04/05/2013

FINAL YEAR B.TECH PROJECT

Final presentation

DYNAMIC ANALYSIS AND DESIGN OF BLOCK

FOUNDATION FOR FRANCIS TURBINE

PRESENTED BY

KULKARNI S.S. -141001088

TANDALE A.M. -110901051
BADSAL A.P. -141001091

GUIDED BY

DR. DAWARI B.M.

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DYNAMIC ANALYSIS AND DESIGN OF BLOCK FOUNDATION FOR FRANCIS TURBINE

OUTLINE OF PRESENTATION

1. INTRODUCTION
INTRODUCTION
2. MODELING

3. FINITE ELEMENT ANALY SIS

4. DESIGN AND DETAILING

5. SUMMARY

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1. INTRODUCTION

LITERATURE REVIEW
SR.NO. NAME OF PAPER NAME OF AUTHORS YEAR CONTENT

Analysis of Machine
G. G. Rensselaer Polytechnic State-of-the-art of analyzing the dynamic response of
1 Foundation Vibrations: 1983
Institute, New York, USA, foundations subjected to machine-type loadings.
State of Art

Turbine-generator foundation CAE is presented.

Dynamic Analysis and
Dr. Arkady Livshits IEC - Israel Electric Different types of foundations are described. Dynamic
2 Structural Design of Turbine 1999
Corporation Ltd, Israel behaviors of the foundations and sources of the
Generator Foundations
dynamic loads are discussed.
Foundations for Industrial
K.G. Bhatia Center for Applied Need for a better interaction between foundation
Machines and Earthquake
3 Dynamics D-CAD Technologies, New 2006 designer and machine manufacturer to ensure improved
Effects -28th ISET Annual Delhi, machine performance.
Lecture

Vibrating, rotating, reciprocating and impacting

Foundation Isolation Solutions Fabreeka shocks and vibration
4 2007 equipment create machine-induced vibration and/or
for Equipment & Machines control company,
shock, which is transmitted into their support systems

Special Issue, April-May 2006, of the

Foundations for Vibrating The methods of analysis for determining the response of
5 Journal of Structural Engineering, 2006
Machines SERC, Madras. INDIA, \
foundations subjected to vibratory loads.

The design of a turbo generator foundation for a thermal

6 Turbo Generator Foundation Sukanta Adhikari 2008
power plant..

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1. INTRODUCTION

MOTIVATION

MACHINE
FOUNDATION

MORE A LIVE
DEMANDING PROBLEM

INDUSTRIAL DYNAMIC
MACHINE ANALYSIS

NEEDS SPECIAL
CHALLENGING
ATTENTION

COMPLEX
BEHAVIOUR [C. Ravishankar Et.Al., 2008]

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1. INTRODUCTION

• TYPES OF MACHINES

1. Reciprocating machines:
(such as steam engines)
less than 600 rpm.

2. Impact machines:
(such as forging hammers)
speeds 60 to 150 blows per minute.

3. Rotary machines:
3,000 rpm and up to 12,000 rpm

[ Shamsher P. And Vijay P., 2006]

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1. INTRODUCTION

a) BLOCK-TYPE FOUNDATION b) BOX OR CAISSON-TYPE FOUNDATION

c) WALL-TYPE FOUNDATION d) FRAMED-TYPE OF FOUNDATION

[ SHAMSHER P. AND VIJAY P., 2006 ]

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1. INTRODUCTION

NECESSITY:

• Special consideration; because they

transmit dynamic loads to soil in
addition to static loads due to weight
of foundation, machine and
accessories.
• Dynamic load is applied repetitively
over a very long period of time
• Resonance .

