Documente Academic
Documente Profesional
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Prepared by
Anthony J. Smalley
P. Joe Pantermuehl
Prepared for
December 2006
S O U T H W E S T R E S E A R C H I N S T I T U T E
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SOUTHWEST RESEARCH INSTITUTE
6220 Culebra Road
San Antonio, Texas 78238
SYSTEMS MOUNTING
GUIDELINES FOR SEPARABLE
RECIPROCATING COMPRESSORS
IN PIPELINE SERVICE
Prepared by
Anthony J. Smalley
P. Joe Pantermuehl
Prepared for
December 2006
Approved:
____________________________________
Danny M. Deffenbaugh, Director
Mechanical and Fluids Engineering
S O U T H W E S T R E S E A R C H I N S T I T U T E
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EXECUTIVE SUMMARY
The objective of this GMRC project is to develop a consensus best-practice guideline for
the installation of pipeline reciprocating compression equipment. The intent is to ensure
installations that are free from damaging vibrations, operate reliably with acceptable alignment
over the long term, and present the owner with affordable life cycle costs. The need for these
guidelines was driven by a number of problem installations. The GMRC recognized that it was
desirable for all segments of the industry to learn from such problems and so to minimize or
avoid them in the future.
This document presents a set of guidelines on the mounting of large horsepower, medium
to high-speed, separable, reciprocating compressors for pipeline service. The emphasis is on
modern separable compressors with low-pressure ratio, powers of 1,500 to 10,000 HP, and
speeds of 500 to 1,200 RPM. Mounting includes support of the compressor, the driver,
compressor cylinders, filter bottles, vessels, and other appurtenances. In addition, mounting
covers the functions provided by the skid or skids, reinforcements, grout and concrete, the mat
and foundation, anchor bolts and washers, mounting plates, chocks, piers, clamps, cylinder
supports, frames, and other support structures.
The guidelines are intended to capture the knowledge base, which has been accumulated
across a number of organizations in the process of procuring, engineering, installing, and
operating this class of compression over the last decade. The guide acknowledges that, in a
competitive environment, without very explicit specifications in critical areas, packagers and
other suppliers may make some decisions during the bid process on the basis of initial installed
cost rather than integrity and long-life. Therefore, this guideline strives to provide the end-user
with a framework and mechanism for requesting the same scope of work from all bidding
organizations, which also helps the suppliers provide a competitive price on an equal basis. The
document further emphasizes the due diligence needed by all stakeholders to ensure the
installation meets expectations.
This document is organized to provide the user both background and specific guidelines.
The specific guideline is presented in Chapter 4, while the background information addressing
why the guidelines are given is presented in the first three chapters. It is recommended that the
first time user familiarize himself/herself with the overall subject by reviewing all four chapters.
During implementation for a specific project, it is only necessary to refer to Chapter 4.
Figure 2-1 Large Skid for 5,000 HP Motor Driven JGU/Z, with Beams Alone
Weighing Over 85,000 lbs and Completed Skid Weighing Over 220,000 lbs
After Addition of Concrete ................................................................................... 30
Figure 2-2 Crane Lift of Skid with 6-Cylinder Ariel JGD Compressor Already Mounted ....... 31
Figure 2-3 Rugged Support Structure for 4-Chamber (3 + Common Chamber) Suction
Filter Bottle on JGU6, Replacing 3-Chamber ...................................................... 33
Figure 2-4 Cat G3616/Ariel JGD6 Installation (5 Units) ........................................................ 34
Figure 2-5 Ariel JGD4 Installation Showing Modifications to Control Observed
Vibrations: Cylinder Supports Grouted with Anchor Bolts at Their Base; An
Increased Number of More Rugged Clamps; An Increased Number of More
Rugged Wedges; Cross-Bracing on Suction Chokes; Added Cross Beams
to Skid Structure.................................................................................................. 34
Figure 2-6 Model of Block and Frame of Separable Slow Speed Compressor Used for
Calculating Anchor Bolt Transverse Loads ......................................................... 36
Figure 2-7 Comparison of Maximum Transverse Force as Predicted by Rigid Frame
(RIGID) Assumption, by Finite Element Analysis (FLEX), and by Frame
