Li 2020 IOP Conf. Ser. - Earth Environ. Sci. 585 012101

IOP Conference Series: Earth and Environmental Science
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2020 6th International Conference on Energy, Environment and Materials Science IOP Publishing
IOP Conf. Series: Earth and Environmental Science 585 (2020) 012101 doi:10.1088/1755-1315/585/1/012101
Reconstruction design of a turbine generator foundation
Ming Li1, Junjie Hu1*, Zhiyong Zhou2 and Mingxiang Chen3,4

1
Hubei Electric Power Survey and Design Inst. Co.,Ltd, Wuhan 430040, China
2
Research Institute of Wuda Jucheng Structure Co., Ltd, Wuhan 430223, China
3
School of Civil Engineering, Wuhan University, Wuhan 430072, China
4
Engineering Research Center of Ministry of education for building detection and
reinforcement of Wuhan University, Wuhan 430072, China
*
Corresponding author’s e-mail: hujj@heec.com
Abstract. The key to the reconstruction of turbine foundation is the dynamic performance
control and the anti fatigue performance and durability of the new and old concrete interface.
Based on the finite element analysis method, the natural vibration analysis of the steam turbine
foundation before the reconstruction is carried out, and the calculation data of the natural
vibration frequency and mode are compared with the field dynamic test data to verify the
rationality of the finite element calculation model. On this basis, the natural vibration analysis
and the harmonic response analysis of the reconstruction scheme are carried out, and the
vibration line displacement of the key points of the disturbance force of the steam turbine
foundation meets the vibration displacement control standard within the frequency range of 0 ~
62.5Hz. The static analysis is carried out for the transformation scheme, and the prestressed
reinforcement is arranged to ensure the compression of the new and old interface; the project
abandoned bonded rebars with limited service life and adopted self-locking anchors with the
same life as the original structure to connect old and new concrete bonding surface. The low
cycle fatigue test of self-locking bolt and concrete base material is carried out. The test results
show that there is no fatigue failure, which shows that the reinforcement scheme can meet the
requirements of fatigue resistance and durability.
1. Introduction
Turbine generator is the heart of the whole power plant, and steam turbine foundation is one of the
most important parts in power plant civil engineering. The steam turbine foundation is different from
other structures. For steam turbine under dynamic load, load is not used as the control index,
amplitude is used as the control index. Therefore, the analysis of the dynamic characteristics of the
steam turbine foundation is very important [1]. The form and nature of structural members determine
the amplitude. While designing and reconstructing the dynamic foundation structure, the structural
form needs to be adjusted through dynamic characteristic analysis so that the amplitude of the
foundation structure is under the control index. As the result of the improvement of computer and
calculation methods, numerical simulation has become more and more widely used in the study of
dynamic characteristics of dynamic foundations [2-7]. In this paper, the static and dynamic performance
of the structure are analysed with finite element software, as the basis for design. The project
abandoned bonded rebars with limited service life and adopted self-locking anchors with the same life
as the original structure to connect old and new concrete bonding surface.
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
Published under licence by IOP Publishing Ltd 1
2. Reconstruction plan
2.1.Engineering Situation
A 2 × 25MW condensing turbine built in 2011 was changed to a 2 × 25MW back pressure turbine. The
project prefers replacing the steam turbine and retaining the original generator. The size of the front
bearing seat of the new steam engine is basically the same as that of the existing steam engine, but the
size of the rear bearing seat is moved. The overall size of the steam turbine foundation is 14.99m long,
8m wide and 9.95m high. The seismic fortification intensity of the location where the steam turbine is
located is 6 degrees, the design basic seismic acceleration is 0.05g, and the site characteristic period is
0.35s.
2.2.Reconstruction plan
A new concrete beam is added to support the rear axle seat of the new turbine foundation, and a
concrete column is added at each end of the beam. The new beam is connected with the original
structural longitudinal beam. In order to ensure the structure is not affected by vibration. two new
concrete columns are added. The plan view after reconstruction is shown in Fig.1.
(a) Plan view

(b) Sectional view of 1/Ⅱ axis

Fig.1 Schematic
2.3.Key technologies
2.3.1.Dynamic characteristics of the structure after reconstruction.