OBJECTIVES
• To ensure safety of turbine foundation
• To analyze the turbine foundation for dynamic loads
• To identify critical zones of stress concentration

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1. INTRODUCTION

DESIGN OF BLOCK FOUNDATION

CRITERIA FOR DESIGN :

[ P. Shrinivasalu And C.V. Vaidyanathan , 2009]

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1. INTRODUCTION

DESIGN OF BLOCK FOUNDATION

Degrees of Freedom of A Rigid Block Foundation

DYNAMIC
ANALYSIS

MACHINE
VIBRATION
DATA

UNBALANCED MACHINE
FREE FORCED
FORCE SPEED

NATURAL MODE
AMPLITUDE
FREQUENCY SHAPES

MASS

STIFFNESS
[ Shamsher P. And Vijay P., 2006 ] [ Sukanta Adhikari , 2008]

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DYNAMIC ANALYSIS AND DESIGN OF BLOCK FOUNDATION FOR FRANCIS TURBINE

1. INTRODUCTION

DESIGN OF BLOCK FOUNDATION

METHODS OF ANALYSIS

1 Linear elastic spring method

The Linear Elastic Spring method (Barkan, 1962) treats the problem of foundation vibrations as
spring- mass model , neglecting damping in the soil.

2 Elastic half-space analogs method

The elastic half space theory can be used to determine the values of equivalent soil springs and
damping.

3 The impedance function method

They also provide values of soil spring and damping for surface and embedded foundations.

[ Shamsher P. And Vijay P., 2006 ]

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DYNAMIC ANALYSIS AND DESIGN OF BLOCK FOUNDATION FOR FRANCIS TURBINE

1. INTRODUCTION

• IS 2974 (Part-3)1992 Design and Construction of Machine Foundation

Data Required Loading Condition Load Cases Analysis & Design Steps
a) Dead Loads
• Machine data • DL+OL+NUL+ a) Modeling
b) Operational Loads
• Geotechnical TLF b) Free Vibration Analysis
c) Unbalance Forces
data • DL+OL+NUL+ c) Forced Vibration
d) Temperature Forces
TLF+SCF Analysis
e) Short Circuit Breaker
• DL+OL+TLF+L d) Seismic Analysis
f) Bearing Failure Load
BL/BFL e) Static Analysis
g) Seismic Forces
• DL+OL+NUL+
h) Erection Loads
TLF+EQL
• Determination of Equivalent Forces

F [1 + (2ξ r )2 ] Where,
=
P [(1 − r 2 )2 + (2ξ r ) 2 ] r =frequency ratio
ξ =critical damping ratio
Pn [1 + (2ξ r )2 ] P= dynamic load
Fmax =
2ξ
F = pseudostatic load
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2. MODELING

• Problem Formulation Pench Hydroelectric Project

Existing RHS Plant

Capacity = 2 X 2 MW

Proposed LHS Plant

Capacity = 2 X 2 MW

• Location of Right Hand Side H.E.P.

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2. MODELING
• Progress of work during July 2011
• Right Hand Side Hydro Electric Project At Pench
[ Courtesy Koyna Design Circle, Pune]

DRAFT TUBE WHILE ERECTING PENSTOCK ERECTION POWER HOUSE

CASING FOR RUNNER GENERATOR COMPLETED POWER HOUSE

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2. MODELING

Visit for
understanding
the various
structures
required for
power
generation at
Power house at Dhom Dam Penstock with pressure relief valve Dhom and
Dhom Balkavdi
Dam

Penstock casing with reinforcement Partially opened valve

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DYNAMIC ANALYSIS AND DESIGN OF BLOCK FOUNDATION FOR FRANCIS TURBINE

2. MODELING

GEOMETRICAL REQUIREMENT OF TURBINE FOUNDATION AT PENCH

[Courtesy Koyna Design Circle, Pune]

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2. MODELING

GEOMETRICAL REQUIREMENT OF TURBINE FOUNDATION AT PENCH

[Courtesy Koyna Design Circle, Pune]

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DYNAMIC ANALYSIS AND DESIGN OF BLOCK FOUNDATION FOR FRANCIS TURBINE

2. MODELING

CASING PENSTOCK
RUNNER

GENERATOR
LOCATION

BUTTERFLY
VALVE

PEDESTAL

DRAFT TUBE

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3. FINITE ELEMENT ANALYSIS

• 2-Dimentional Analysis ANSYS 12.0 ANSYS 12.0

S.No. Parameters Result for Result for
220kN 231.42kN
Given Load Calculated Load
1. Max Displacement 0.587 mm 0.616 mm
2. Shear Force Y 550 kN 577.5 kN
3. Shear Stress xy 4.21 N/mm2 4.42 N/mm2
4. Principal Stresses 4.24 N/mm2 4.45N/mm2

SHEAR STRESS DISTRIBUTION PRINCIPAL STRESS DISTRIBUTION

• This analysis shows some
greater stresses because
of stress concentration at
the edges of plates on
which force is applied

• From this it could be concluded that for more reliability of analysis one should go for 3D
analysis with brick element rather than shell element because it gives higher results.