with Zero Bending Stiffness (SOFT) ................................................................. 37
Figure 2-8 Cross-Bracing Between Suction Bottles.............................................................. 41
Figure 2-9 Schematic of a Cylinder, Showing Also Piston, Piston Rod, Crosshead,
Crosshead Bearing, Pin Bearing, Connecting Rod, and Crankshaft ................... 41
Figure 2-10 Illustration of Load Balance at Crosshead Pin from Which Vertical Force on
Crosshead Bearing is Determined....................................................................... 42
Figure 2-11 Axial View of Ariel JGC:D Frame......................................................................... 44
Figure 2-12 Axial View of Ariel JGU:Z Frame ......................................................................... 45
Figure 2-13 Axial View of Ariel KBB:V Frame......................................................................... 46
Figure 2-14 Cross-Section of Wartsila Engine........................................................................ 47
Figure 2-15 Cat GCM Cross-Section ...................................................................................... 48
Figure 2-16 Cat G3600 Series Engine Oblique Cutaway ....................................................... 48
Figure 2-17 End Elevation of Cat G3616 ................................................................................ 49
Figure 2-18 Pedestal for Skid Mounted Wartsila Engine ........................................................ 50
Figure 2-19 Engine Skid for G3616 ........................................................................................ 50
Figure 2-20 Concrete Well to Accommodate GCM34 Sump for Concrete Block Mounted
Installation of 8180 HP Engine and Ariel JGV6 compressor ............................... 51
Figure 2-21 Typical Induction Motor Dimensions 680-Frame (Courtesy Siemens) ................ 52
Figure 2-22 Typical Induction Motor Dimensions 800-Frame (Courtesy Siemens) ................ 53
Figure 2-23 Typical Induction Motor Dimensions 1120 Frame (Courtesy Siemens) .............. 54
Figure 2-24 Overview of Cat G3608 Driven Ariel JGD4 ......................................................... 58
Figure 2-25 Vertical Vibrations on Cylinders 2 and 4 of the Compressor of Figure 2-24........ 59
Figure 2-26 Vertical Vibrations on Cylinders 1 and 3 of the Compressor of Figure 2-24........ 60
Figure 2-27 Comparison of 4th Order Vibrations for Cylinders 1, 2, 3, and 4 with
Ineffective Head End Supports at Cylinders 1, 2, and 4...................................... 60
Figure 2-28 ANSYS Model of Ariel JGD4 with Cylinders, Bottles Head End Supports,
Viewed with Orientation Similar to Figure 2-24 ................................................... 61
Figure 2-29 Mode Shape for 48.7 Hz Cylinder-Bottle Mode without Head End Support ........ 62
Figure 2-30 Mode Shape for 50.1 Hz Cylinder-Bottle Mode without Head End Support ........ 62
Figure 2-31 Mode Shape for 53.1 Hz Cylinder-Bottle Mode without Head End Support ........ 63
Figure 2-32 Mode Shape for 53.7 Hz Cylinder-Bottle Mode without Head End Support ........ 63
Figure 2-33 Influence of Crosshead Guide Support Stiffness on Frequency of the Four
Predicted Cylinder-Bottle Modes ......................................................................... 64
Figure 2-34 Influence of Discharge Bottle Wedge Support Stiffness on the Frequency of
the Four Predicted Cylinder-Bottle Modes........................................................... 65
Figure 2-35 Illustration of Bottle Ovalization in Response to Nozzle Vertical Load and
Rigid Wedge Under Bottle ................................................................................... 65
Figure 2-36 Influence of Cylinder Head End Support Attachment Stiffness on the Four
Predicted Cylinder-Bottle Modes ......................................................................... 66
Figure 2-37 Need for Head End SupportInfluence on Vertical Cylinder-Bottle Modes
and Comparison with 4th Order Excitation Range ............................................... 67
Figure 2-38 Comparison of Cylinder Maximum Vibration Component Before and After
Modifications, which Include Re-Grout of Head End Supports and Added
Anchor Bolts ........................................................................................................ 67
Figure 2-39 Cat G3608 Engine Mount Before Modification to Control Vibrations and Soft
Foot Under Vibracons ......................................................................................... 70
Figure 2-40 Close-up: Cat G3608 With Vibracon Mounts With Steel Plates Between
