5.

04

FOUNDATION, RIGID AND RESILIENT

MOUNTED GEN-SET

Introduction Concrete foundation block

The generator set (gen-set) foundation has the General requirements
dual functions of supporting the gen-set and The foundation for the gen-set with auxiliaries to
preventing, or minimising, the propagation of be designed as a concrete block carried out in re-
structural borne vibrations. inforced concrete.
In addition to static forces, the foundation must be The concrete block must be designed isolated
designed to resist the vibrational forces causing from other foundations and building construc-
oscillating flexural stresses, and the forces due to tions, in order to avoid transfer of vibrations to
differential thermal expansion of gen-set and the these.
foundation. The foundation must also be capable The design and size of the foundation block must
of withstanding the effects of misfiring, occasion- be done so that the block is able to transmit all
al short circuit and faulty synchronisation torque loads to the supporting ground.
forces without detriment.
The gen-set foundation consists of a steel struc- The following loads to be taken into considera-
ture, on which the gen-set is fitted by means of tion:
foundation bolts, and a concrete structure. The • Static load
steel structure is fixed to the concrete structure by • Dynamic loads
anchor bolts. The gen-set may be rigid or resilient • Thermal expansions
mounted on the concrete structure.
The foundation block must satisfy the following
The concrete foundation structure differ some- fundamental design criteria.
what, depending on the soil supporting capacity,
in two main designs: See also BSI CP 2012: Part 1:1974 Code of
Practice for Foundations for machinery.
a) Soil with a high supporting capacity, i.e. solid
rock.
If the concrete foundation is well tied by anchor Static criteria:
bolts to the solid rock, the requirements for the 1) Soil supporting capacity.
main dimensions and weight of the concrete ( W + Wf ) ( 9, 81 )-
k--------------------------------------------
= < Ps
foundation is limited. L×B

b) Soil with a low supporting capacity, i.e. blast where:

rock, sand, gravel and clay. k = Safety factor, normally = 2
The requirements for the concrete foundation W = Weight of generating set (tons)
design, when related to main dimensions and Wf = Weight of concrete block (tons)
weight, is more stringent as the foundation has to L = Length of concrete block (m)
be designed as a floating raft (concrete block). B = Width of concrete block (m)
Ps = Soil supporting capacity (kN/m2)
The designing requirements below are specially See table 1.
related to item b).
The transfer surface (L x B) between the con-
For static forces (weights) see chapter 5.05. crete block and the supporting ground must
For dynamic forces and moments see chap. 5.02. be so large that settlements causing damages
to the installed gen-set with equipment do not
occur. Especially, it is important to avoid dif-
Note: The main contractor (turn-key operator) are
ferential settlements. Maximum acceptable
responsible for the concrete foundation design.
settlement is normally 5 mm.

Power Plant Application, B-engine, Gas Foundation, rigid and resilient mounted gen-set
P/B/DGO 0806 Page 1 : 11
5.04
2) Center of gravity.
E1 = Gravity between W + Wf and W shall
not exceed 0,05 x L
E2 = Gravity between Wf and W shall not
exceed 0,05 x B
2a) The center of gravity for the gen-set and the
concrete block to be located on the same
vertical axis.
): For Z < F / 2 : L = 2 (F - Z)
For Z > F / 2 : L = 2 Z
F = Length of gen-set foundation frame/
foundation plate.
Z = Longitudinal position of gen-set
gravity center
2b) In addition, due to the following reasons, the
center of gravity for the total system (gen-set
and concrete block) should be located as low
as possible.
• Stability of the foundation for occasional
short circuit condition
• Settlement of the supporting ground caused
by gen-set vibrations
Fig. 1 Concrete block design.
Page 2 : 11 P/B/DGO 0806
W ( A + D + H ) + Wf × H ⁄ 2
Y = --------------------------------------------------------------------
W + Wf
For rigid mounting: Y≤H
For resilient mounting: Y ≤ 1,1 H
Y = Vertical position of gravity center for the
total system (gen-set and concrete block)
H = Concrete block height
A + D = Vertical pos.of gen-set gravity center
3) Stability of foundation for occasional short
circuit condition
3 × T kn
W + Wf > ----------------- (tons)
B
for a short circuit torque of 15 Tkn
Tkn = Nominal engine torque (kNm)
B = Width of concrete block (m)
Due to the weight of the engines, the above
requirement for stability is not decisive for the
concrete block design.
B 1004/07
Power Plant Application, B-engine, Gas
5.04