Turbine foundations must meet vibration control requirements and carrying capacity requirements.
The finite element method is used for calculation to ensure that the reinforcement scheme meets the
above requirements.
2.3.2.Connection of new and old concrete.

In the reinforcement project, the contact surfaces of new and old concrete are weak points, and the
contact surfaces must meet the requirement of fatigue stress under power frequency vibration. The
self-locking anchors will be applied as the connecting reinforcement [8] and prestressed reinforcement
will be added. The connection of new and old concrete structures is shown in Fig.2.

Fig.2 Schematic diagram of new and old structure connection
3.Finite element calculation

The following analysis is performed using the general finite element analysis software ABAQUS:
According to the field dynamic detection, the modal parameters are obtained from the frequency
response through the modal analysis software; the natural vibration analysis of the steam turbine
foundation before the reconstruction is performed, and the obtained structural modal parameters are
compared with the field Comparison of dynamic test data, correction of mechanical assumptions and
main parameters of the numerical model to verify the rationality of the finite element calculation
model analysis; dynamic and finite element analysis of the finite element according to the
reinforcement scheme to verify whether the reinforcement scheme meets the vibration control
requirements and Capacity requirements.
3.1.Calculation model
3.1.1.Calculation model.
Build 3D models by actual size. In order to get closer to the real situation during the dynamic analysis
and strengthen the constraint on the columns, 2m high backfill soil and 10cm thick C15 concrete on
the surface were added into the calculation model. The unit type is C3D8R.
Fig.3The finite element model of the foundation before reconstruction

In the dynamic analysis, the translational degrees of freedom in the three directions x, y, and z of
the column bottom and the soil bottom are constrained; in the static analysis, the translational degrees
of freedom in the three directions x, y, and z are constrained, The embedded steel bars constrain its
axial freedom of rotation.
3.1.2.Load.
In the dynamic analysis, the disturbance load needs to be considered. The disturbance force is the
excitation force that causes the foundation plate to vibrate due to the centrifugal force caused by the
residual imbalance during the rotary motion of the machine rotor. According to the current standard
Code for Design of Dynamic Machine Foundation (GB50040-96) [9] (if there is no special instruction,
this regulation is hereinafter referred to as the Dynamic Code) 5.2.2 Stipulates that when calculating
the linear displacement of vibration, Disturbance value supported by the manufacturer should be used.
When lack of disturbance data, the basic allowable vibration linear displacement can be calculated as
the vertical and lateral disturbance force is 0.2 times the rotor weight, and the longitudinal disturbance
force is calculated as 0.1 times the rotor weight.
3.1.3.Material parameters.
Turbine foundation concrete structure strength grade is C30. In addition, at the junction of the two-
story internal structure air duct board and column is 25a channel steel. The added concrete strength
grade is C35. Only the linear elastic behavior of the material is considered. The material parameters
refer to the design specification. In order to be closer to reality when performing dynamic analysis, the
backfill soil was built into the calculation model. The surface layer of the soil was 10 cm thick C15
concrete. The effect of the soil only provided stiffness (E = 20MPa) with no mass, so its density was
set to 0.
3.2.Analysis of foundation natural vibration before and after reconstruction

In order to obtain the basic natural vibration mode characteristics, frequency analysis was applied in
ABAQUS, and the first 70 order modes were calculated. The first 3 main vibration modes of x-
direction translation, z-direction translation, and y-axis rotation effective mass participation the total
quality of the sum accounts for 96.85%, 93.14%, and 91.49%, which meets the requirement of
reaching more than 90% of the total quality.
The comparison of the natural frequency of finite element analysis with the measured data of the
turbine foundation for the first three orders before and after the reconstruction is shown in Table 1.
The calculations are similar to the measured results, and the finite element model is rational. After the
reconstruction, after adding concrete columns and beams, the natural frequency of each order has
increased, and the modal characteristics are the basis for the dynamic analysis of the next
reconstruction scheme.
Tab.1comparison of the self-vibration frequency(Hz)
Foundation Foundation Foundation
finite element Measured finite element
Modal
results before results before results after
reconstruction reconstruction reconstruction
First order 5.0945 5.859 5.5116
Second order 5.3151 / 5.8931
Third order 8.9047 8.398 9.1662
3.3.Analysis of basic harmonic response after reconstruction