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3. FINITE ELEMENT ANALYSIS PSUEDO-STATIC ANALYSIS

R
U
N
N
E
R BRICK
ELEMENT

F
O
U
N
D
A
T
I
O
N

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3. FINITE ELEMENT ANALYSIS PSUEDO-STATIC ANALYSIS

R
U
N
N
E
R

F
O
U
N
D
A
T
I
O
N

Fig showing different types of stresses

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DYNAMIC ANALYSIS AND DESIGN OF BLOCK FOUNDATION FOR FRANCIS TURBINE

3. FINITE ELEMENT ANALYSIS MODAL ANALYSIS

R
U
• Modal analysis is necessary for structures which are subjected to dynamic loads to
N know the natural frequency of structure to check the resonance.
N
E
R

F
O
U
N
D
A
T
I

FREQUENCY (Hz)
O
N

MODE SHAPE NO.

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3. FINITE ELEMENT ANALYSIS MODAL ANALYSIS

R Mode Shapes
U
N This figure
N shows total
E deformations
R at all locations
for different
natural
F frequencies
O
U
N
D
A
T
I
O
N

TOTAL DEFORMATIONS

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3. FINITE ELEMENT ANALYSIS MODAL ANALYSIS

• Mode Shape for frequency 19.85 Hz

• Showing Total Deformation

• Runner and Draft Tube Foundation

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3. FINITE ELEMENT ANALYSIS MODAL ANALYSIS

G
E
N
E
R
A
T
O
R

F
O
U
N
D
A
T
I
O
N

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3. FINITE ELEMENT ANALYSIS MODAL ANALYSIS

• Mode Shapes

• As the
Generator
Foundation
is massive
structure as
compared to
loads , it can
be observe
that total
deformations
are quite
less.

• Generator Foundation
TOTAL DEFORMATIONS

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3. FINITE ELEMENT ANALYSIS MODAL ANALYSIS

• Mode Shape for frequency 73.75 Hz

• Showing Total Deformation

• Generator Foundation

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DYNAMIC ANALYSIS AND DESIGN OF BLOCK FOUNDATION FOR FRANCIS TURBINE

3. FINITE ELEMENT ANALYSIS MODAL ANALYSIS

R
U
• Harmonic analysis is necessary for structures which are subjected to dynamic loads
N to know the effect of forcing frequency and cyclic loading on structure.
N
E
R

F
O
U
N
D
A
T
I
O
N

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3. FINITE ELEMENT ANALYSIS HARMONIC ANALYSIS

• Various types of stresses and there distribution over the structure can be seen in
these diagrams.

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3. FINITE ELEMENT ANALYSIS HARMONIC RESPONSE ANALYSIS

• Harmonic Response of Structure at 12.5 Hz (750 rpm)

• Showing Total Deformation

• Runner and Draft Tube Foundation

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3. FINITE ELEMENT ANALYSIS HARMONIC RESPONSE ANALYSIS

Harmonic Response 1 Harmonic Response 2

DEFORMATIONS ACCELERATION

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3. FINITE ELEMENT ANALYSIS HARMONIC RESPONSE ANALYSIS

Harmonic Response 3 Harmonic Response 4

STRESSES STRAINS

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3. FINITE ELEMENT ANALYSIS HARMONIC RESPONSE ANALYSIS

G Harmonic analysis is necessary for structures which are subjected to dynamic
E
loads to know the effect of forcing frequency and cyclic loading on structure
N
E
R
A
T
O
R

F
O
U
N
D
A
T
I
O
N

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3. FINITE ELEMENT ANALYSIS HARMONIC RESPONSE ANALYSIS

• Harmonic Response of Structure at 12.5 Hz (750 rpm)

• Showing Maximum Principal Stresses

• Generator Foundation

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3. FINITE ELEMENT ANALYSIS HARMONIC RESPONSE ANALYSIS

• Various
types of
stresses and
there
distribution
over the
structure
can be seen
in these
diagrams.

