TRAINING - VII 19" August, 2005 BOPL DESIGN OF MACHINE FOUNDATIONS, By B.GK Murthy 1.0 Introduction ‘The process of Cement production requires installation of different types of ‘Machines at various stages of production. These are of both heavy and light types. The main equipment is quite heavy operating at different frequencies. Some are of fixed speed and some, of variable speed within a specified range. Unbalanced forces are generated during their operation and accordingly these machines impart both static and dynamic loads to the supporting structure and foundations. This supporting system has to safely cary these loads and transfer them to the founding strata without excess vibrations and amplitudes. 1.1 Following criteria have to be satisfied while designing machine foundations: Resonance conditions are to be avoided Amplitude of vibrations must be within acceptable limits Adjoining ‘structures should not be affected during operation of machines ‘+ Sub-strata properties should not be affected as to jeopardize the performance of the machine. 1.2 This note covers the principles of sizing of satisfactory foundations to carry safely the static and dynamic loads to the founding strata / system. Guide lines for preliminary sizing are given. Soil parameters required for foundation design for dynamic loads and the methods of dynamic analysis are also dealt. Permissible amplitudes of vibrations for different types as per standard norms are given 2.0 General guidelines for preliminary sizing of foundation 2.1 The following steps will guide in sizing of foundations for Equ This is only for preliminary sizing. Subsequently dynamic analysis of critical equipment shall be carried out to satisfy the safe limits of performance. iv Spread Foundations:The foundation should not be placed on previously backfilled soil on a vibration sensitive soil. Recommendations of the Geo-technical report shall be followed. Bottom of the foundation should preferably be above ground water table wherever possible. In case of poor soils special foundations like Piles may have to be provided Foundation shall be isolated at all erids from the main building, / adjoining structure as far as possible. Rigid block-type foundation shall have a mass of 2 to 3 times mass of the centrifugal machines and 3 to 5 times the mass, in case of Reciprocating machines. Top of the block is normally kept about 300 mm above the finished floor or pavement level. This is to prevent any possible damage due to surface water runoff. Vertical thickness of the block shall be as dictated by the length of Anchor bolts Thickness should be more than one fifth of the least dimension, and one tenth of the largest. In no case itis less than 600 mm. The foundation should be wide enough to increase damping in the rocking mode. The width should be at least 1 to 1.5 times the vertical distance from the base to the Machine centerline, Having decided the thickness and width, the length is determined according to the required minimum weight, provided sufficient plan area is available to support the Machine plus 300 mm clearance from the edge of the machine base to the edge of the block for maintenance purposes. Proportion the base dimensions for about half the static soil bearing capacity. The static + dynamic bearing pressure should be not more than 75% allowable static pressure. The length and width of the foundation are adjusted so that the load C.G. of the machine plus equipment coincides with the C.G of the foundation weight. Further the combined C.G should coincide with the center of the soil resistance. This will provide reasonably uniform soil pressure and settlement. If it is unavoidable, eccentricity should not be more than, 5% of the length / width in either direction In case of large Reciprocating machines, it is desirable to increase the embedded depth in soil such that 50 to 80% of the depth is embedded in soil. This will contribute in inereasing the damping ratios for allmodes of vibration and also lateral restraint. To ensure this the gap (at least 150 mm.) between the foundation concrete face and the excavated earth faces shall be filled up with cohesion-less soils. If the dynamic analysis predicts resonance condition, the mass of the foundation is increased or decreased such that the foundation is either over-tuned or under- tuned. Even if the Resonance amplitude is acceptable the system frequency should be at least + or ~ 20% away from the machine operating frequency. iW Block foundations supported on piles ‘The mass of the pile cap should be 1.5 to 2.5 times the mass of Centrifugal machines and 2.5 to 4 times of that of reciprocating machines, The thickness, length and width of the block shall be selected as mentioned above, The number and size of piles are selected such that maximum load on a pile should not exceed one half of its design load. The arrangement of the piles should be such that C.G of the pile group coincides with the CG of the combined structure and machine loads Vertical piles provide small resistance to horizontal unbalanced forces. Battered (maximum 1 in 8)may be used if possible to resist the lateral forces. Piles must be anchored properly to the pile cap for adequate rigidity and for meeting the design conditions assumed during the analysis. If resonance conditions are possible the pile cap needs modification as mentioned above. 