of dynamic forces in the
turbo-generator is mass eccentricity, when the mass center of
The supporting structure transfers the loads from top deck rotating parts does not coincide with the center of rotation.
slab to the foundations. The top deck slab is normally built Unbalanced masses of the rotor produce centrifugal forces
monolithically with the supporting structure For large steam that lead to vibrations of the turbo-generator foundation.
turbine of coal-fired power station the thickness of the top
deck slab is about 3.5 m and the base mat thickness may
Jayarajan P., Kouzer K.M. 31

The analysis of the turbine foundation is normally done in  Performance criteria in terms of frequency ratio and
the following four steps. amplitude of vibration.

 Dynamic analysis to calculate the natural frequencies of  Allowable bearing capacity of the soil


the system to ensure that it is out of tune to the operating
frequency of the machine by ±20%. Dynamic shear modulus, Poisson’s ratio and mass


density of soil.
Calculation of the dynamic amplitude to check that the
same are within the acceptable limits as prescribed in the Once the above check list is satisfied, the engineer can
code or as pre-defined by the equipment supplier. proceed for the preliminary sizing of various members of the


foundation to be checked later by a detailed dynamic
Earthquake analysis if the same is perceived critical for analysis.
the foundation.


4. PRELIMINARY SIZING OF TURBINE
A pseudo–static analysis to obtain the design moment, FOUNDATION
shear and torsion induced in the members and to check
the stresses induced in the different structural elements The guidelines given below can be used to obtain
like beams, columns and slabs. preliminary sizing of turbine foundations to be used for
dynamic analysis.


The paper focuses on the first two steps of the analysis
and accordingly details the various aspects involved in the The overall dimensions of the top deck slab shall be
development of a realistic finite element model required for finalized taking into consideration the sizes of
dynamic analysis. The response of the foundation is then machines, the space requirements for its operation and
obtained through free vibration analysis (Eigen analysis) and maintenance.


harmonic forced vibration analysis.
All columns should be sized in such a way that they are
3. INPUT DATA almost equally stressed under vertical loads. As a rule of
thumb, the columns shall have load carrying capacity of
The dynamic analysis of a turbine foundation requires about six times the actual vertical load and shall be
critical machine input data from turbine & generator placed not less than 3.6 meters center to center.


manufacturer and soil properties from geotechnical specialists.
A check list required for the Turbine foundation design is The depth of the longitudinal and the transverse beam
given below. shall be one fifth the clear span with the width equal to


the width of the column.


Overall dimensions of the machine


The turbine frame should in principle act as a rigid shear
The anchor bolt locations, diameter and length of bolts frame as such the flexural stiffness of the top deck
including their anchoring details. beams shall be two times the flexural stiffness of the


columns.


The height at which the centre line of the shaft of the
The bottom of the raft shall not be placed above the
machine is located from top of concrete deck slab. level as suggested by the geotechnical consultant where

the thickness (t) of the slab shall not be less than, t =
Operating speed of the machine. 0.07L4/3, where L is the average distance between

columns.
The loads and locations of valves and pipes to supported
on deck slab.  The mass of the top deck plus mass of half the length of

the column shall not be less than the mass of the
Dynamic loads generated during the operation of the supported turbine and its auxiliaries on the top deck.
machine.


The total mass of the frame plus the raft shall not be less
Cut outs in the top deck including its size and location. than three times the mass of the machine.
 Different load combinations for which the turbine  The stress induced in soil shall not exceed 50% of the
foundation has to be designed specially from mechanical allowable bearing capacity of the soil. For foundations
considerations like short circuit moments, breaking of supported on piles the most heavily loaded pile shall not
impeller and thermal differential etc. carry 50% of its allowable load.

