PAHARPUR COOLING TOWERS LIMITED

CALCUTTA – 700 027

PCT ORDER NO. 13-2I-0017A&B

CUSTOMER: NTPC LIMITED, UTTAR PRADESH.
PROJECT: CT FOR 1X500MW VINDHYACHAL SUPER THERMAL POWER PROJECT (STAGE-V)
AT VINDHYANAGAR, DIST. - SINGRAULI, MADHYA PRADESH.
MODEL: 84848-14V-16B

FAN VIBRATION ANALYSIS

FOR
COOLING TOWER

DOCUMENT NO. 13-2I-0017A&B/DGN/06 ( REV. 0 )

( PAGES 01 TO 18 )
NTPC DOC NO 2260-135-PVC-U-009
REV 00
DT 03.09.14

Approved by PE CIV-DEEPAK GOEL

Rev. Date Description Prepd. By Digitally

Chkd. signed
By Appd. By
Signature Not Verified
by Tapas Dey
Date: 2014.09.16
0 28/08/14 FIRST ISSUE A.R.C 18:23:19
SRIST RB
Reason: CAT IV
Location:
NTPCEOC
PCT ORDER NO. 13-2I-0017A&B
CUSTOMER: NTPC LIMITED, UTTAR PRADESH.
PROJECT: CT FOR 1X500MW VINDHYACHAL SUPER THERMAL POWER PROJECT (STAGE-V)
AT VINDHYANAGAR, DIST. - SINGRAULI, MADHYA PRADESH.
MODEL: 84848-14V-16B

CONTENTS

DESCRIPTION PAGE NOS

1. Introduction 01

2. Methodology 01

3. Analysis details 02 - 06

4. Model in ANSYS software 07 - 08

5. Boundary condition 08 - 10

6. Results 10

7. Discussion 10

8. Tabulation of natural frequencies 11 - 15

9. Tabulation of displacement 16 - 18
 Page No. : 1
PCT ORDER NO. 13-2I-0017A
CUSTOMER: NTPC LIMITED, UTTAR PRADESH.
PROJECT: CT FOR 1X500MW VINDHYACHAL SUPER THERMAL POWER PROJECT (STAGE-V)
AT VINDHYANAGAR, DIST. - SINGRAULI, MADHYA PRADESH.
MODEL: 84848-14V-16B

FAN VIBRATION ANALYSIS OF IDCT FOR

1.0 INTRODUCTION
The project details are as below.
CLIENT : NTPC LIMITED, UTTAR PRADESH.
PLANT : 1X500MW VINDHYACHAL STPP (STAGE-V)
AT VINDHYANAGAR, DIST. - SINGRAULI, MADHYA PRADESH.
STRUCTURE : Induced Draft Cooling Tower (IDCT)
SUPPLIER : Paharpur Cooling Towers Ltd. (PCTL), Kolkata
PROJECT : Fan Vibration Analysis of IDCT
REFERENCES : PCTL Dwgs. 13-2I-0017AB/G/01, 13-2I-0017AB/G/02, 13-2I-0017AB/G/05,
13-2I-0017AB/G/06, 13-2I-0017AB/C/11 & 13-2I-0017AB/C/21
REPORT : Contains the results, findings and recommendation of the computerized
dynamic analysis estimating the vibration levels of the IDCT structure
due to the motions of mechanical equipment.

2.0 METHODOLOGY
The analytical model of a representative cell of the IDCT has been developed considering the exten
of the structure upto which the vibration effect is present, thereby, introducing fixed support at the
level below the fandeck level. The analysis is carried out using Static, Natural Frequencies / Mode
Shapes and Frequency Domain response options of the ANSYS software which is technica
based on internationally accepted software.