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3. FINITE ELEMENT ANALYSIS HARMONIC RESPONSE ANALYSIS

Harmonic Response 1 Harmonic Response 2

DEFORMATIONS ACCELERATION

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3. FINITE ELEMENT ANALYSIS HARMONIC RESPONSE ANALYSIS

Harmonic Response 3 Harmonic Response 4

STRESSES STRAINS

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RESULTS
R
U
N
N PSUEDO - STATIC ANALYSIS MODAL ANALYSIS HORMONIC ANALYSIS

E Total
TYPE OF minimum maximum frequency minimum maximum TYPE OF minimum maximum
R STRESSES value (MPa) value (MPa)
Deformatio
(Hz) value (mm) value (mm) STRESSES value (MPa) value (MPa)
ns
Equivalent 1 0 0.7 0.7 Equivalent
0.003 2.1 0.002 1.07
Stresses Stresses
F 2 3.21 0.005 1.31
Maximum Maximum
-0.38 1.82 3 5.02 0.68 0.7 -0.07 1.04
O principal stresses principal stresses
middle principal 4 10.14 0.002 1.48 middle principal
U -0.54 0.56 -0.22 0.23
stresses 5 10.22 0.027 1.1 stresses
N minimum minimum
-2.34 0.31 6 11.12 0 1.75 -1.06 0.77
D principal stresses 7 13.69 0.008 1.62 principal stresses
A maximum shear
0.002 1.06 8 14 0.006 2.72 maximum shear
0.001 0.56
stresses 9 19.85 0.006 4.02 stresses
T
10 20.7 0.012 3.2
I
O PERMISSIBLE STRESSES IN CONCRETE (M25)
N
COMPRESSIVE = 25MPa
SHEAR = 3.1MPa
TENSILE = 3.5MPa

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RESULTS
G
E
MODAL ANALYSIS HARMONIC ANALYSIS
N
E Total Minimum Maximum Type Of Stresses
Minimum Value Maximum Value
Frequency (Hz) (Pa) (Pa)
R Deformations Value (mm) Value (mm)
A Equivalent Stresses 7.08 12407
T 1 1.45 0.63 0.68

O 2 3.22 0.015 1.26 Maximum Principal Stresses -135.75 15142

R
3 3.54 0.22 1.05 Middle Principal Stresses -727.07 4466.3
F 4 6.39 0.02 1.22
O Minimum Principal Stresses -4596.9 1822

U 5 6.78 0.06 1.14

Maximum Shear Stresses 4.02 6941.2
N 6 7.38 0.02 1.32
D
7 39.66 0.022 1.42 Stress Intensity 8.05 13882
A
T 8 41.3 0.008 1.78 Normal Stresses -4217.6 15141
I
O 9 54.51 0.014 1.66 Shear Stresses
-2143.4 2770.4
N 10 73.75 0.008 1.7
Total Deformation
0.02 mm 0.06 mm

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4. DESIGN AND DETALING

D Design of PEDASTAL of Turbine Pu
E There are four PEDASTALs under turbine. Two PEDASTALs are of 1100 X 1100 mm size = 0.007
and two
f ck bd
S PEDASTALs are of 850 X 1100 mm size.
I Mu
= 0.007
G Design of PEDASTAL of size 1100 X 1100 f ck bd 2
Lex=Ley
N = 0.79*1.2 =0.948 m
Pt
Lex/ D ≅0
= 0.948*1000/1100 =0.86182 < 12 f ck
O Lex/ b
F = 0.948*1000/1100 =0.86182 < 12 Minimum Reinforcement= 0.4%
design as short column
Axial load on PEDASTAL = 220 kN 10 Nos. of 25mm Dia Bars
P Horizontal reaction on PEDASTAL = 235 kN
E Moment at base of PEDASTAL = 235*0.79 kN-m Provide at outer edges
= 185.65 kN-m
D
A
S
T
A
L
S