Journal of Civil Engineering and Environmental Technology

Print ISSN: 2349-8404; Online ISSN: 2349-879X; Volume 1, Number 4; August, 2014
 32 Dynamic Analysis of Turbo-generator Machine Foundations

 The center of rigidity of the columns shall coincide with But for modeling a turbine foundation frame there is a
the CG of the equipment plus the top half of the structural difference with normal building frames where the beams and
loads both in the transverse and longitudinal direction. columns are modeled at their centre lines. In the case of
Turbine foundations , as the columns are of large dimensions
The preliminary sizes obtained as per the above (1500-2000mm) and design bending moment in beams are
guidelines can also be used to perform the hand calculations required at the face of columns, the beam column junction
before a detailed dynamic analysis. For the detailed hand should consist of three nodes instead of one connected by
calculations [1] can be used. rigid links as shown in Figure 3. For the beam elements as
the span by depth ratio is significant it is preferable to
5. FINITE ELEMENT METHOD consider the shear deformation of the girder during the
analysis.
Finite element method is the most commonly accepted
analysis tool for the design of turbine foundations as it enables
the modelling of machine, foundation and soil in one go,
which brings behaviour of the machine-foundation system
closer to that of the prototype, resulting in improved
reliability. However, it shall be noted that the accuracy of
analysis results depends on many factors such as the
modelling techniques, element types and the model
refinement.

6. MODELLING OF TG FOUNDATIONS
A frame foundation comprises base raft, set of columns and
top deck consisting of (longitudinal and transverse) beams and
slabs. The top deck is made of RCC with required openings,
depressions, raised pedestals, and extended cantilever
projections. There are many ways of representing the model of
a frame foundation using the beam elements, shell elements,
solid elements, or a combination of all of these each with its Figure 3. Beam column junction with rigid link
associated limitations. A typical conceptual model of a turbine The mathematical model for the superstructure shall also
foundation resting on a bottom raft supported by soil is shown not be complicated with the addition of minute details such
in Figure 2.Some important considerations to be kept in mind as haunches, depressions, raised blocks etc. which increases
for the modelling of various components of TG foundations the problem size without any significant gain in the accuracy
are given below. of results. Only those elements that contribute significantly
to the stiffness and mass, like large openings, sizeable
depressions, etc., must be accounted for and modeled in
detail, whereas the elements like pockets, small notches, etc.
could easily be ignored while modelling.

6.2. The Foundation Raft

The foundation raft usually consists of a slab of about
2000/2500 mm thick resting on soil or pile. While the raft
can be modeled using plate bending elements, beam
elements supported on soil springs or even 8-noded brick
element, the engineer needs to be aware of the limitations in
each case. While the use of Kirchoff-type of plate based on
the thin plate theory neglect the contribution of transverse
shear acting along the edge of plate (dominant in the case of
thick rafts), Mindlin-type of thick plate considers shear
contribution along the edge. However such thick plate
Figure 2. 3D model – turbine frame foundation
elements suffer from many other technical problems such as
6.1. The Super structure sensitivity to geometrical meshing.
Brick elements could also be a good choice for
The obvious choice for the super structure is to model it modeling the turbine raft. From convergence point of view
as a space frame where the beams and columns are idealized brick elements are stable. However it has been observed that
as beam elements having six degrees of freedom at each node.

Journal of Civil Engineering and Environmental Technology

Print ISSN: 2349-8404; Online ISSN: 2349-879X; Volume 1, Number 4; August, 2014
Jayarajan P., Kouzer K.M. 33

the eight nodded brick element usually have poor speed. These loads are normally provided by the machine
approximation capability and higher order elements having 16 manufacturer. In case these loads are not available, they may
or 24 nodes are usually used for efficient solution. Besides this be calculated via the balance quality grade of the rotor.
brick element suffers from one serious lacunae in terms of The balance quality grade “G” is the product of the
design. Brick elements in most of the commercially available maximum permissible eccentricity “e” (mm) and the
software give output in terms of normal and shear stress maximum angular velocity of the rotor “”(rad/s) as shown
parameters whereas for the turbine raft design we are basically in Figure 4. In industry, balance quality grades are usually
looking for output in terms of moment, shear and torsion. The determined in accordance with ISO 1940-1 [6]. They are
back calculation of these design parameters from the computer separated from each other by a factor of 2.5. For turbines
output is extremely tedious. In terms of ease of use as well as and generators, the intended balance quality grade is usually
convergence of results, beam elements do make a very G=2.5 mm/s. The resultant unbalanced load F(t) (N) is
attractive choice for modelling the turbine raft. calculated with the rotating mass “m” (kg) and the balance