Fig. 2 Amplitude limits of foundation block (Extract of BSI CP 2012, Part 1: 1974).
Dynamic criteria:
4) Resonance between the excitation frequencies
of the gen-set (1/2, 1-order etc.) and the natural
frequencies of the concrete block must not occur.
5) The maximum concrete block amplitude of vi-
brations up to 20 Hz must normally not exceed
0,2 mm. See fig. 2.
The allowed amplitude, however, to be based on
soil mechanical researches for the actual project
L 783/57
Concrete block designing
The designing of the concrete block is to be based
on items 1-5 above, the actual gen-set weight and
steel foundation dimensions, taking into consider-
ation the data for dynamic forces and moments in
chapter 5.02.
However, for estimation of the block weight and
the main dimensions, the calculation formulas
item 6 or 7 below may be used.
For practical reasons, with the intention to reduce
the concrete block height (H), we recommend a
concrete block width (B) as shown in fig. 1.

Power Plant Application, B-engine, Gas

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Note: The gen-set may be rigid or resilient Materials

mounted on the concrete block. The foundation block must be constructed in rein-
A resilient mounting is recommended, as this forced concrete with cube strength within 28 days
design transfer the least vibrations to the soil and after mixing: Min. 35 N/mm2.
other constructions. Resilient mounting is specially In order to minimize the temperature stress in the
recommended when facing difficult soil conditions. concrete block during the hardening process, it is
The installation time and cost for mounting of a recommended to use a retarder in the concrete, or
resilient gen-set at site are lower than for a rigid
water cooling.
mounted gen-set.
The reinforcement steel to be “cam steel” with a
6) For resilient gen-set mounting:Wf/W ≥ 1,5
nominal floating limit of min. 400 N/mm2.
7) For rigid gen-set mounting: Wf/W ≥ 2,5
Mild steel reinforcing bars shall always be
hooked. The concrete block shall be reinforced in
An interconnection of the concrete blocks at multi
all three directions. The approximate reinforce-
engine plants, is in general not recommended, and
ment can be estimated to 50-70 kp/m3 of con-
particularly not for rigid mounted gen-sets
crete.
equipped with a generator bearing of the roller
bearing type.
In order to fasten anchor bolts etc.to the concrete
block, expanding concrete added epoxy with a
Soil properties strength as for the rest of the concrete, must be
The concrete block can be placed directly on the used.
natural soil if this has sufficient supporting capac-
ity, as for rock, blasted (crushed) rock, firm sand The holes for anchor bolts etc. in the concrete
and gravel. block should be of conical shape, with the small-
est diameter at the top.
Note: The soil supporting capacity must be deter-
mined by soil investigations and the settlement to
be calculated.
Pile foundations; end-bearing- or friction piles
must be used in cases where there is need to make
significant change in frequency in one or more
modes of vibration or where piles are required to
support the loads.

Average Flexible pipe

Supposed
Type of soil supporting connections
settlement mm
capacity kN/m2 necessary *)
Rock; granite, gneiss 4000 0 No
Rock; limestone, sandstone 2000 0 No
Blasted rock, consolidated 250 Yes
Sand and gravel; hard packed 400 Yes
Must be based on soil
Sand and gravel; loosely packed 250 investigations Yes
Clay; not sensitive 150 Yes
Table 1. Soil supporting capacity

*) For rigid mounted gen-set.

(Resilient mounted gen-sets are always to be equipped with flexible pipe connections.)

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Calculation example for estimating of