Vibracons and Skid .............................................................................................71
Figure 2-41 Motor-Driven Ariel JGV6...................................................................................... 72
Figure 2-42 Crosshead Guide Support and Compressor Pedestal for Motor Driven Ariel
JGV6 ................................................................................................................... 72
Figure 2-43 Peak Hold Spectrum Load Step 5 (Asymmetric) .............................................. 74
Figure 2-44 Peak Hold Spectrum Symmetrical Load Step (Load Step 1)............................ 74
Figure 2-45 Vertical Vibration Profile Motor-Driven Unit 156 Hz....................................... 75
Figure 2-46 Model of Cylinder, Frame, Bottles, and I-Beam Support Structure ..................... 75
Figure 2-47 Model Without Bottles ......................................................................................... 76
Figure 2-48 I-Beam Pedestal Structure (Plate Model) ............................................................ 76
Figure 2-49 Detail Showing Compressor to I-Beam Interface ................................................ 77
Figure 2-50 Case Study 2 Predicted Mode Shape at 98.9 Hz ............................................. 77
Figure 2-51 Axial Profile of Frame Vibration Amplitudes Under Asymmetric Unbalanced
Gas Loading ........................................................................................................ 78
Figure 2-52 Compressor Base Response (Horizontal, Perpendicular to Cranshaft) as a
Function of Frequency......................................................................................... 79
Figure 2-53 Vertical Profile of Vibration Amplitudes (Horizontal, Perpendicular to
Crankshaft).......................................................................................................... 79
Figure 2-54 Compressor Base Response as a Function of Frequency Under
Asymmetric Loading; Pedestal Stiffness Increased by 4X; No Sliding at
Mount .................................................................................................................. 80
Figure 2-55 Vertical View Profile of Frame Vibration Amplitudes, Corresponding to Peak
of Figure 2-54 ...................................................................................................... 80
Figure 2-56 Minimum Friction Coefficient for Cast-Iron on Various Other Materials, from
GMRC Technical Report TR97-3 [2] ................................................................... 81
Figure 2-57 Siemens Motor Driven JGV6 with Replacement 4-Chamber Suction Bottle
Installed and Rugged Support Structure for Suction Bottle ................................. 82
Figure 2-58 Rugged Support Structure for New 4-Chamber Bottles in More Detail
Showing Clamp Holding Bottle Against Wedges and Long U-Bolts
Providing Substantial Bolt Stretch Length ........................................................... 82
Figure 2-59 Comparison of Primary and Secondary Discharge Bottle Configuration
Against Single 4-Chamber Discharge Bottle ....................................................... 83
Figure 2-60 Original Discharge Bottle on JGU6, With No Clamps Holding Bottle Against
Wedges ............................................................................................................... 85
Figure 2-61 Original 3-Chamber Suction Bottle on Ariel JGU6 Driven by Cat G3616 ............ 85
Figure 2-62 Illustrative Prediction of JGU6 Compressor Manifold Vibration........................... 86
Figure 2-63 Discharge Bottle with Added Strap to Control Vibrations; Ariel JGU6
Installation ........................................................................................................... 87
Figure 2-64 JGU6 with Replacement 4-Chamber Suction Bottle............................................ 87
Figure 2-65 Original Installation of G3520-JGT4 .................................................................... 88
Figure 2-66 Views of Modified Installation of G3520-JGT4 .................................................... 89
Figure 2-67 Very Stiff Crosshead Guide Support, which is a Single Structure for Two
Adjacent Cylinders; Installed to Control Cylinder Vibrations Identified with
Less Stiff Individual Cylinder Guide Supports ..................................................... 89
Figure 2-68 Three-Dimensional Schematic of Common Chamber Suction Filter Bottle
[14] ...................................................................................................................... 92
Figure 2-69 Model of Manifold System, Piping, and Cylinders for 6-Cylinder Single-
Stage Compressor, which Uses Shell Elements for 4-Chamber Suction and