F(t) = m e
quality grade “G” (mm/s) as follows.
6.3. The Soil
The basic soil parameter which needs to be known to
mathematically model the soil is dynamic shear modulus (Gs).
The soil being a continuum itself can either be modelled based
on FEM as 3D brick elements, 2D plane strain elements or
discrete springs. For the particular case of turbine foundation
analysis, the common practice is to model the soil as
frequency independent linear springs based on Richart or
Wolf’s springs. In this approach, the soil is represented by a Figure 4. Scheme of unbalance loads
set of three translational springs, attached at each node at the
base of the foundation in contact with the soil. Approximate 8. DYNAMIC ANALYSIS
formulae for computation of dynamic stiffness of rigid
foundations (frequency dependent & independent) can be Dynamic analysis of turbine foundation is done after
found in [2,7]. modelling, mass lumping at appropriate locations and
In case soil is modelled as a continuum, it becomes application of dynamic loads are completed. The dynamic
necessary to confine it to a finite domain and accordingly the analysis is performed in two stages, namely free vibration
extent of soil domain to be modelled becomes an important analysis to obtain all natural frequencies and forced
issue. Though there is no definite answer to this, experience vibration analysis to obtain peak response of the foundation
shows that soil domain equal to three to five times the lateral under dynamic loads. Detailed procedure for performing
dimensions in plan on either side of the foundation and five dynamic analysis of different structural systems can be
times along the depth should work out to be reasonably good. found in [4]. The number of significant modes to be
If the soil profile indicates the presence of layered media, considered for the analysis shall be based on modal mass
appropriate soil properties are assigned to the respective soil participation factor. The number of modes that excite at least
layers. 95-99% of the mass should be considered in the analysis.
Further the highest natural frequency calculated should be at
6.4. The Machine least ten percent higher than the operating frequency of the
machine [5].
Machine is relatively rigid compared to the foundation and
soil. While modeling the machine, the broad objective is to 9. EXAMPLE
represent the machine in such a way that its mass is truly
reflected, and CG of the overall mass of the model matches A table top framed foundation shall be constructed for
with that of the prototype. Thus, modeling of the machine with the proposed turbo-generator with the following data.
rigid links or rigid-beam elements is considered good enough. Operating frequency of machine = 4500 rpm.
Machine mass is considered lumped at appropriate locations Centre line axis of shaft =1.950m above the top deck
so as to correctly simulate the CG location. This should be All columns = 1200 x 1000 mm
cross-checked with the mass distribution given by the Top of deck slab = EL 108.000 (100.000-GL)
supplier/manufacturer. [3] provides guidelines for advanced Bottom of foundation raft = EL 96.750
modelling of machine including the rotor and stator. Thickness of foundation raft = 1500 mm
Thickness of top deck slab = 1000 mm
7. DYNAMIC LOADS
Shear modulus of soil (from geotechnical report)
The main dynamic loads acting on the turbine foundation Gs = 545.5 MPa (as per client specification dynamic analysis
during its operation are caused by the unbalance of the shall also be performed for 0.75*Gs & 1.25*Gs). Various
rotating parts with a frequency corresponding to the operating

Journal of Civil Engineering and Environmental Technology

Print ISSN: 2349-8404; Online ISSN: 2349-879X; Volume 1, Number 4; August, 2014
 34 Dynamic Analysis of Turbo-generator Machine Foundations

details including the mass of rotor part for individual machines Table 1. Natural frequencies of TG foundation
along with the corresponding maximum expected unbalance
loads are obtained from vendor drawing.

9.1. Finite Element Modelling

The table-top foundation structure for turbine is analyzed
using SAP2000 (Version 14) software [8]. SHELL (thick)
elements which include the effects of transverse shear
deformation are used for modeling of base raft & deck slab.
Reinforced concrete columns & Tie Beams are modeled using
FRAME element. To consider the effect of rigidity of column
from mid-plane of raft to top-surface of raft and from soffit of
top-deck slab to mid plane of top-deck slab, element
OFFSETS are modeled. Soil is modeled using SPRING
element in horizontal X, Y direction and in vertical Z direction
at every node of the base raft bottom. The SAP2000 3D model
for the foundation structure is shown in Figure 5.