2.2 Sizing of Foundations for major equipment Design of foundations of heavy equipment like Crushers, Vertical Roller Mills, Tube / Ball Mills and Kilns shall be based on the recommendations of the Equipment Manufacturers. However the guide lines given above are still applicable except the mass ratios which shall be as per Manufacturers recommendations, Static and dynamic loads and critical load combinations shall be considered in the designs. Dynamic analysis shall be carried out to check resonance and the amplitude. Operating unbalanced forces and the Dynamic characteristics of the founding strata shal! be duly considered for this analysis.3.0 Dynamic parameters of founding strata ‘The following parameters of the founding strata are needed for dynamic analysis of the Machine foundations. Dynamic Shear modulus, G=E/1+p) =pVe Damping ratio, € Mass density, eas Velocity of shear wave, Vs =OLN' mys (Lmai-1977) G =12N°*MPa — (Ohsaki and Iwasaki-1973 Average STP value in a zone of depth equal to foundation width = N Dynamic modulus of elasticity, EB Poisson’s ratio, BH Coefficient of elastic uniform compression, c= Ex) ((-’) x VBL) Coefficient of elastic non-uniform compression, — Cy = 1.7 to 2.3 Cy Coefficient of elastic uniform shear, C, = 0.67 to 0.5 Cy Coefficient of elastic non-uniform shear, Length of the base of the block, L Width of the base of the block, B Table-1 Values of constant, C, (Barkan) LBC 10 [7.06 15 | 1.07 2.0 | 1.09 30 | 1.13 5.0 | 1.22 10.0 | 1.41 Table-2 Representative values of Dynamic shear modulus, G (Bowles) Material Mpa(MN/m Clean dense quartz sand | 12 20 Micaceous fine sand 16 Loamy sand 10 Dense sand-gravel 70Wet soit silty clay Dry soft silty clay Drysilty clay Medium clay Sandy cla} ‘Table-3 Representative values of Dynamic E and p values of rocks Rock Dynamic E value | Poisson’s ratio Mpa (MN/m?) Sound granite 3.2105.8x 10" | 0.1510 024 Partially decomposed granite | 0.7 to 1.4x 10° | 0.15 to 0.24 Lime stone 2.1t04.9x 10" | 0.16 100.23 Sand stone 1.4102.8x10' | 0.17 Uniform compression, C, (Barkan) Table-4 Recommended design values of the Coefficient of clastic Permissible | Coefficient Load on soil | of Soil under action | elastic Group | Soil group of uniform category static load | compression Only, Cy, ke/em? (SBC) | kg/cm? | T Weak soils (clays and silty clays with sand, in a plastic state; clayey and silty sands; also soils of categories Il and III with laminae of organic silt and peat) Upto — | Upto3 un Soils of medium strength (clays and silty i clays with sand, close to the plastic limit; sand) 15-35 3-5 sti Strong soils (clays and silty clays with sand, of hard consistency; gravels and gravelly sands; loess and loessial soils) 35-5 5-10 Vv Rocks greater than | greater than 5 104.0 Desi i, ii, xii xiii xiv. xy, xvi xvii, xvii. xix. Table-5 Poisson’s ratio, (Barkan) Sandy soils 0.15 to 0.25 Clayey soils with some sand and silt 0,30 to 0.35 Clays 0.35 to 0.40 (Gazetas Nearly dry sands, stiff clays, and rocks 0.25 Saturated clays and sands, below water table 0.50 Wet silty sands 035 ‘Nearly saturated clays below water table 040 ign Inputs required from the Equipment Manufacturer Machine’s function, its operation process and service Outline drawing of the machine assembly, dimensions of the machine base plates and location, type and size of anchor bolts including their fixing details Space restrictions and maximum maintenance lift load Weights of the machine and its rotating parts Mass and eccentricities of rotors Points of action of the weights and loads along with the directions Machine speed for rotary components of rotating machines. In case of variable speed machine, its range of speed and the maximum continuous operating speed Frequency of unbalanced primary and secondary loads of reciprocating machinery Magnitude, direction, and point of application of unbalanced forces and /or couples, for vertical and horizontal directions ‘Mass moment of inertia of driving and driven machines about three principal axes Number and weights of components of the rotor Loads due to abnormal sudden stoppages and dynamic short circuit conditions Gear box ratios Horsepower Permissible amplitudes of vibration Maximum operating temperature in the machine base Recommendations of the Manufacturer for sizing and minimum weight of the foundation Maximum allowable static deformation Details of embedded parts, openings, grooves, pockets for anchor bolts, etc. 5.0 Dynamic analysis of foundations Basically there are three methods of design: i. Linear elastic weightless spring method (Barkan)5. 