The model has been analyzed for static loads due to self-weight, weight of mechanical equipment a
live load on fandeck. The dynamic analysis is carried out for the steady state response of the IDCT
model subjected to harmonically loads due to the motions of mechanical equipmen
The dynamic loads are generated during operations by the moving components of Fan Assembly,
Gear Reducer, Motor, Drive Shaft comprising the mechanical equipment and are applied at their
relevant supporting points on the analytical model. The analysis is carried out for one cell i
operational condition, for the following load cases :
a) Static Analysis for Dead Load (DL), Machine Load (ML) and Live Load (LL) on fandec
b) Dynamic Analysis for Frequency characteristics.
c) Dynamic Analysis for Operating Condition considerin
Centrifugal force due to fan motion, moment due to eccentricity of unbalanced fan assembly
101.1 RPM ( 1.69 Hz) for the balance quality grade of the fan corresponding to Q16.
 Fan thrust load at 101.1 RPM ( 1.69 Hz)
 Motor torque at 1500 RPM ( 25 Hz)
 Thrust load corresponding to blade passing over the supporting structures at a frequency of
8 times the fan rotation and equal to 808.8 RPM ( 13.48 Hz)
d) Dynamic Analysis for One Blade failure condition considering loads similar to above c
( proportioned with a ratio of 7 : 8 )
 Page No. : 2
PCT ORDER NO. 13-2I-0017A
CUSTOMER: NTPC LIMITED, UTTAR PRADESH.
PROJECT: CT FOR 1X500MW VINDHYACHAL SUPER THERMAL POWER PROJECT (STAGE-V)
AT VINDHYANAGAR, DIST. - SINGRAULI, MADHYA PRADESH.
MODEL: 84848-14V-16B

3.0 ANALYSIS DETAILS

The basic data of mechanical equipment and the relevant data derived from the basic data for carry
out the analysis are given below and in the summary tabl

Mechanical Equipment

Equipment Basic Data

Motor Power = 75 HP, Mass = 0.5 Te
Frame = 250M, Speed = 1500 RPM
Gear Reducer Series = SR-32.2, Mass = 0.79 Te, Ratio = 14.54 : 1
Drive Shaft Series = SR-351, Class-III, Mass = 0.2 Te
Height above gear reducer plinth level = 426 mm
Fan Assembly Diameter = 10 m, Mass = 0.855 Te
Number of blades = 8 , Thrust = 1.152 Te = 11298 N
Single Blade : Mass= 0.068 Te
Centroidal distance = 2340 mm from axis
Height above gear reducer plinth level = 1112 mm

Mechanical Equipments’ Analytical Data Derived from Basic data

Motor Weight = 0.5 * 9807 = 4904 N

Torque, T = ( HP * 4500 ) / ( 2  N ) = 75 * 4500 / (2* 1500 )
= 3.58E+01 kgm = 3.51E+05 N-mm
Speed wm = 1500 / 60 = 25 Hz
Gear Reducer Weight = 0.79 * 9807 = 7748 N
Fan Assembly Weight = 0.855 * 9807 = 8385 N
Speed wf = ( 1500 / 14.54 )/ 60 = 103.2 / 60 = 1.72 Hz =
= 1.72 * 2 = 10.81 rad/sec

Effective masses and weights at the end of :

Motor : Motor mass and half of the mass from Drive Sha
Mm = 0.5 + 0.2 / 2 = 0.6 Te
Wm = 0.6 * 9807 = 5884 N
Gear Reducer : Gear Reducer mass and half of the mass from Drive Shaft
Mg = 0.79 + 0.2 / 2 = 0.89 Te
Wg = 0.89 * 9807 = 8728 N
Considering Fan Assembly, total mass MT= 0.89 + 0.855 = 1.745 Te
total weight = 1.745 * 9807 = 17113 N
 Page No. : 3
PCT ORDER NO. 13-2I-0017A
CUSTOMER: NTPC LIMITED, UTTAR PRADESH.
PROJECT: CT FOR 1X500MW VINDHYACHAL SUPER THERMAL POWER PROJECT (STAGE-V)
AT VINDHYANAGAR, DIST. - SINGRAULI, MADHYA PRADESH.
MODEL: 84848-14V-16B