Discharge Bottles ................................................................................................ 95
Figure 2-70 Details of Model at Joint Between Nozzle and Suction Bottle Showing Shell
Elements Used for Bottle and for Reinforcing Pad .............................................. 95
Figure 2-71 Predicted Stress Distribution in Bottle Modeled with Beam Elements................. 96
Figure 2-72 Predicted Stress Distribution in Bottle Modeled with Shell Elements .................. 96
Figure 2-73 Beam Element Model of Compressor Manifold ................................................... 97
Figure 2-74 Shell Element Model of the System Modeled with Beam Elements in Figure
2-73 ..................................................................................................................... 97
Figure 2-75 Velocity Spectrum Predicted with Beam Elements (Model of Figure 2-73) ......... 99
Figure 2-76 Velocity Spectrum Predicted with Shell Elements (Model of Figure 2-74) .......... 99
Figure 2-77 Stress Distribution Predicted with Beam Element Model of Figure 2-73 ........... 100
Figure 2-78 Stress Distribution Predicted with Shell Element Model of Figure 2-74 ............ 100
Figure 2-79 Predicted Vibration Velocity for Unbraced Suction Bottles................................ 101
Figure 2-80 Predicted Vibration Velocity for Braced Suction Bottles .................................... 101
Figure 2-81 Cat G3608 Installation; Vibracon Mounts with Jacking Screws for Vertical
and Horizontal Motion ....................................................................................... 104
Figure 2-82 Simplified Illustration of Forces and Couples Acting on a Compressor
Frame ................................................................................................................ 107
Figure 2-83 Free Body Diagrams for Two Contacting Bodies Illustrating Friction Forces
in Reaction to Externally Applied Forces........................................................... 109
Figure 2-84 Schematic of Canister Bolt (Courtesy Robert L. Rowan) .................................. 111
Figure 2-85 Illustration of Anchor Bolt and Compressed Sandwich, Including Grout
Layer ................................................................................................................. 112
Figure 4-1 Foot of JGV6 Compressor Driven by Wartsila 18 Cylinder Engine ................... 135
Figure 4-2 Compressor Foot of JGD4 Driven by Cat G3616, Mounted on Chock Set in
Grout Box .......................................................................................................... 135
Figure 4-3 Stiff Crosshead Guide Support Connecting JGV6 (GCM34 Drive) Guide
Directly to Block................................................................................................. 136
Figure 4-4 Skid Being Lifted Into Position on Foundation Block Prior to Grouting to
Block.................................................................................................................. 137
Figure 4-5 Stiff Crosshead Guide Structure Covering 2 Cylinders of Ariel JGD4, Driven
by Cat G3608 .................................................................................................... 137
Figure 4-6 Crosshead Guide Support for Wartsila Engine Driven JGV6 ............................ 138
Figure 4-7 Compressor Section of Skid Before Compressor is Mounted ........................... 139
Figure 4-8 Close-Up of Jacking Screw for Skid of Figure 4-14........................................... 139
Figure 4-9 Anchor Bolt for JGV6 Compressor Frame Extending Below Skid ..................... 140
Figure 4-10 Box Structure for Achieving Stretch Length for Anchor Bolts ............................ 140
Figure 4-11 Bottle Mounted on Skid and Resulting Elevated Compressor Mounting ........... 142
Figure 4-12 Foundation Block for Cat G3612 Installation ..................................................... 143
Figure 4-13 Staggered Concrete Levels as a Means of Controlling Height from Which
Discharge Bottle is Supported ........................................................................... 143
Figure 4-14 Underside of Skid for Cat G3616/JGD6 Installation, Showing Concrete in
Skid Under Compressor, and Jacking Screws for Leveling and Alignment
Along the Side ................................................................................................... 145
Figure 4-15 Crosshead Guide Supports and Anchor Bolts for JGV6.................................... 146
Figure 4-16 Mounting Foot Mounted on Chock Set in Grout Box, With Shims Between
Chock and Foot for Alignment and Leveling...................................................... 146