According to Section 5.2 Dynamic calculation of frame foundation 1-5 of the Dynamic Code, the
dynamic design of turbine is controlled by vibration line displacement. The occurrence of generate
resonance is conceptually allowed, as long as the vibration displacement meets the requirements. The
working frequency of the steam turbine foundation is 50Hz or 3000r / min. According to the Dynamic

Code, within the range of working rotate speed ± 25%, that is, within the range of 2250 ~ 3750r / min,
the maximum vibration linear displacement is allowed to be 0.02mm; while rotate speed is less than
75% working speed, that is, less than 2250r / min, resonance may occur, the maximum allowable line
displacement of vibration is 0.03 mm.
This section applies ABAQUS harmonic response analysis to calculate the vibration line
displacement of the foundation at different frequencies during normal operation, startup and shutdown.
Harmonic response analysis is a technique used to determine the steady-state response of a linear
structure when subjected to a load that changes in time with the a sine law. It only calculates the
steady-state forced vibration of the structure. ABAQUS harmonic response analysis is “A mode-based
steady-state dynamic analysis”.
When calculating the vibration line displacement, the disturbance force at any rotate speed can be
calculated as follows:
2
n 
P0i =Pgi  0  (1)
n
Where: P0i is the disturbance force (kN) of any rotate speed; n 0 is rotate speed (r / min).
According to 5.2.7 of the Dynamic Code, when there are m disturbances, the vibration line
displacement of the mass point i can be calculated as follows:
2
 A 
m
Ai = k =1 ik
(2)
Where: A i is the vibration linear displacement (m) of the mass point i; Aik is the vibration linear
displacement (m) of the k-th disturbance force on the mass point i.
When optimizing the reconstruction scheme, focus on the vibration line displacement of each
disturbance point.
The maximum longitudinal displacement of the disturbance point of the turbine foundation under
the longitudinal (x-direction) load is 11.37um, which occurs near the frequency of 29.17Hz (less than
37.5Hz), which is less than the maximum allowable displacement of Dynamic Code by 30um. The
maximum vertical displacement of the disturbance point of the turbine foundation under the vertical
(y-direction) loads is 12.07um, which occurs near the frequency of 38.49Hz (greater than 37.5Hz),
which is less than the maximum allowable displacement of Dynamic Code by 20um. The maximum
lateral displacement of the disturbance point under the lateral (z-direction) load is 11.33um, which
occurs near the frequency of 24.95Hz (less than 37.5Hz), and the maximum displacement is less than
30um.
In summary, under the influence of horizontal, vertical, and longitudinal disturbance loads , the
vibration amplitude displacement of key points of steam turbine foundation after reconstruction meets
"in the range of 37.5 ~ 62.5Hz, the maximum vibration liner displacement allowed is 0.02mm; Less
than 37.5Hz, the maximum vibration linear displacement allowed is 0.03 mm", which indicates that
the design of the steam turbine foundation after reconstruction meets the vibration control standard of
Dynamic Code.
3.4.Static analysis of reinforcement scheme

The calculation of the foundation's bearing capacity is carried out according to the 5.3.1 of Dynamic
Code, focusing on the resultant force of the interface between the old and new concrete. The
arrangement of the anchors makes the new and old concrete tightly connected. Separate calculations
are made for temperature analysis and seismic analysis.
3.4.1.Temperature effect.
In the temperature effect analysis, the temperature difference between the internal and external
temperature of some steam turbine beams is 25 degrees, the temperature of the inner surface of the

turbine foundation beam is 55 degrees, the temperature of the outer surface is 30 degrees, other
surfaces such as columns are 20 degrees. Set these faces as heat sources. In addition, the initial
temperature of the overall model is set as 20 degrees. When analyzing heat conduction, as a reference
temperature, the temperature difference of the entire model is obtained, and the thermal stress is
analyzed.
3.4.2.Analysis of earthquake action.