Static Analysis
The model details for Static Analysis are given in Section B showing mapping of user specified no
numbers and bandwidth optimized internal node number
The static loads considered are,
i) Dead Load (DL) of the structure from the model
ii) Weight of Mechanical Equipment
iii) Live Load (LL) on Fan Deck
The GRDR and Fan Assembly loads are applied at nod 405
The Motor loads are applied at node 565

Dynamic Analysis
The details for Dynamic Analysis showing nodal masses due to mechanical equipment and frequen
dependent loads under Operating and Blade Failure conditions are given in sections C, D and E.
a) Free Vibration Analysis
The natural frequencies, modal participation factors and mode shapes of the analytical model are
obtained for checking the dynamic characteristics of the structure. The nodal masses are given in p
C.2 with respect to internal node numbers (refer page B.2
b) Forced Vibration Analysis
The forced vibration analysis is carried out for the structural model in order to obtain its response
to dynamic loading generated by the motions of mechanical equipment. For blade broken condition
the thrust will act at an eccentricity. As a general case, thrust load is taken as dynamic loads. The
steady state vibration amplitudes, forces and moments are obtained for the following case
 Unbalance Loads (UBL) corresponding to Q16 balance quality grade of the fan assembly at
operating speed of 103.2 RPM and motor speed at 1500 RPM. The eccentricity is taken at
1.6 mm from axis. Only moment due to weight of fan assembly is conside
 Unbalance Loads corresponding to single blade failure condition (BFC). Due to loss of one blad
the unbalanced mass, thrust, torque are reduced in the ratio o 7 : 8
The eccentricity is calculated to be 203.79 mm from axis as calculated in the next page.
 The analysis is carried out at an assumed blade passing frequency of 808.8 RPM.
c) Dynamic Loads
Centrifugal force for unbalanced mass of Mb at eccentricity due to angular speed of wf radians/sec
Fc = Mb * wf * wf * e
 Page No. : 4
PCT ORDER NO. 13-2I-0017A
CUSTOMER: NTPC LIMITED, UTTAR PRADESH.
PROJECT: CT FOR 1X500MW VINDHYACHAL SUPER THERMAL POWER PROJECT (STAGE-V)
AT VINDHYANAGAR, DIST. - SINGRAULI, MADHYA PRADESH.
MODEL: 84848-14V-16B

Operating Case (UBL) :

For Fan Assembly mass of 0.855 Te at e = 1.60 mm and wf = 10.81 radian/sec, the centrifugal
force Fc = 0.855 * 10.81 * 10.81 * 1.6= 159.86 N
The Fan Weight of 8385 N is already included in gear reducer weight taken as static load.
Moments due to unbalanced fan weight of 8385 N at eccentricity of 1.6mm and due to
corresponding centrifugal force of 159.86 N at height of 1112 mm is,
M = 8385 * 1.6+ 159.86 * 1112 = 1.91E+05 N-mm

Fan thrust load = 11298 N

Motor torque = 3.51E+05 N-mm (components Mx = Mz = 2.48E+05 N-mm)

Blade passing thrust= 11298 / 8 = 1412.25 N at the frequency of 13.48 Hz.

Blade Failure Case (BFC) :

Blade mass = 0.068 Te. Fan assembly mass = ( 0.855 - 0.068 ) = 0.787 Te
For fan assembly mass of 0.787 Te at wf = 10.81 radian/sec and
e = 0.068 * 2340 / 0.787 +1.6 = 203.79 mm, the centrifugal force
Fc = 0.787 * 10.81 * 10.81 * 203.79 = 18742 N
The fan weight is already included in gear reducer weight taken as static load. Moment due
unbalanced fan weight of 0.787 * 9807 = 7718 N at eccentricity of 203.79 mm
at a height of 1112 mm is M = 7718 * 203.79 + 18742 * 1112
= 2.24E+07 N-mm

Fan thrust load = 11298 * 7 / 8 = 9886 N (1 blade failure case)