Figure 4-17 Cat G3616 Engine Mounting Foot, with Adjustable Vibracon Supports
Mounted Directly onto Skid ............................................................................... 147
Figure 4-18 Freestanding Stretch Tube on Compressor Pedestal for JGV6 Installation
Later Reinforced with Horizontal Plate Mid-Way Down Bay Between
Gussets ............................................................................................................ 147
Figure 4-19 Mounting for 4-Chamber Suction Bottle Support Structure Retroactively
Installed on JGV6 .............................................................................................. 149
Figure 4-20 Mounting of Structural Support for 4-Chamber Bottle Retroactively
Designed and Installed for JGU6....................................................................... 149
Figure 4-21 Block Mounted JGV6 Installation ...................................................................... 152
Figure 4-22 Schematic of Canister Bolt (Courtesy Robert L. Rowan) .................................. 156
Figure 4-23 Photograph of Several Canister Bolts (Courtesy Robert L. Rowan).................. 157
Figure 4-24 Siemens Motor Driven JGV6 with Replacement 4-Chamber Suction Bottle
Installed and Rugged Support Structure for Suction Bottle ............................... 158
Figure 4-25 Acoustic Filter Options Which Impact Mounting ................................................ 161
Figure 4-26 Cat G3612 Driven Installation ........................................................................... 161
Figure 4-27 JGT4 Installation; Rugged Low Profile On-Skid Mounting of Secondary
Bottle ................................................................................................................. 162
Figure 4-28 Cat G3616/JGD6 Installation (5 Units) .............................................................. 163
Figure 4-29 Robust Off-Skid Mounting for Lateral Piping ..................................................... 163
Figure 4-30 Cat G3608 Installation Showing Bracket Added to Control Piping Vibration..... 164
Figure 4-31 Cat G3608 Installation With Added Clamping on Piping ................................... 164
Figure 4-32 Pipe Support Added to Insulated Elbow ............................................................ 165
Figure 4-33 Insulated Flange at Building Wall Installed Before Wall was Installed and
Now Very Difficult to Get a Wrench to Because of the Wall .............................. 166
Figure 4-34 Skid for Ariel JGT4/Cat G3520 Installation With Grout Showing Anchor Bolt
With Supernut and Jacking Screw for Leveling Skid ....................................... 168
Figure 4-35 Corner of Skid Showing Grouting, Skid Anchor Bolt, and Skid Jacking
Screw ................................................................................................................ 169
Figure 4-36 Epoxy Filled Self-Aligning Mount (U.S. Rotech, Inc.) ........................................ 171
Figure 4-37 Riverhawk Stud Tensioner Graphic (from
http://www.riverhawk.com/tools.html) ................................................................ 173
1.1 INTRODUCTION
This document presents a set of guidelines on the mounting of separable reciprocating
compressors, with speeds generally referred to as medium and high speed. The guidelines are
intended to capture the knowledge base, which has been accumulated across a number of
organizations in the process of installing such compressors between 1997 and 2006. The need
for these guidelines arises because certain problems arose, often for identifiable reasons, and it is
desirable for all segments of the industry involved to minimize or avoid such problems in the
future. Such problems have frequently resulted in unanticipated and undesirable extra cost
often to a number of the stakeholders. Delays in the added capacity anticipated from new
compression has been another common result. The first half of the guidelines document
provides background, and the second half presents general and specific guidelines.
1.3.1 MOUNTING
Mounting is the location, weight support, alignment, mechanical and gas load
management, and tie-down of the compressor, its driver, associated systems, and appurtenances.
1.3.3 PACKAGE
In principle, a package is the compression systemeverything between the suction
flange and the discharge flange, with a driver and support systems; a turnkey system which just
has to be set in place, connected to compressor station gas headers, connected to fuel or power
lines, started, and operated. In fact, it is this turnkey concept, which needs some qualification
and rethinking when applied to large pipeline compressors, as the guidelines will discuss.
