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Machine Foundations in Oil and Gas Industry: by Varanasi Rama Rao B.E, M.S. (I.I.Sc.)
Machine Foundations in Oil and Gas Industry: by Varanasi Rama Rao B.E, M.S. (I.I.Sc.)
Chennai Office
By
Varanasi Rama Rao B.E, M.S.(I.I.Sc.)
CONTENTS
1. INTRODUCTION
2. INPUT
3. ANALYSIS&DESIGN
4. REFERENCES
January 2011
1. INTRODUCTION
The analysis and design of structure or foundation subjected to vibratory
loading is a complex problem as it involves interaction of three domains viz.
Structural Engineering, Geotechnical Engineering and Structural dynamics.
The machines used in Oil and Gas industry are usually supported on a
concrete block or a concrete frame and occasionally on steel frames. In
majority of the cases the machines are supported on a simple concrete block.
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2. Reciprocating Machines
Fig-2
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Fig-3
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Reciprocating Machine
Fig-4
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CONCRETE
BLOCK
CONCRETE/ST
EEL FRAME
CONCRETE BASE
RAFT
SOIL
SOIL
1.Block (Concrete)
Type
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MACHINE
CONCRETE
BLOCK
CONCRETE/ST
EEL FRAME
SOIL
SOIL
1.Block (Concrete)
Supported by piles
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2. INPUTS
What inputs are needed for foundation design?
The inputs are broadly categorized as
Project Design basis for Machine foundation
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2. Poissons Ratio
3. Damping factor
Secondary Parameters
1. Coefficient of Elastic uniform compression Cz
2. Coefficient of Elastic uniform shear C
3. Coefficient of Elastic non uniform compression C
4. Coefficient of Elastic non uniform shear C
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Laboratory tests:
Resonant Column test
Cyclical Tri axial Test
The above test are conducted usually by a Geotechnical Contractor and
appropriate values are recommended by him in the Geotechnical report
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Fig-7
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Fig-8
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Fig-9
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Fig-10
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Fig-11
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Fig-12
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The process of evaluating the critical soil properties that influence soil
structure interaction is probably the most difficult part of the machine
foundation design- Dr. K.G.Bhatia
The significant aspects of soil properties which influence soil-structure
interactions are:
Energy transfer mechanism- Not quantifiable
Soil mass participation in vibration of the foundation- Not quantifiable
Effect of embedment of foundation- Approximately quantifiable
Applicability of Hookes law to soil- To some extent
Dynamic soil parameters-Approximately quantifiable
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Drive
machine
coupling
Fig-13
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Driven
machine
A typical data set required for each of the components shown in the previous
schematic is:
For dynamic response analysis of foundation:
Total mass of machine ( including rotating parts), Radius of gyration and its over
all centroid location.
Mass of rotating parts of the machine, operating speed, height of the centre of the
rotor from machine base frame, etc
Foot print of machine base frame, details of holding down bolts
Dynamic forces generated by the machine under operating conditions
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Centre of Mass
Centre of Rotation
Balanced condition
Fig-14
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Centre of Mass m
e
Centre of Rotation
Fig-15
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Fig-16
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Picture of Rotor
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Fig-17
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Picture of Rotor
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Fig-18
Fig-19
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Fig-20
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Fig-21
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Fig-22
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Foundation Parameters
Under tuned foundation:
The vertical vibration frequency is < operating frequency of the machine
Preferred for Medium to High speed Machines
Over tuned foundation:
The vertical vibration frequency is > Operating frequency of the machine
Preferred for very low to low speed machines
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Permissible amplitude in
Microns
100 to 500
200 to 80
500 to 1500
80 to 40
1500 to 3000
40 to 20
3000 to 10000
20 to 5
Permissible amplitude in
Microns
300 to 1500
1000 to 20
100 to 300
1000
The above are only approximate values. Actual permissible should be
given by the Machine Vendor/Manufacturer
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Foundation Stiffness:
Foundation parameters that govern the dynamic response are its mass
and its area of contact with the soil. In specific cases projected parts of
foundation having finite stiffness also influence the dynamic response.
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Strength Design:
Since the block foundation behaves like a rigid body supported on a soft media like soil,
invariably the block foundations would turn out to be having adequate strength vis--vis
forces imparted by machine.
Strength design is done considering the forces and moments on the foundation due to
static loads, dynamic loads, emergency loads and applicable earthquake/wind loads.
Anchor bolts: All anchor bolts should be checked for pullout force caused due to
Dynamic and Emergency loads
Stability Checks:
The foundation shall be checked for sliding and overturning . But these checks are not
compulsory.