Moment, M = 9886 * 203.79 = 2.01E+06 N-mm

Motor torque: 3.51E+05 * 7 / 8 = 3.07E+05 N-mm

(components Mx = Mz = 2.17E+05 N-mm)

Blade passing thrust= 1412.25 at the frequency of 13.48 * 7 / 8 =

11.8 Hz
 Page No. : 5
PCT ORDER NO. 13-2I-0017A
CUSTOMER: NTPC LIMITED, UTTAR PRADESH.
PROJECT: CT FOR 1X500MW VINDHYACHAL SUPER THERMAL POWER PROJECT (STAGE-V)
AT VINDHYANAGAR, DIST. - SINGRAULI, MADHYA PRADESH.
MODEL: 84848-14V-16B

Dynamic Loading Summary (Eccentricity along Z-direction)

Freq. Load
Cond. Loading Details & ID.
(Hz) Case
Fan(f) mass unbalance : node 405 Mass= 1.745 Te, ez = 1.6mm
1.72 11
Fz = 159.86 N Mx = 1.91E+05 N-mm
Full thrust (t) at node 405
1.72 12
Fy = -11298 N e = 0.0
UBL
Motor torque (m) components at node 565
25 13
Mass= 0.6 Te Mx = Mz = 2.48E+05 N-mm
Blade passing (p) thrust at nod 405
13.48 14
Fy = -1412.25 N
Fan(f) mass unbalance : node 405 ez = 203.79 mm
Mass= 1.745 - 0.068 = 1.677 Te 1.72 15
Fz = 18742 N Mx = 2.24E+07 N-mm
Full thrust (t) at node 405 Fy = -9886 N
1.72 16
BFC ez = 203.79 mm Mx = 2.01E+06 N-mm
Motor torque (m) components at node 565
25 17
Mass= 0.6 Te Mx = Mz = 2.17E+05 N-mm
Blade passing (p) thrust at nod 405
11.8 18
Fy = -1412.25 N
Dynamic Loading Summary (Eccentricity along X-direction)
Freq. Load
Cond. Loading Details & ID.
(Hz) Case
Fan(f) mass unbalance : node 405 Mass= 1.745 Te, ex = 1.6mm
1.72 21
Fx = 159.86 N Mz = -1.91E+05 N-mm
Full thrust (t) at node 405
1.72 22
F = -11298 N e = 0.0
UBL y
Motor torque (m) components at node 565
25 23
Mass= 0.6 Te Mx = Mz = 2.48E+05 N-mm
Blade passing (p) thrust at nod 405
13.48 24
Fy = -1412.25 N
Fan(f) mass unbalance : node 405 ex = 203.79 mm
Mass= 1.745 - 0.068 = 1.677 Te 1.72 25
Fx = 18742 N Mz = -2.24E+07 N-mm
Full thrust (t) at node 405 Fy = -9886 N
1.72 26
BFC ex = 203.79 mm Mz = -2.01E+06 N-mm
Motor torque (m) components at node 565
25 27
Mass= 0.6 Te Mx = Mz = 2.17E+05 N-mm
Blade passing (p) thrust at nod 405
11.8 28
Fy = -1412.25 N
 Page No. : 6
PCT ORDER NO. 13-2I-0017A
CUSTOMER: NTPC LIMITED, UTTAR PRADESH.
PROJECT: CT FOR 1X500MW VINDHYACHAL SUPER THERMAL POWER PROJECT (STAGE-V)
AT VINDHYANAGAR, DIST. - SINGRAULI, MADHYA PRADESH.
MODEL: 84848-14V-16B

IDCT Fan Vibration Analysis Model

Member Properties

Material Properties :

Concrete Grade :M 30 fck = 30 N/sq.mm

Weight density wc = 25E-06 N/cu.mm
Modulus of Elasticity Ec = 340000 kg/sq.cm = 33343.8 N/sq.mm
Poisson's ratio c = 0.15
Plate elements : considering plane stress conditio
Cxx = Cyy = Ec / (1 - c2) = 34111.3 N/sq.mm
Cxy = Ec *  c / (1 -  c2 ) = 5116.7 N/sq.mm
Gxy = Ec / 2 (1 + c) = 14497.3 N/sq.mm