In the ABAQUS analysis of earthquake action, the response spectrum analysis is used. The response
spectrum mode decomposition combination method adopted in this paper is SRSS.
3.4.3.Analysis of static calculation results.

Aiming at the problem of the connection between the new and old concrete of the reinforced
reconstruction structure, a large number of anchor bolts are arranged at the interface, and the new and
old concrete beams are tightly connected. It is shown that 10 steel bars are arranged on the left and
right sides of the new beam, and 14 anchors through the beam are arranged on the upper and lower
surfaces of the new beam separately. The reinforcement element is B31 (3-dimensional first-order
beam element), and all reinforcements are HRB400. In order to reduce the stress of the local tensile
area on the cross section, the interface between the new and old concrete is not disconnected. Three
prestressed steel bars are arranged on the upper part of the new beam. The prestress is applied as a
concentrated force of 30kN at both ends of the steel bar.
The axial combined force Fz of the new beam section, obtained from static calculations under all
load combinations, is negative, which is beneficial for the connection between the new and old
concrete interfaces. The local tensile stress is borne by the steel bars and anchors to ensure that the
interface between the new and old concrete is always in contact.
When calculating the stress of the reinforcing bar, temperature plays a major role. The maximum
stress of the cross-end steel bar is 69.594 MPa, and this value is used as the reference value for
determining the magnitude of the fatigue stress test.
4.Anti-fatigue performance of anchored steel bars

The connection of added reinforcement with the original structure relies on self-locking anchors,
which can achieve bottom expansion. The gap is filled with high-strength inorganic grout. The bottom
anchor and the bonding force of the linear section are used to provide tensile strength. The anchoring
force is reliable, but the research results on its anti-fatigue performance are few. In order to study the
connection performance between the concrete specimen and the self-locking anchor, a low-cycle
cyclic fatigue test of the self-locking anchor-concrete base specimen was designed.
4.1.Experiment design
The concrete base is a 400mm cube, the anchoring reinforcement is an HRB400 reinforcement with a
diameter of 18mm, the external elongation is 390mm, and the embedding depth is 270mm. The upper
end of the test piece is fixed on the steel plate by cross beam channel steel, steel bars and bolts, and a
pad is placed on the lower end. The initial stress of the fatigue test is set to 72 MPa (that is, 20% of the
design stress value of the HRB400 rebar), the maximum stress is taken to be 180 MPa (that is, 50% of
the design stress of the HRB400 rebar design), and the corresponding load sizes are 18.31kN and
45.78kN. The running frequency is 4Hz, and the load sine change cycle is 2 million times.
4.2.Test results
4.2.1.Test phenomenon.
Figure 4 is a comparison diagram of reinforced-concrete test blocks before and after more than 2
million cycles. There are no obvious defects in the concrete test block and the anchor reinforcement,

and no fatigue failure occurs, which indicates that the anchor reinforcement effect is good under the
fatigue stress of 4Hz and 72 ~ 180MPa.
(a) Initial state (b) State after 2 million times

