Foundations for industrial machines

FOUNDATIONS FOR INDUSTRIAL MACHINES,

Handbook for Practising Engineers

FOUNDATIONS

FOR

INDUSTRIAL MACHINES

~ Rotary Machines

~ Reciprocating Machines

~ Impact Machines

~ Vibration Isolation System

Handbook for Practising Engineers

K.G. BHATIA

DrK G Bhatia

Foundations for Industrial Machines

First Edition 2008

While every effort is made to publish error-free information in this handbook, the author makes no

representations or warranties of any kind, express or implied, about the completeness, accuracy,

reliability, of the information, guidelines, methodologies or related graphics contained in the

handbook, for any purpose. Any reliance placed on such information is therefore strictly at one's

own risk, unless that information is duly consulted and verified with the author, and subsequently

confirmed in writing. In no event will the author be liable for any loss or damage including without

limitation, indirect or consequential loss or damage, or any loss or 'damage whatsoever arising from

loss of data or profits, arising out of, or in connection with, the use of this handbook.

Copyright © 2008 by D-CAD Publishers

All rights reserved. This material may not be published, broadcast, rewritten or redistributed in

whole or part without the express written permission of the author. The book may contain

copyrighted material, trademarks and other proprietary information, including, but not limited to,

text, graphics, and users shall not publish and distribute such material (in whole or in part) and/or

to incorporate it in other works in any form, media or technology now known or hereafter

developed.

ISBN 978-81-906032-0-1

www.machinefoundation.com

Published by D-CAD Publishers, 158; Vardhman Grand Plaza, Mangalam Place, Sector 3, Rohini,

New Delhi I 10085

Printed through Bharat Law House, New Delhi

In the loving memory of

My parents

Late Shri Kartar Chand Bhatia & Late Smt. Leelawanti Bhatia

who, in spite of sufferings on account of partition, struggled hard

and devoted their active life in upbringing me and my siblings

In expression of my gratitude to

My brother

Shri MG Bhatia, who sacrificed his career

in support of my studies

Dedicated to

My wife

Manjufor her constant encouragement and support

throughout the tenure of writing of this handbook

My deep Sense o/Gratitude to:

Organisations of Excellencefor Wok Experience

Bharat Heavy Electricals Limited

New Delhi

Engineers India Limited

New Delhi

Institutions of Excellence in Learning

Indian Institute o/Technology

New Delhi, India

International Institute o/Seismology

& Earthquake Engineering

Tokyo, Japan

Indian Institute o/Technology

Roorkee, India

Institute o/Technology

BHU, Varanasi, India

About the Handbook

The author has been engaged in designing, testing and review of machine

foundations for various industrial projects viz. Petrochemicals, Refineries, Power

plants etc. for the last about three decades.

The handbook is written primarily for practising engineers as well as for students

at Post Graduate level. Handbook shares author's long experience on the subject

and focuses on the improvements needed in the design process with the sole

objective of making practising engineers physically understand and feel the

dynamics of machine foundation system.

The handbook covers basic fundamentals necessary for understanding and

evaluating dynamic response of machine foundation system. The author has also

conducted extensive tests on machine foundation models as well as on prototypes.

For over two decades, the author has been associated with Failure Analysis

Studies on various types of machines.

Observations from all the above studies suggest need for improvement in the

design o/foundationsfor better performance of machines. These include:

a) More comprehensive evaluation of Site Soil Data

b) Better understanding of Machine Data and its use infoundation design

c) Improvement in the Design Philosophy that suggests

i) Improvement in the Modeling Technique

ii) Improvement in Analysis Technique

x

iii) Improvement in Structural Design process, and

iv) Improvement in Construction Technology

It is the author's concerned observation that in most of the cases, due recognition

to Machine, Foundation and Soil data is lacking. More often than not, machine

data as well as soil data is treated as black box and used in the design without its

proper understanding. A better interaction between foundation designer and

machine manufacturer would definitely improve the foundation performance and

thereby machine performance. Over the years, author has observed that such

interactions are lacking. It is the author's concerned opinion that such an

interaction is not only desirable but essential too.

It is anticipated that this handbook shall serve as a Reference Book. The author

is confident that it shall bridge the knowledge gap and shall be beneficial to the

practising engineers, students, academicians/researchers as well to the industry.

The text is divided in to 5 Parts.

Part I takes care of Theoretica( Aspects

• An overview providing basic familiarization with the subject is covered

in Chapter 1.

• Necessary understanding of Theory of Vibration with specific application

to machine foundation design is included in Chapter 2 and Chapter 3.

Chapter 4 caters to Basic Theory of Vibration Isolation.

Part II caters to Design Parameters

• Chapter 5 provides reasonable coverage to Soil Dynamics and

evaluation of Design Soil Parameters as applied to Machine Foundation

Design.

• Desired emphasis has been given to Design Machine Parameters.

Translation of Machine Data to Design Data is given in Chapter 6.

• Chapter 7 is attributed to Design Foundation Parameters. It covers all

those aspects related to foundation that play vital role in computing

Dynamic Response.

Xl

Part III deals with design of Foundations for Real Life Machines.

• Chapter 8 is devoted to Modeling and analysis including Finite Element

Analysis. All possible aspects of modeling related to design of foundation

have adequately been covered.

.• Chapter 9, 10 & 11 cover Design of Foundation for real life Rotary

Machines, Reciprocating Machines and Impact Type Machines

respectively.

Part IV caters to Design of Foundations with Vibration Isolation System

• A good amount of emphasis is given to Vibration Isolation of the

Foundations. Design of Foundations with Isolation Devices is covered in

Chapter 12.

Part V caters to Construction Aspects and Case Studies related to machine

foundation

• Construction Aspects are covered in Chapter 13.

• Case studies and observations are given in Chapter 14

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CONTENTS

About the Handbook ix

1 Machines and Foundations 1-3

1.1 An Overview 1-3

1.2 Design Philosophy 1-6

1.3 Machine Foundation System 1-7

1.4 Machines 1-8

1.5 Foundation 1-8

1.5.1 Block Foundation 1-9

1.5.2 Frame Foundation 1-9

1.5.3 Tuning of the Foundation 1-10

1.5.4 Foundation Material 1-10

1.5.5 Foundation Analysis and Design 1-10

XIV

1.6 Soil

1.7 Vibration Isolation

1.8 Field Performance and Feedback

PART-I

THEORY OF VIBRATION

I-II

1-12

1-12

BASIC UNDERSTANDING WITH SPECIFIC APPLICATION

TO

MACHINE FOUNDATION DESIGN

2 Single Degree of Freedom System

2.1 Free Vibration

2.1.1 Undamped System - SDOF Spring Mass System

2.1.2 Damped System

2.2 Forced Vibration

2.2.1 Undamped System - Dynamic Force Externally Applied

2.2.2 Damped System - Dynamic Force Externally Applied

2.2.3 Damped System - Dynamic Force Internally Generated

2.2.4 Damped System - Dynamic Excitation Applied At Base

2.2.5 Undamped System - Subjected to Impact Loads

2.2.6 Undamped System - Subjected to Impulsive Loads

Example Problems

3 Multi-Degree of Freedom Systems

3.1 Two Degree of Freedom System - Free Vibration - Undamped

3.1.1 Two Spring Mass System- Linear Springs

3.1.2 A Rigid Block supported by Vertical and Translational Springs

3.1.3 A Rigid Block Supported by Vertical and Rotational Springs

2-3

2-4

2-4

2-28

2-37

2-38

2-46

2-55

2-59

2-63

2-65

2-71

3-3

3-4

3-5

3-11

3-14