concrete block dimensions 167, 1
H = --------------------------------------------- = 1,91 m
11, 2 × 3, 25 × 2, 4
Design criteria:
• Engine type B35:40V-16AG
• Engine power: Re. item 2b)
E = 6995 kW at n = 750 RPM. If possible Y ≤ 1,1 H
• Resilient mounting ): Ymax = 1,1 x 1,9 = 2,1 m
• Single gen-set installation
• Soil; clay with a supporting capacity: Mb = 0
Ps = 150 kN/m2 ): W(A+D+H) + Wf x H/2 - (W + Wf) Y = 0
• Gen-set weight, wet
(engine and actual generator make): W × ( A + D + H ) + Wf × H ⁄ 2
W = 111,4 tons ): Y = -------------------------------------------------------------------------
W + Wf
-
• Width of steel foundation plate for the actual , 4 × ( 2, 075 + 1, 9 ) + 167, 1 × ( 1, 9 ) ⁄ 2
generator make: = 111
---------------------------------------------------------------------------------------------------------
278, 5
C = 2,34 m. See fig. 1.
• Length of steel foundation plate: = 2,09 m
F = 9,89 m
• Position of gen-set gravity center for the ): The requirement Y ≤ 1,1 H is fulfilled.
actual generator make:
Z = 4,31 m. ( W + Wf ) × 9, 81 278, 5 × 9, 81
Psactual= ------------------------------------------- = ---------------------------------
A + D = 2,05 + 0,025 = 2,075 m. See fig. 1. B×L 36, 4 × 3, 25
• Concrete specific gravity including
reinforcement steel presumed: = 23,1 kN/m2
q = 2,4 (tons/m3)
Re. item 3)
3 × Tkn
): Re. item 6) W + Wf > ------------------- (tons)
B
Wf = 1,5 x W = 1,5 x 111,4 = 167,1 tons.
): W + Wf = 111,4 + 167,1 = 278,5 tons. Tkn = 9,55 x E/n (kNm)
= 9,55 x 6995/750 = 38,136 kNm
Re. item 1) 3 × Tkn 3 × 38, 136
): ------------------- = --------------------------- = 35,2 (tons)
k × ( W + Wf ) × 9, 81 B 3, 25
L x B = ----------------------------------------------------
Ps
2 × 278, 5 × 9, 81 As (W + Wf) = 278,5 tons,
= ------------------------------------------ = 36,4 m2
150 the requirements for stability related to occasional
Re item 2a) short circuit condition is fulfilled.
For Z < F/2 : L = 2 (F - Z)
= 2 (9,89 - 4,31) = 11,2 m.
Conclusion: Wf = 167,1 tons and
Wf/W = 1,67
Note: The weight of possible piping and cable
trenches are not taken into consideration.
L = 11,2 m.
B = 3,25 m.
L × B 36, 4 H = 1,91 m.
): B = ------------- = ------------ = 3,25 m ): B > C
L 11, 2 Y = 2,09 m.
Further: Ps = 23,1 kN/m2
Wf
Wf = L x B x H x q ): H = ----------------------- ( m )
L×B×q
and for q = 2,4 (tons/m3) Note: The dynamic criteria to be checked.

Power Plant Application, B-engine, Gas

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5.04

Rigid mounting
Rigid mounted gen-set
3. The anchor bolts are wrapped with paper or
The foundation frame for standard Bergen En- tape in order to prevent sticking to the con-
gines rigid mounted gen-set is shown in fig. 4. crete.

Mounting instructions 4. After alignment of the foundation frame by

use of spacers under the adjusting screws,
See drawing L 761/06 “Foundation frame for
concrete is poured in to a height of approx.
rigid mounting”.
half of the total height as shown.
1. Well-reinforced concrete is required for the
5. When the concrete has hardened, the anchor
foundation.
bolts are “unlocked” and the nuts, item no. 2,
are loosened.
2. Anchor bolts and adjusting screws are fitted
The foundation frame is aligned exactly by
in the foundation frame as shown.
the adjusting screws.
The anchor bolts are “locked” in position by
means of the foundation bolts. See item 1.
6. Then concrete is poured in again to finish the
casting of the foundation.

Fig. 4 Foundation for rigid mounting. Cast-in frame. L 761/06

Power Plant Application, B-engine, Gas

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Chockfast system guidelines for

designers. (rigid mounted gen-sets)

1. The CHOCKFAST system may be used for
rigid mounting of gen-sets, provided atten-
tion is paid to the design parameters regard-
ing chock loading and chock temperature
discussed below *)
2. CHOCKFAST is a compression load bearing
material. Because of its low viscosity and
low surface tension, liquid CHOCKFAST
will precisely conform to any reasonable
irregularity in the chocking interface, and fill
completely the designed chocking space, in
individual chocks or complete grout as
required.
3. Two grades are used, CHOCKFAST OR-
ANGE and CHOCKFAST GREY.
For foundation of gen-sets only CHOCK-
FAST ORANGE should be used. *)
This because, it offers high physical proper-
ties particularly at elevated temperatures, it
gives precise alignment and can stand a con-
tinuous chock temperature that may exceed
52 °C (125 °F) but not 70 °C (160 °F).
6. The quantity of resin required is the volume
of the cock plus approximately 10%.
Chockfast Orange is packaged in predeter-
mined units as follows:
3,4 kgs (7,5 lbs) and 6,8 kgs (15 lbs)
1800 cc (110 cin) and 3600 cc (220 cin)
7. Critical alignment applications of CHOCK-
FAST ORANGE should be controlled in
accordance with the following instructions:
a.) Maximum deadweight loading 7 kg/cm2
(100 psi).
b.) Maximum total loading, deadweight plus
holding-down bolt tension 35 kg/cm2
(500 psi).
c.) Hold-down bolt torque should be calcu-
lated and specified by the engineer and per-
manent locking is required. (Bolt tension
should exceed 4,5 times deadweight but not
exceed requirement in pt. b. above).