1.3.7 GROUT
A pourable material, which cures and hardens with time, to form a stiff layer, and fills the
previously empty space into which it has been poured. The hardened grout forms a structural
element of the mounting system for skids, sole plates, chocks, compressors and their drivers.
Once the grout is hardened, anchor bolts are tightened at certain locations on mounted equipment
or a skid, with the effect of compressing the grout. Grouts in this application are epoxy material
formed from long chain polymer compounds, which can be formulated to provide a Youngs
1.3.10 CHOCK
A chock is a stiff, flattish element, rectangular in plan view, with typical dimensions of 6
to 12 inches on a side, and 1 to 3 inches of thickness. A chock separates a component to be
mounted from the structure to which it is to be mounted. Normally, a single anchor bolt passes
through the chock, and the tensioning of the anchor bolt produces a high normal force between
the interfaces involved (e.g., the compressor to chock interface, the chock to skid interface, or the
chock to concrete interface).
1.3.13 CYLINDER
This is a compressor component, which contains the compressed gas as it changes
pressure under the action of the piston and its motion. The cylinder incorporates suction and
discharge valves, gas flow passages, and packing. The valves manage the gas flow into and out
of the cylinder volumes and trap the gas while it is being compressed under the action of the
reciprocating piston. There is most commonly one cylinder per throw, and an equal number of
1.3.14 CROSSHEAD
A sliding component, which moves along a straight line, guided by a slider bearing and
acted upon by the connecting rod. The crosshead is the slider of this slider-crank
mechanism. The piston rod projects from and is driven by the crosshead; the piston rod
imposes reciprocating motion on the piston.
1.3.17 WEDGE
This is an incline plane device to hold and restrain a bottle or section of pipe. Used
strictly in pairs these present flat surfaces at about 45 degrees to the vertical below and on either
side of the bottle. Wedges are adjustable by means of long bolts, which pull the pair of wedges
together to tighten them against the bottle. With high or variable discharge temperatures, the
vertical growth of discharge nozzles requires care in the use of discharge bottle wedges, but for
pipeline applications, this is the preferred configuration for bottle support.
1.3.19 PEDESTAL
A structure, commonly built of I-beams or wide flange beams, to provide a mounting
surface at appropriate height for the compressor or its driver on the skid. An important function
of the pedestal under the engine is to locate the engines feet so the sumps lowest point is at the
desired position relative to the main skid. The function of a pedestal under the compressor (if a
pedestal is used here) is to elevate the compressor shaft centerline to the same level as that of the
driver.
1.3.21 ALIGNMENT
Alignment normally refers to the process of adjusting the position of driver and
compressor on their mounts so the shafts of each are very close to collinear while avoiding
undesired axial or thrust forces at normal operating temperatures. Alignment is further used in
this document to refer to the leveling and elimination of twist and bending within the frame of
both driver and compressor.
1.3.26 FOOT
This is a localized component integral with or bolted to a compressor or engine frame for
use in mounting. The foot presents a flat surface, facing downwards, which mates with a
mounting plate facing upwards, with precision thickness shims or sometimes with an adjustable
mount between the foot and the mounting plate.
1.3.29 VIBRACON
A mount of cylindrical shape, used increasingly to support engine drives from the skid,
which provides vertical adjustability and self-alignment and thereby can aid in vertical alignment
of mounted equipment.
1.6.1 MAINLINE
Mainline applications generally involve larger horsepowers; examples exist of medium
speed separable reciprocating compressors as large as 8,500 HP in mainline transmission, and
many exist in the range of 4,000 to 8,000 HP. (Existing frame sizes and rod load capacities
could produce compression power as high as 12,000 HP.) At the low end at least one example of
mainline transportation in the range of 1,750 HP exists.
