Designing a Machine Foundation for a 10.

89 MW Diesel
Generator

Machine Design I

Submitted to:

Engr. Rosello Lyndon H. Roble, PME

Submitted by:

Rickle Vincent B. Pilongo

Mil-rey Enriquez

September 2010
 Designing a Machine Foundation for a 10.89 MW Diesel Generator

Generator Specifications:

Nameplate MAN B&W

Engine Type 18V40/45
Provenance Germany
Rated Power 10.89MW
Suitable Fuel 180CST/50C
Already Run Hours 40,000h
Number of cylinder 18
Rated Speed 600
Cylinder bore/Piston 400/450
Fuel Consumption  200+5%
G/KW.H (Under ISO Condition, Lev=42700kj/kg
Engine Dimensions( mm) 10,150×4,750×3,300(mm)
Engine Weight 128,000Kg

Solution:
1. Weight of the Machine Foundation, WF

WF = e × We × √N

Where:
WF = weight of machine foundation, kg
We = weight of the engine, kg
e = empirical coefficient, [Table 2.4, 2.3(4) PSME Code]
N = engine speed, rpm
Given:

We = 132 tons; N = 600 rpm; e = 0.11

Substituting,
WF = 0.11 × 128 × √600
WF = 344 888 kg

2. Volume of the Machine Foundation, V F

VF = WF / 2406
density of concrete, ρ = 2406 kg/m³
substituting,
VF = 344 888 / 2406
VF = 143. 345 m³
3. Lower width of the machine foundation, b
b = N (WF + We) / Sb × L
where:
Safe Soil Bearing Capacity = 78 – 98 tons/m²
N, factor of safety, usually = 2
WF = 344.888 tons
We = 128 tons
Safe Soil Bearing Capacity = 78 – 98 tons/m²
clearance, c = 0.3 m
machine bedplate length, L = engine length + 2c
= [10.15 + 2(0.3)]
L = 10.75 m
substituting,
b = 2 × (344.888 + 128) / 88 × 10.75
b = 1.0 m
finding:
a = bedplate width of machine, m
a = w + 2c
a = 4.75 + 2(0.3)
a = 5.35 m
since,
b<a
therefore let,
b = a = 5.35 m
which is a rectangular machine foundation

4. Depth of machine foundation, h

h = 2 VF / ( a + b ) × L
h = 2 × 143.55 / (5.35 + 5.35) × 10.75
h = 2.496 ≈ 2.5 m
5. Quantity of sand and gravel in 143. 345 m³ concrete foundation with 1 : 2 : 4
concrete mixture:
given:
Material Relative Density Density (kg/m³)
Cement 3.10 1428
Sand 2.64 1680
Gravel 2.50 1525
Using:
26 liters of water per bag of cement; assuming one bag of cement as 0.028 m³ per
bag of cement, loose volume
Let:
Vc, Vs, Vg, Vw = compact volume of cement, sand, gravel and water
respectively
Then,
Vc = 1428 (0.028) (1) / 3.10 (1000) = 0.0129 m³ / batch
Vs = 1680 (0.028) (2) / 2.64 (1000) = 0.0356 m³ / batch
Vg = 1525 (0.028) (4) / 2.50 (1000) = 0.0683 m³ / batch
Vw = 26 / 1000 = 0.0260 m³ / batch
Vtotal = 0.1428 m³ / batch

Total no. of batches = 143.345 / 0.1428 = 1003.82 batches

Volume of Sand required = 1003.82 (0.028) (2)

Vs = 56.214 m³
Volume of Gravel required = 1003.82 (0.028) (4)
Vg = 112.428 m³
Volume of Cement required = 1003.82 (0.028)
Vc = 28.1 bags
Volume of Water required = 28.1 × 26
Vw = 730.8 liters
 6. Steel Bar reinforcements requirement (to avoid cracking):
Weight of steel bars (½% - 1% total weight) = ¾ %
Using ½ in. steel bars with a weight of = 0.668 lb/ft
Therefore,
Weight of steel bar = (0.0075) (344 888)
WSB = 2586.66 kg. = 5702.6 lb
Length of steel bar = 5702.6 (0.668)
LSB = 3809.34 ft.

Recommendations
1. Foundation should be isolated from floor slabs or building footings by at least 25
mm around its perimeter to eliminate transmission of vibration.

2. The machine should not be placed on the foundation until seven (7) days have
elapsed and operated until seven (7) days have passed

3. Anchor Bolts should be imbedded in the concrete at least 30 times the bolt
diameter.

4. Foundation bolts specified size should be used and surrounded by a pipe sleeve
with an inside diameter of at least 3 times the diameter of the anchor bolt and a
length 18 times the diameter of the bolt. No foundations shall be less than 18 mm
diameter.

5. Machine should be leveled by driving wedges between the machines base and
concrete foundation and with the aid of a spirit level. Grout all spaces under the
machine bed with a thin mixture of one part cement and one part sand. The level
wedges should be removed after the grout thoroughly set and fill wedges holes
with grout.

Reference:

 Prime Review Center Mechanical Engineering Reference Manual:

Machine Foundations