4. A chock thickness of about 25 mm (1”) is d.) Continuous chock temperature must not
convenient and economical. The chock thick- exceed 70 °C (16 °F).
ness should be not less than 10 mm (½”) and
not exceed 40 mm (1¾”). Please consult the
actual maker for more specific advice.

5. The total chock area should be sufficient to

keep the specific loading within the recom-
mended values. The individual chocks are
arranged similarly to conventional iron ones
and no chock should be less than
130 cm2 (20 in2) in area. Removal of grease,
oil, mill scale and/or rust or paint is the only
preparation usually necessary for machinery
bearers. Bearing surfaces should be cleaned
if covered by other than a thin coat of inor-
ganic zinc or similar.
*) Synthetic resin spacers of other make may be
used provided the qualities are identical to
CHOCKFAST ORANGE. The actual make have
to be approved by the classification society.

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Resiliently mounted gen-set, Installation of common steel foundation (base

Mounting instruction, instr. B978/39. frame)
The installation has to be in accordance with Dwg "Flexible mounting", not shown.
Rolls-Royce Marine AS drawing "Foundation for
flexible mounting", see last page. The common steel foundation is delivered to site
All item number refers to this drawing. separate from the Bergen B-gas engine and the
Prior to casting the concrete foundation block in generator. And it should be placed on its concrete
the power house, the engine concrete foundation foundation in the engine room by suitable gear.
has to be planned and designed in detail. (Depending on local conditions, it is possible to
mount the engine and generator on the common
steel foundation outside the engine room. Subse-
Installation of foundation plates
quently the gen-set must be placed on the founda-
The concrete foundation block must have neces-
tion plates in the concrete foundation as one unit.)
sary grooves for foundation plates with attached
anchor bolts (foundation bolts). The foundation
The circular spacers, item no. 4, should be fitted
plates, item no. 1, 2, 3 and 4, with attached anchor
to the flexible rubber elements, item no. 5, by al-
bolts (foundation bolts), item no. 7, and adjusting
len screws, item no. 2. Tightening torque is 10
screws, item no. 5, are to be placed in the
Nm (1,0 kpm). Flexible elements and shims (shim
grooves. The location of the plates must be
if necessary) must be fitted under the common
checked lengthways and sideways with respect to
steel foundation by allen screws, item no. 1. Shim
the arranged exhaust piping in the power house.
on top of flexible element. Screw thread protec-
tors should first be removed from the holes in the
Plates for adjusting screws, item no. 6, must be
bottom flanges. Then the flexible elements should
placed under the adjusting screws. The height of
be mounted under the common steel foundation.
the foundation plates, can then be adjusted by the
Tightening torque is 30 Nm. (3,0 kpm)
adjusting screws, item no. 5, grease the screws
first. The anchor bolts (foundation bolts), are
The steel foundation must be lowered carefully
wrapped with paper, taped or greased from head
down. If the underside of the flexible elements
to screw thread in order to ensure that only the
(spacers) and foundation plates are out of paral-
bolt heads will be casted.
lelism, the flexible elements can absorb this.
The foundation plates must finally be aligned in
The spacers are to be interval welded to the foun-
exact position by the help of a levelling instru-
dation plates. The flexible elements must be pro-
ment, - and then casted. Expanding mortar has to
tected against welding sparks, and they must not
be used, with compression strength not less than
be overheated during welding.
for the concrete foundation block. A vibrator is
used for equal distribution of the mortar in the
grooves. Minimum hardening time for the con-
crete is 7 days. However, the anchor bolts (foun-
dation bolts) should not be tightened before the
concrete has hardened for 2 weeks.