5.2 53 ii, Elastic half-space method (Reissener, Richart etal.) iii, Lumped — mass method (including the method ii above) Linear elastic weightless spring method (Barkan) In this method it is assumed that the foundation block is resting on weightless springs. Zone of resonance is avoided while designing the foundations. As such the effect of damping on amplitude will be quite small and accordingly effects of participating soil mass and damping are neglected, Elastic half-space method (Reissener, Richart etal.) In this method the machine foundation is idealized as a vibrating mechanical oscillator with a circular base resting on an elastic, homogeneous, isotropic, semi-infinite body. This is more rational in comparison to the first one. Lumped — mass method (Bowles) This method of obtaining the vibration frequency and amplitude of foundation is simpler in comparison to the Elastic half-space method. The design procedure is basically extension of the same. This is dealt in detail as this is being adopted for sizing and assessment of the performance of Equipment foundations. 5.3.1 Design steps i Compute, measure, or estimate the foundation soil properties of Dynamic shear modulus G, Poisson’s ratio 1, and the unit weight ‘7. The unit weight is the total value including any water present, ii, Unbalanced forces of the Equipment causing the foundation to vibrate are to be obtained from the manufacturer. If these are not available, they are to be calculated with assumed extreme operational conditions. Foundation dimensions, fixing details, static and dynamic loads and their points of application, special provisions in the foundation block etc. are also to be obtained from the manufacturer. iii, The base dimensions must satisfy both static and dynamic Joadings on the founding strata. iv. Compute the combined weight of the machine and foundation so that the mass, m = Wigvi vii viii, ix. xi, Table 6 Mass Calculate the static soil springs k; as appropriate to the mode of vibration under consideration. The formulae to be used are given in Tables 4 and 5. The soil springs are used to compute the undamped natural frequency of the foundation system as Sn = Ln [iC km)] Compute the equivalent mass radius r, using the equations in the Table . The mass radius is used to compute the mass ratio B; for the relevant vibration mode using equations given in the Table 4. Compute the damping ratio D;, using the mass ratio and the equations in the Table 5. Calculate the resonance frequency as follows. For constant force excitation Se= fal - 2D") For frequency-dependent force excitation (rotary equipment) fr = fuk W [Ml ~ 2D?) Having calculated the resonance frequency, frequency ratio Jr /Ja can be obtained. From this magnification factor can bbe arrived at using the Fig 1 and 2. Considering this amplitude of vibration can be computed as F,/k;, This shall be multiplied by the magnification factor to obtain the maximum amplitude. Maximum horizontal amplitude shall include rocking and translation modes. radius ro and moments of inertia ;equations ‘Vibration mode to I Translation (x,y, Rocking Torsion 2) | ro = BL/t) _ ro = BL'3) Ig =m (544 + 17/3) (ueeD EE) | le = mare’ | on J Rocking mode: rr, = based on circular area with equivalent moment of inertia Jy = mass moment of inertia of a cylinder of height / about an axis through its base Torsion mode:ro = same explanation as given above for rocking Jp = mass moment of inertia with respect to the vertical axis (polar /) m = mass = arZhry/g for both J Table 7 Spring constants k;, Mass ratio B, and damping factors D; Mode of ‘Spring constants | Mass ratio Damping vibration Rigid circular bases Vertical Dz = O.425/-)B: 7-84) Horizontal By, By=32(1-wyre’ | Dey = 0.288//Bxy 304 Rocking ky =8Gr By=8 pre Dy=0.15/ (14ByJ 3 w) B:) th ‘Torsional ky = 16. Gr A Bo= pro Dy = 0.50/ (14289) 3 W = weight of foundation + ‘equipment p=mass of soil=y/g Y= unit weight of soil Rigid T> = _ equivalent rectangular radius of foundation bases (obtain F factors from Table 6) Vertical ky =F.G S[BL/ Aw] Horizontal hc ky = LPG (+u) JBL) | Rocking ky = | Fy GB /-w) for L/B> 1 .10 Table 8 F coefficients for rectangular footings subject to vibrations LB 05/10 [2.0 [3.0 [50 [100 Fe = [212] 2.181226 [2.44 12.82 FY - | 3.64 | 2.35 | 1.82] 1.38 | 1.01 2.08 | 2.00 | 2.04 | 2.10 | 2.30 | 2.50 1.85 | 1.74 | 1.74] 1.81 | 1.90 | 2.08 1,69 | 1.58 | 1.57] 1.61 | 1.70 | 1.88 1.54 | 1.41 | 1.37 | 1.40 | 1.46 | 1.88 Amplitude-frequency relationships for damped forced vibration of mass- Spring system: ‘ a Tt prsio(on Fig 1 Constant-amplitude exciting forceu a rr a ae) Me Fig 2. Exciting force dependent on exciting frequency @ Here the spring K and damping c are constant. For soil vibrations both K and c are frequency dependent so the resulting curve shape will be slightly different. This difference is neglected in this. Permissible amplitudes 6.1 Limiting amplitudes of vibration generally have to satisfy the following given in Fig 3, F080 46,009 00 2080 Frequency,com 5012 Fig 3 Permissible vibration limits 6.2 As per IS: 2974 the following allowable limits are specified for different categories of Machines S:no | Type of machine Permissible amplitude, mm 