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5. SUMMARY

• Rigorous FEM analysis depicts realistic behavior of foundation

subjected to dynamic loads of turbine.
• Rigorous FEM analysis shows the critical zones of stress
concentration.
• Total deformations at any location are within limit, there are no
excessive deformations.
• All stresses are within limit, and there is no failure of any
element of foundation.
• In harmonic response analysis, observed amplitudes are ‘not
noticeable to person’.
• Stresses for Pseudo Static Loads are more than Dynamic Loads,
so it is preferable to design the elements of foundation for
Pseudo Static Loads.
• Safety of runner foundation as well as generator foundation is
ensured.
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FUTURE SCOPE

1. Grade of concrete could be changed according to various zones

and stress levels

2. Reinforcement could be modeled in concrete mass

3. Performance of foundation with the isolators may be checked

4. Detailed analysis may separately be carried out for connections

5. Further work may carried out for analysis of foundation for

earthquake loading

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PUBLICATIONS

1. Presented a Paper entitled as “Pseudo-Static Analysis of Concrete Block

for Turbine” in “National Conference On Emerging Technology for
Sustainable Development-2012” at Shivaji University Kolhapur.

2. Presented a poster on “Turbo Block for Small Hydro-Project” in OKLUS-

2k13 a state level competition at S.B.Patil College of Engineering and
Polytechnique, Indapur, Maharashtra.

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REFERENCES
1. “Analysis Of Machine Foundation Vibrations: State Of Art” George Gazetas Rensselaer Polytechnic Institute, Troy, New York, USA,
1983.
2. “Dynamic Analysis And Structural Design Of Turbine Generator Foundations” Dr. Arkady Livshits IEC - Israel Electric Corporation
Ltd, Israel Nativ Ha-Or St, 1, POB 10, Haifa 31000, Israel, 1999.
3. “Foundations For Industrial Machines And Earthquake Effects” 28th ISET Annual Lecture K.G. Bhatia Center for Applied Dynamics D-
CAD Technologies, New Delhi,2006
4. “Foundations For Vibrating Machines” Special Issue, April-May 2006, of the Journal of Structural Engineering, SERC, Madras. INDIA,
2006.
5. “Turbo Generator Foundation” Sukanta Adhikari , 2008.
6. “Handbook of Machine Foundation” P. Shrinivasalu and C.V. Vaidyanathan, Tata McGraw-Hill Education, 2009.
7. “Vibration of Structures - Applications in Civil Engineering Design” by J.W. Smith Chapman, London, 1988.
8. “Structural Dynamics for Engineers” H. Buchholdt. Published by Telford Publication , Thomas Telford Services Ltd.1 Heron Quay
London E14 4JD. 1997
9. IS 2974 (Part-3)1992, Design And Construction of Machine Foundation – Code of Practice.
10. IS 456: 2000, Plain and Reinforced Concrete (Fourth Revision) – Code of Practice.
11. “Finite Element Dynamic Study on Large Framed Foundation of Steam Turbine Generator”, Ahmed Mounir Ibrahim Abou Elsaoud, The
American University in Cairo, 2011.
12. “Skywalk - Analysis And Design”, Baraskar M. A., Bhadbhade S. M., Chinta C. A., Inamdar N. J., Raghatate A.M., College of
Engineering Pune, 2009

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ACKNOWDGEMENTS

.

Officials associated with the Water Resources Department,
Koyana Design Circle, Jal-Sampatti Bhavan, Pune .

Mr. T. N. Munde Superintending Engineer

Mrs. Anita Modi Assistant Engineer Grade -I
Mrs. Seema Mohite Assistant Engineer Grade -I
Mrs. Namrata Patil Assistant Engineer Grade -II

Miss. Pallavi Gavali

Senior Scientist, C-DAC Pune

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THANK YOU

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