Geometric Properties :

Fan Deck Slab = 150 mm

End wall & partition wall = 150 mm
Fandeck beam at grid A, E, I, 1, 5, 9 = 400 mm (Width) x 300 mm (Depth)
Fandeck beam at grid B to D , F to H , 2 to 4 , 6 to 8 = 250 mm (Width) x 500 mm (Depth)
Ring beam below fancylinder (5.675m dia) = 250 mm (Width) x 400 mm (Depth)
Column = 400 mm x 400 mm
Inclined Column = 400 mm x 400 mm
 Page No. : 7

1. Geometry and meshed model: The model is meshed with SHELL 181
element of ANSYS and the beams and columns are modeled with BEAM 188
element of ANSYS. Mass of fan assembly, motor, gear reducer are modeled with
clumped mass element of ANSYS i.e. mass21 element (Fig. 1 and Fig. 2). The
model is made up to eliminator level as suggested by Paharpur Cooling Towers
Ltd.

Motor plinth Diameter 10409 mm

Fan plinth
29440 mm

29440 mm
2 110 mm

Fig.1. Geometry of the model

 Page No. : 8

Fig.2. Meshed Model

2. Boundary Conditions: All degrees of freedom at the bottom of the

model i.e. at eliminator level are fixed in all degrees of freedom as
shown in Fig. 3. Gravitational acceleration is provided in the model.
 Page No. : 9

Fig.3. Boundary Conditions

3. Material Properties
Concrete Slab:

Young’s Modulus (E) : 0.341 E 11 N/m2 ; Poisson’s Ratio = 0.15 ;

Density: Total (2550+3188)=5738 Kg/m3; here 3188Kg mass is considered for

live load for each quarter

For Beam:
 Page No. : 10

All above properties except density is 2550 Kg/m3

4. Results
The analysis input data, nodal loads, nodal masses, results due to dead load and
fan vibration are enclosed in this report (Geometry, loading and boundary
conditions are being applied for this simulation as per the recommendation of
engineers of Paharpur Cooling Towers Ltd.). The fan vibration loads having
frequency separation more than 10% are combined by SRSS method to obtain the
design loading due to fan operating conditions. The prints of frequency
characteristics are also included in this report. The forces and moments to be
considered in the design as obtained from this analysis are presented in the report.
The summary of results considering maximum of all structural members in a group
are presented below for reference.

Maximum deflection in horizontal plane under Dynamic Fan Operating Case is

0.070mm (Reference Table 1 and Fig. 8).

Frequency Characteristics: Fundamental frequency f1: 16.9 Hz

5. Discussion
The IDCT structure is analysed for static loads due to Dead Load, Machine Loads
and Live Load, frequency characteristics, dynamic loadings due to Fan & Motor
operations and also due to single blade failure condition of the fan motion. The fan
vibration loading has been conservatively taken for a much lower quality of
balancing (approximately Q16) although the fan is balanced to the quality of 3.96 (
less than Q=6.3 ). The design adequacy of the IDCT structure is established as
below,

 The fundamental frequency f1 of 16.9 Hz is separated by almost 10 times

from the fan operating speed of 1.69 Hz and is separated by almost 30%
from the motor operating speed of 25.0 Hz.