Fig.4Comparison of rebar - concrete test blocks after different cycles
4.2.2.Test curve.
The maximum and minimum displacements vary with the number of cycles and the difference
between the maximum and minimum is shown in Figure 5. The results show that the amplitude of the
load applied during each cycle is basically stable; the difference between the maximum and minimum
displacements has remained unchanged, indicating that after more than 2 million cyclic loading the
anchoring effect between anchoring steel and concrete is good, and the connection is reliable. The
small fluctuations in the test process are systematic errors and are normal.
Fig.5A curve in which the maximum and minimum values of positions vary with the cycle
5.Conclusion
 The key technologies of steam turbine foundation reconstruction are vibration control and
mechanical properties and durability of the new and old interface.
 The finite element method was used to analyze the dynamics of the structure before
reconstruction; the results are compared with the measured results. The calculations are similar to the
measured results. The results show that the calculation method in this paper is reliable.
 Based on this, a scheme of steam turbine foundation was carried out for self-vibration analysis
and harmonious response analysis. The results show that the maximum amplitude of the structure in
the frequency range of 0 ~ 62.5Hz of this reconstruction method meets the vibration regulation
standards of the Dynamic Codes.

 The static calculation analysis shows that the axial combined force of the cross section of the
new beam adopting the reconstruction scheme of prestressed reinforcement is all pressure. The self-
locking anchor is used as the new and old concrete connection. The service life of the self-locking
anchor is the same as the original structure and has good durability. According to the static calculation
structure, the fatigue test of the self-locking anchor-concrete base material is performed. The results
show that the anti-fatigue performance of the the self-locking anchor meets the requirements. The
above two methods ensure the durability of new and old concrete and stable and reliable contact at the
interface.
References
[1] Leng Guihua, Zhu Hongshan. Research on the problem of basic design of steam turbine[J]. China
Water Transport, 2009, 9(05): 116-117.
[2] Zhang Zheng. Analysis and Study on Dynamic Performances of Turbine Generator Foundation[J].
Zhejiang Electric Power, 2008(05): 10-13.
[3] Yu Jun, Liu Jing, Huang Youqiang. Research on techniques for optimizing design of 1 000 MW
turbo-generator foundation[J]. Engineering Journal of Wuhan University, 2009, 42(S1): 474-
477.
[4] Hu Qi, Chen Renpeng, Chen Yunmin, et al. Optimization Design of Foundations of Large Steam
Turbine-Generator Sets[J]. Journal of Power Engineering, 2007, 27(03): 327-331.
[5] Li Zhaojun, Li Zheng, Wang Xicheng, et al. A parallel multi-objective optimization method for
turbine foundation[J]. Journal of Dalian University of Technology, 2015, 55(03): 229-235.
[6] Li Hongxia, Fu Xu, Wang Minjie, et al. Dynamic characteristics analysis and optimization for
stream turbine generator foundation[J]. Chinese Journal of Applied Mechanics, 2018, 35(01):
178-184.
[7] Luo Guoshu, Zhui Rongmin, Shao Xiaoyan. Dynamic Analysis Methods and Standards for
Turbine Generator Foundation[J]. Electric Power Construction, 2010, 31(03): 79-83.
[8] DB42/T 1488-2018 Technical specification for broaching self-locking anchorages for rock and
concrete [S]. Wuhan, 2019.
[9] Code for design of dynamic machine foundation: BG 50040-96[S]. Beijing: China Planning Press,
1997.

Li 2020 IOP Conf. Ser. - Earth Environ. Sci. 585 012101

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PAPER • OPEN ACCESS You may also like

This content was downloaded from IP address 37.111.135.29 on 14/12/2021 at 15:55

Reconstruction design of a turbine generator foundation

Ming Li1, Junjie Hu1*, Zhiyong Zhou2 and Mingxiang Chen3,4

(a) Plan view

(b) Sectional view of 1/Ⅱ axis

2.3.1.Dynamic characteristics of the structure after reconstruction.

2.3.2.Connection of new and old concrete.

Fig.2 Schematic diagram of new and old structure connection

3.Finite element calculation

Fig.3The finite element model of the foundation before reconstruction

3.2.Analysis of foundation natural vibration before and after reconstruction

3.3.Analysis of basic harmonic response after reconstruction

3.4.Static analysis of reinforcement scheme

3.4.2.Analysis of earthquake action.

3.4.3.Analysis of static calculation results.

4.Anti-fatigue performance of anchored steel bars

(a) Initial state (b) State after 2 million times

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