1. | Reciprocating machines | 02 2. | Hammers For foundation block —_| 1.0 to 2.0 For anvil 1.010 3.0 3. Rotary machines i. speed < 1500 rpm 02 ii, speed 1500 to 3000 rpm | 0.04 to 0.06 vertical vibration 0.07 to 0.09 horizontal vibration iii, speed > 3000 rpm 0.02 to 0.03 vertical vibration 0.04 to 0.05 horizontal vibration 6.3 According to German norms VDI: 2056 the following four graphs give the Limits of amplitude and vibration velocity for four different groups of Equipment: type K, M, Gand 7. Group K: Individual parts of driving gears and motors upto 15 kW. Group M: Medium size machines without requirements of specia foundations, electric motors of 15 to 75 kW and rotating machinery up to 300kW. Group G: Major parts of driving gears on rigid or heavy foundations ,highly over tuned in the direction of vibration, large prime movers. Group 7: Large prime movers with only revolving masses, supported on special foundations, deeply under-tuned (turbine sets) especially with modem light foundations gagseest epi Aaa tae SDSS a Fig 4 Group K equipment Fig 5 Group M equipmentVise css 38 Fig 6 Group G equipment 70 14 segigses2gssaeie Se a a ae 1 ae rece Fig7 Group T equipment ‘The above limits are generally adopted for monitoring the performance of different types of machinery. Construction details Minimum grade of conerete for Machine foundations is M20 - IS 456: 2000. Water cement ratio shall not exceed 0.45, Slump of 50 to 80 mm is acceptable. Foundation block shalt preferably be cast in single continuous operation. In case of blocks more than 4.0 m thick, construction joints may be provided. Such joints shall be properly treated and if required from horizontal loads and moment considerations, suitably designed dowel bars shail be provided across the joint, Construction Joint treatment: Before placing the new layer of concrete, the previously laid surface shall be thoroughly cleaned, washed by a jet of water and then covered by a rich | : 2 cement grout, 20 mm thick. Fresh concrete should be placed not later than 2 hours after the grout is laid In case of foundations subjected to high dynamic loads, Dowels of 12 or 16 mm diameter at 600 mm centers shall be embedded to a depth of at least 300 mm on both sides of the joint15 All arcas of the foundation shall be provided with top and bottom two-way reinforcement bars. Surface reinforcement shall be provided on all faces in block foundations. The amount of reinforcement in each element of foundation shall not be less than $0 kg/m’. In case of small size-equipment this may be limited to 25 kg/m The minimum reinforcement shall be 12 mm dia. bars placed at not more than 200 mm centers to take care of concrete shrinkage. In case of small-size equipment this can be reduced to 10 mm dia. bars placed at 300 mm centers. Reinforcement should also be provided around all openings, cavities, etc, It should be equal to 0.5 ~ 0.75% of cross sectional area of the opening, It should be ensured that cach part of the foundation shall be properly ‘stitched? together by reinforcement dowel bars or by extension of the reinforcement bars from one block to the adjacent one such that all the blocks are monolithically reinforced and act together. There should not be any comer of the blocks without extension of reinforcement in the three directions. Anchor bolt pockets of major equipment subjected to dynamic loads, shall be provided with inner surface reinforcement. The area of bars along the pocket shall be not less than 1.2 times the anchor blot area. These shall extend beyond the bottom of the by at least the anchorage length. These longitudinal bars shall be tied with links of 8 mm dia, bars spaced at not more than 150 to 200 centers. Conorete cover for reinforcement bars shall be 75 mm at bottom, 50 mm on the sides and 40mm at the top. In case of foundation subjected to high temperatures, such surfaces shall be treated with heat resistant concrete / mortars of adequate thickness. ‘The top surface shall be protected from ingress of any oil or lubricants. Edges of foundations likely to be subjected to impact due to movement of goods or handling equipment shall be protected with steel angles with lugs ( at least angles 50 x 50 x 6 mm with 12 mm dia. lugs spaced at 500 centers) embedded concrete. Machines should not be operated for at least two weeks after the under-filling grout is carried out. It is recommended to provide 150mm thick sand filling around equipment foundations with its top sealed with bitumastic board and weather resistant seal This vertical layer will isolate any vibrations and dampen the foundation movement and thus reducing the amplitudes.16 8.0 Design Example ‘The following attachment to this gives a typical example of a Roller Mill foundation.@ Q2ef24 suet | oF 3 Gils mrorn REFERENCE: CALCULATIONS FL. Smith Ine.» 3040 Avene © Btieha, PA 18017 PEwEsy ce Tenrommeoer | oaTe | 21857 eephore: 10-284.6011 » FAX: 610.254.5170 mewn smth com BGkM 2eleF (CHECKED BY: DATE: ‘APPROVED BY. 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