 The horizontal vibration amplitude of 0.07 mm in operating case is less

than the allowable value of 0.15mm.
 Page No. : 11

6. Modal Analysis
Natural Frequencies of first hundred modes (Hz):
***** INDEX OF DATA SETS ON RESULTS FILE *****

Mode No TIME/FREQ LOAD STEP SUBSTEP CUMULATIVE

1 16.909 1 1 1
2 16.933 1 2 2
3 19.201 1 3 3
4 19.314 1 4 4
5 19.518 1 5 5
6 19.556 1 6 6
7 19.718 1 7 7
8 19.721 1 8 8
9 19.966 1 9 9
10 20.039 1 10 10
11 20.573 1 11 11
12 20.677 1 12 12
13 20.810 1 13 13
14 20.911 1 14 14
15 21.064 1 15 15
16 21.298 1 16 16
17 21.301 1 17 17
18 21.535 1 18 18
19 22.062 1 19 19
20 22.368 1 20 20
21 22.420 1 21 21
22 22.480 1 22 22
23 22.716 1 23 23
24 22.844 1 24 24
25 22.924 1 25 25
26 23.045 1 26 26
27 23.299 1 27 27
28 23.493 1 28 28
29 23.508 1 29 29
 Page No. : 12

30 23.821 1 30 30
31 24.031 1 31 31
32 24.200 1 32 32
33 28.906 1 33 33
34 29.595 1 34 34
35 29.679 1 35 35
36 29.718 1 36 36
37 29.724 1 37 37
38 30.447 1 38 38
39 30.450 1 39 39
40 30.453 1 40 40
41 30.454 1 41 41
42 30.567 1 42 42
43 30.570 1 43 43
44 30.572 1 44 44
45 30.574 1 45 45
46 31.390 1 46 46
47 31.750 1 47 47
48 32.332 1 48 48
49 32.345 1 49 49
50 32.554 1 50 50
51 32.673 1 51 51
52 33.316 1 52 52
53 33.616 1 53 53
54 34.324 1 54 54
55 34.412 1 55 55
56 34.460 1 56 56
57 34.610 1 57 57
58 34.690 1 58 58
59 34.707 1 59 59
60 34.956 1 60 60
61 34.995 1 61 61
62 35.181 1 62 62
63 35.408 1 63 63
64 35.408 1 64 64
65 35.408 1 65 65
66 35.408 1 66 66
67 36.208 1 67 67
68 36.553 1 68 68
 Page No. : 13

69 37.090 1 69 69
70 37.164 1 70 70
71 37.327 1 71 71
72 37.712 1 72 72
73 37.837 1 73 73
74 38.629 1 74 74
75 38.823 1 75 75
76 39.023 1 76 76
77 39.363 1 77 77
78 39.445 1 78 78
79 39.705 1 79 79
80 39.867 1 80 80
81 40.189 1 81 81
82 40.463 1 82 82
83 41.021 1 83 83
84 41.102 1 84 84
85 41.179 1 85 85
86 41.204 1 86 86
87 41.258 1 87 87
88 41.368 1 88 88
89 41.507 1 89 89
90 41.713 1 90 90
91 42.341 1 91 91
92 42.365 1 92 92
93 42.403 1 93 93
94 42.415 1 94 94
95 43.512 1 95 95
96 43.632 1 96 96
97 45.348 1 97 97
98 45.393 1 98 98
99 45.577 1 99 99
100 45.578 1 100 100
 Page No. : 14

Fig. 4. Mode shape of Mode1

Fig. 5. Mode shape of Mode3

 Page No. : 15

Fig. 6. Mode shape of Mode5

Fig. Mode shape of Mode3

Fig. 7. Mode shape of Mode3

 Page No. : 16

7. Response Dynamic Analysis

The results from the response dynamic analysis are shown below.
Table:1 : Displacement results summary

Load Case Maximum Displacement

X (mm) Y (mm)

UBL1 0.058 0.070

0.058 0.070

0.56e-3 0.001

0.003 0.003

UBL2 0.058 0.070

0.058 0.070

0.56e-3 0.001

0.003 0.003

BFC1 0.075 0.071

0.058 0.070

0.56e-3 0.001

0.004 0.004

BFC2 0.059 0.070

0.058 0.070

0.56e-3 0.001

0.004 0.004
 Page No. : 17

Fig. 8. Displacement plot (UY) for load case of UBL1

Fig. 9. Displacement plot (UX) for load case of UBL2

 Page No. : 18

Fig. 10. Displacement plot (UY) for load case of BFC1

Fig. 11. Displacement plot (UY) for load case of BFC2