Minimum Reinforcement :
25 to 50 kg/m3
Minimum dia. of the bar 12 mm
Two way reinforcement on all the faces and shrinkage reinforcement ( when thickness
of block exceeds 1m)
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YAWING OR TWISTING
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Fig-23
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Soil Damping
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mz z cz z k z z P0 sin( t )
Kz
Cz
Kx
k
m
X
Cx
D c ccr
K
C/2
C/2
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Fig-25
ccr 2 k m
Vertical
4Gr
Stiffness k
1
Mass Ratio m(1 )
4 r 3
m
m
Damping
0.425
Ratio, D
m 1/ 2
Fictitious 0.27m
Mass
m
Horizontal
8Gr
2
m(2 )
8r 3
0.288
m 1/ 2
0.095m
m
Rocking
8Gr 3
3(1 )
3I (1 )
8 r 5
0.15
(1 m )m 1/ 2
0.24I x
m
Torsion
16Gr 3
3
I
r 5
0.50
1 2m
0.24I z
m
Closed form solution for free and forced vibration of foundation block subjected
to dynamic loads:
Fig-26
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Fig-27
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Fig-29
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Eccentricity:
For Framed foundation there are two connotations to the term eccentricity:
1. Overall eccentricity: it is defined as the distance between the centre of mass
of the over all system ( machine+ foundation) and C.G of the base contact
area of the foundation with soil. This should be restricted to 5%
2. Top deck eccentricity: It is defined as the distance between the centre of the
Mass Cm ( combined C.G of machine mass, top deck mass and 23% percent
of column mass) and centre of stiffness of frames Ck in the transverse and
longitudinal directions. It is desirable to restrict this eccentricity to 1% of the
respective dimension of the top deck.
Top deck sizing:
Top deck comprises of transverse and longitudinal beams, slab connecting these
beams, projections on all sides of the beams, depressions, cutouts, notches etc.
a. The top deck weight > weight of the machine
b. For beams: Span/Depth = 3 to 5; Depth/width = 1 to 1.5
c. Extent of cantilever projections in plan should not be more than half the width
of the corresponding beam
d. Depth of slab should be invariably same as that of the encompassing beams
except at areas where the recess or depressions are provided to accommodate
machine
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Columns:
Total weight of the columns should be close to the weight of the machinery. This is
desirable but not essential condition
But the following should be kept in mind while assessing the sizes of columns
Centre of stiffness of all the frames should coincide with centre of mass of
machine and top deck.
Lateral natural frequencies of each of the column ( along transverse as well as
longitudinal directions) considering fixed at both ends should not coincide with
Machinery frequency or its harmonics.
Base raft:
Raft plan dimensions are selected such that the bearing pressure generated is
less than 70% of allowable bearing pressure.
Base raft thickness should be such that it acts like a rigid block and undergoes
uniform deformation.
General guide line is weight of the base raft should be about twice the weight of
the machine
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Unlike block members of frame foundation have finite stiffness and are
subjected to considerable elastic deformations.
Framed foundation is considered as elastic body with both mass and stiffness.
Strength design:
Minimum Reinforcement:
Reinforcement for top deck and columns to be in the range of 100 to 120
kg/m3
Reinforcement for base raft shall be in the range of 70 to 80 kg/m3
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Fig-30
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For both the above methods the beams and columns are modeled
using 3 dimensional beam elements, shear walls ( if any) and mat are
modeled using plate-bending elements.
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Fig-32
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Miscellaneous Topics
1. Soil- Structure Interaction effects:
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many questions, so shall be January
the status
of computed dynamic response
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4.REFERENCES
BOOKS:
1. Barkan D.D. Dynamics of bases and Foundations- Mc Grawhill
2. P.Srinivasulu and Vaidyanathan Hand Book of Machine foundations- Tata Mc Grawhill
3. Foundations for Industrial Machines: Hand book for Practicing Engineers- K.G.BhatiaDCAD publishers
4. S.Prakash and V.Kpuri Foundation for machines- Analysis and Design- John Wiley
5. Arya, O Neil and Pincus Design of Structure and Foundation for Vibrating MachinesGulf Publishing
6. Indrajit Chowdhury and P.Dasgupta Dynamic of Structure and Foundation CRC
press
7. Soil Dynamics and Machine foundations Swami Saran- Galgotia
8. Soil Dynamics - Braja M. Das
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CODES:
Indian:
IS2974: 5 parts of which parts 1,3 & 4 are for Reciprocating and Rotating machines
IS 5249: Methods of test for determination of Dynamic soil properties
British:
CP 2012
German:
DIN4024 ( Part 1): For framed type ( Flexible) foundations
DIN 4024 ( Part 2): For block type ( Rigid) foundations
American:
ACI 351
Saudi:
SAES-Q-007
ISO:
1S0 10816 ( 7 parts)
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