These mainline applications are particularly critical, for a number of reasons. First,
mainline transmission is the primary business of the pipelines, and deliverability at all take-off
points on the system is dependent on the reliability and availability of compression assets all
along the line. With more capacity packed into a single unit, the more the system depends on
that unit. On a high load day, all compression capacity becomes essential. Secondly, firm
transportation contracts require regulated interstate pipelines to assure capacity, which is a
function of available compression (whether it is used or not).
1.7.1 API 11P SPECIFICATION FOR PACKAGED RECIPROCATING COMPRESSORS FOR OIL
AND GAS PRODUCTION SERVICES [6]
This standard has actually become obsolete but is still widely referred to. It is replaced
by ISO 13631 (which appears to contain very similar text). Outside of what is covered in its
Section 11 Skids, API 11P briefly covers a number of topics loosely related to mounting, as
well as mechanical integrity, safety and basic performance, and the following bulleted list
summarizes these (details are paraphrased in placessection number indicated should be
consulted for specific language):
1.7.2 API 618 RECIPROCATING COMPRESSORS FOR PETROLEUM, CHEMICAL, AND GAS
INDUSTRY SERVICE, 4TH EDITION, JUNE 1995 [8]
The API 618 standard says very little about mounting of separable compressors apart
from one schematic in an appendix, which is titled Figure L-1 Typical Mounting Plate
Arrangement. API 618 also does not address reciprocating natural gas engines. An important
value of API 618 for pipeline separable compressors is to provide a basis for specifying pulsation
analysis and associated criteria related to pulsations at the cylinder flange, outside the filter
system, and for pressure drop in the piping. Structural dynamic criteria in API 618 are limited to
piping.
API 618 has been undergoing a major revision effort over the last several years; the 5th
Edition has not yet been published, but this event is expected in 2006 or 2007. In the area of
pulsations, much of the 4th Edition material is expected to be replaced.
1.7.5 ASTM A193 STANDARD SPECIFICATIONS FOR ALLOY STEEL AND STAINLESS STEEL
BOLTING MATERIALS FOR HIGH TEMPERATURE SERVICE [10]
This specifies material requirements for high strength anchor bolts, as recommended in
this guidelines document.
1.7.6 ASTM A194 STANDARD SPECIFICATIONS FOR CARBON AND ALLOY STEEL NUTS
FOR BOLTS FOR HIGH PRESSURE AND HIGH TEMPERATURE SERVICE [11]
This specifies material requirements for the nuts to go with the bolts of ASTM A193, as
recommended in this guidelines document.
1.7.9.2 GMRC 97-3 Friction Tests: Typical Chock Materials and Cast Iron, by
P. J. Pantermuehl and A. J. Smalley, December 1997
The data in this report would help with the engineering of tie-downs with interfaces of
particular material combinations.
1.7.9.6 Recommended Practice for Control of Torsional Vibrations for High Speed
Separable Reciprocating Compressors, by R. E. Harris and A. J. Smalley,
February 2002 (GMRC)
This document provides detailed recommendations for torsional design and analysis for
medium and high-speed separable compressors.
This section of the guidelines more specifically defines important factors in procurement,
engineering, and installation of medium and high-speed compressors in pipeline service, and the
challenges faced by the end users project engineering team. It comprises five sub-sections:
The Compression System (2.1)
Physical Interfaces (2.2)
Forces to Recognize and Manage in Designing the Mounting System (2.3)
Geometries to be Managed (2.4)
Experience Base (2.5)
Technical Background and Topics to Support Specific Guidelines (2.6)
The last sub-section includes the identification of state-of-the-art limitations, pointing to
areas where research is needed to comprehensively support the reliable engineering of separable
reciprocating compressors in the future. The incomplete knowledge base most commonly
involves the interaction of forces defined in Section 2.3 with the mounting system, and how to
engineer this interaction. Research is also needed to quantify alignment criteria in terms of
damage risk when the criteria are exceeded.
Figure 2-1. Large Skid for 5,000 HP Motor Driven JGU/Z, with Beams Alone Weighing Over
85,000 lbs and Completed Skid Weighing Over 220,000 lbs After Addition of Concrete
Prior to grouting the skid, its weight with added concrete, and mounted equipment must
be carried on a series of vertical jacking screws. It is not unknown for these jacking screws to be
undersized (or too few) and to deform under the required loadparticularly since, during
alignment, load sharing between jacking bolts can be far from even; thus, care must be taken to
ensure and document adequate jacking screw strength.