Figure 6. Foundation mode shape - first mode

To perform the forced vibration analysis, the machine
unbalance load provided by the equipment manufacturer is
Figure 5. SAP 2000-TG foundation 3D model applied on the SAP2000 model at bearing locations through
TIME HISTORY function. The displacement plot of a
The machine lumped masses are modeled at its mass typical bearing represented by joint 2001 in Y direction is
centers as provided in vendor drawing. To connect these given in Figure 7. The maximum amplitude of 75 microns is
masses to the top-deck slab joint BODY CONSTRAINT within the manufacturer specified limit of 80 microns. The
facility is used. The self weight of foundation structure is steady state response analysis available in SAP2000 can be
modeled using consistent mass approach. SAP2000 will used to obtain the variation in peak foundation responses
internally convert the masses on account of self weight of over a range of frequencies.
elements as a lumped mass at every nodes based on
contributory length/area. The weights of various machine
components are applied at mass centers described in vendor
drawing using “JOINT LOAD” command which are then
automatically converted to mass in SAP2000.

9.2. Dynamic Analysis Results

From the results of free vibration analysis, it is found that
almost 100% of structure mass is excited (modal participating
mass ratio=1) in all directions on considering the first twenty
natural modes of vibration. Further all natural frequencies of
vibration are well below the operating speed of 75 Hz
avoiding the resonance. The SAP2000 free vibration analysis
results for the TG foundation are presented below in Table-1.
The mode shape of the structure corresponding to mode-1 is
shown in Figure 6. Figure 7. Forced response of node- 2001

Journal of Civil Engineering and Environmental Technology

Print ISSN: 2349-8404; Online ISSN: 2349-879X; Volume 1, Number 4; August, 2014
Jayarajan P., Kouzer K.M. 35

10. CONCLUSIONS [3] Bhatia K.G., "Foundations for Industrial Machines and
Earthquake Effects", ISET Journal of Earthquake Technology,
The dynamic analysis of turbine foundations needs Paper No.495,Vol.45,No.1-2,March-June 2008, pp. 13-29.
attention to detail both in modelling and interpretation of the
[4] Biggs, J.M., Introduction to Structural Dynamics, McGraw-
results. The paper highlights various issues related to the Hill, New York, 1964.
mathematical modelling of structure, machine and soil for
dynamic analysis of the foundation system. Finite element [5] IS 2974(Part 3):1992, Indian Standard design and construction
method provides an efficient tool for the modelling and of machine foundations- Part 3: Foundations for rotary type
dynamic analysis of turbo-generator foundations. SAP2000 machines (Medium and high frequency), Bureau of Indian
provides a real computational environment for the modelling Standards, New Delhi.
of structure, machine and soil in a single model and to perform
the free and forced vibration analysis. [6] ISO 1940-1 (1993) Mechanical Vibration – Balance Quality
Requirements of Rigid Rotors – Part 1: Determination of
Permissible Residual Unbalance.
11. REFERENCES
[1] Alexander Major, Vibration Analysis and Design of Foundations [7] Kameswara Rao N.S.V, Foundation Design: Theory and
for Machines and Turbines, Collet's, Collet's Holdings Limited, Practice, John Wiley & Sons(Asia) Pte Ltd.
London, 1962.
[8] SAP2000 v14, Structural Analysis Program, Computers and
[2] Artur Pais, Eduardo Kausel, "Approximate Formulas for Structures Inc., Berkeley, California. www.csiberkeley.com.
Dynamic Stiffness of Rigid Foundations”, Department of Civil
Engineering, MIT, Cambridge, USA..

Journal of Civil Engineering and Environmental Technology

Print ISSN: 2349-8404; Online ISSN: 2349-879X; Volume 1, Number 4; August, 2014