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Installation of engine, generator and coupling
Before installing engine and generator to the
common steel foundation, the steel foundation
must be supported by steel beams on the founda-
tion plates in order to avoid unequal force distri-
bution to the flexible elements.
Lifting of the engine according to Rolls-Royce
Marine AS, Engines - Bergen lifting instruction.
Only original lifting equipment must be used.
Transport supports under engine to be removed
from engine block by loosen the bolts.
*) If engine and oil sump are transported
separately, the oil sump must now be mounted
on engine.
Note: During this operation, dust or other particles
must not enter the crankcase or the oil sump!
Indoor operation is preferable. If not, necessary
protection against wind, dust, rain etc. must be
taken outdoors.
• Remove the transport covers on top of the oil
sump, take care of the gasket (O-ring).
• Remove the transport covers under the
engine block.
• Locate the oil sump under the engine.
• Remove the crankcase covers to get access to
the crank case. Avoid dirt on the covers.
• The oil sump can be lifted carefully by a
forklift truck, or a threaded bolt in each cor-
ner of the sump can be utilized to lift the
sump. Alternatively the engine can be low-
ered carefully by a crane. Avoid transferring
the weight of the engine from the crane to the
oil sump.
• The holes in the oil sump must be aligned
with the holes in the engine block. The corner
bolts to be attached loose first, then the bolts
in the middle. There must not be any particles
left on the oil sump top surface or at the
engine block bottom surface.
Power Plant Application, B-engine, Gas
P/B/DGO 0806
• Nuts with washers to be mounted on the
engine block side. Tightening torque 200
Nm. (20 kpm). The screws must be tightened
from the middle of the engine and alternately
out towards the ends.
• Mount the cable from the level switch in oil
sump, up inside the crank case on the middle
of the engine A-side, and out through a hole
in the engine block.
• Mount the oblique steel strainer plates in the
oil sump. Then mount the horizontal steel
strainer plates. Mount the crankcase covers.
Mounting of engine:
Dwg "Mounting of engine foundation",
not shown.
Clean the surfaces on common steel foundation
and engine block, facing each other. Engine must
be lowered carefully on to the common steel
foundation.
The holes in the engine block must be aligned
with the holes in the common steel foundation by
using guiding bolts diagonally in engine block.
Alignment must be checked.
Engine should be mounted to the common steel
foundation with bolts (screws), item no. 1, and
self-locking nuts, item no. 2.
Nuts to be mounted on the engine block side.
Tightening torque is 1250 Nm. (125 kpm)
Mounting of generator:
Dwg "Alternator arrangement", not shown.
If the flexible coupling is mounted on the genera-
tor, it must be dismantled. The coupling hub can
remain on generator shaft.
Before installing the generator on the common
steel foundation, the bottom surfaces on the gen-
erator supports must be cleaned. Particles and
sharp edges or machining burrs, if any, must be
removed. Place one 10 mm thick spacer, item no.
2, under each generator support and then check
generator hub to flywheel for proper alignment.
Page 9 : 11
5.04

Generator should then be lowered carefully onto

the common steel foundation. The holes in the Flywheel shield must be mounted on the common
generator supports must be aligned with the holes steel foundation.
in the common steel foundation by using guide
pins diagonally. Check of crankshaft deflection
Check the crankshaft deflection according to
Generator should be mounted to the common
separate procedure. If the deflection is outside the
steel foundation with bolts (screws), item no. 3,
tolerances given in the instructions, please contact
and self locking nuts, item no. 4.
Rolls-Royce Marine AS, Engines - Bergen.
Nuts to be mounted on the generator support side.
Tightening torque is 2600 Nm. (260 kpm)
Pipes, cables, service platform and floor support-
ing brackets must not be installed closer to the
Mounting of coupling
generating set than 40 mm.
Dwg "Flexible coupling arrangement",
not shown. The high voltage cables to the generator must be
installed with a large bend radius in order to en-
Normally the coupling hub is already heat sure a flexible connection.
shrinked to the generator shaft drive end. If not,
this must be done on site. (Heating temperature In general, there should be a minimum distance of
approx. 130 °C above ambient temperature.) 40 mm between the generating set and any fixed
installations.
Alignment must be checked carefully before con-
necting the flexible coupling to the flywheel on
engine. Check the clearance in the generators
thrust bearing, see generator instructions.

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Fig. 6 Foundation for flexible mounting B 962/44

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