Figure 2-2. Crane Lift of Skid with 6-Cylinder Ariel JGD Compressor Already Mounted
Figure 2-3. Rugged Support Structure for 4-Chamber (3 + Common Chamber) Suction
Filter Bottle on JGU6, Replacing 3-Chamber
Note clamp and wedge support for bottle with 2-tie bolts on wedges, tying bottle to stiff I-beam structure.
An option sometimes considered for suction bottle support is close coupling the bottle,
structurally, to an adjacent vertical vessel. This option should be carefully analyzed, if
considered.
Cross-bracing similar bottles on opposite sides of a compressor is widely applied practice
and is recommended as general practice in these guidelines (see below). It is a conservative
design approach to include the brace attachment points in the vessel construction, even if the
analysis indicates that they are not needed.
Figure 2-5. Ariel JGD4 Installation Showing Modifications to Control Observed Vibrations:
Cylinder Supports Grouted with Anchor Bolts at Their Base; An Increased Number of More
Rugged Clamps; An Increased Number of More Rugged Wedges; Cross-Bracing on Suction
Chokes; Added Cross Beams to Skid Structure
2.3.9.2 Counterbalancing
On a 2- or 4-throw compressor, it is normal practice for compressor OEMs to provide
some level of rotating counterbalance on the crankshaft to offset the primary couple induced by
the reciprocating motion on a pair of throws. Typically, this counterbalancing is a compromise
because the reciprocation is horizontal while the rotating counterweights produce both a vertical
and horizontal component. In addition, the components at 2X produced by the slider crank
mechanism of each throw cannot be directly balanced by counterweights rotating at 1X
(although the peak-to-peak variation in the complex wave of unbalanced force may be influenced
by counterweight magnitude).
For 6-throw compressors, it is normal to phase the throw pairs at 120 degrees to each
other, and for a single-stage compressor as a whole the sum of the primary and secondary
couples is balanced in this way.
2.3.9.4 GMRC Analysis of Frame Flexibility for a Low Speed Separable Compressor
Figure 2-6 shows the finite element model of a chock-mounted low speed separable
compressor used to quantify load transfer mechanisms and the load carried by the anchor bolts.
Figure 2-7 shows an interesting result for the highest predicted transverse load at any anchor
bolt, and how this maximum load varied with frame flexibility assumption. The rigid frame
assumption was non-conservative by a factor of ten with a predicted anchor bolt load of about
1,100 lbs. The FEA gave a load of 10,740 lbsthis is the most accurate analysis. Assuming the
frame has no bending, stiffness gave an anchor bolt load of 26,847 lbs.
The rule of thumb established from this GMRC research was that the individual tie-
downs for the compressor frame should be able to carry at least half the maximum lateral local
shaking force of the throw to which they are adjacent. In the absence of a comparably detailed
analysis for medium and high-speed separable compressors, this rule is a conservative approach
for such compressors. Ideally, this analysis should be undertaken as a future research
investigation for medium and high-speed compressors.
Figure 2-6. Model of Block and Frame of Separable Slow Speed Compressor Used for Calculating
Anchor Bolt Transverse Loads
8000
Max Individual
6000 Anchor Bolt Load
4000 1090
2000
0
RIGID FLEX SOFT
Figure 2-7. Comparison of Maximum Transverse Force as Predicted by Rigid Frame (RIGID)
Assumption, by Finite Element Analysis (FLEX), and by Frame with
Zero Bending Stiffness (SOFT)
Figure 2-9. Schematic of a Cylinder, Showing Also Piston, Piston Rod, Crosshead, Crosshead
Bearing, Pin Bearing, Connecting Rod, and Crankshaft
Connecting rod oriented to cause vertical force components.
It is essential to engineer for the effect of these dynamics forces acting on the
compressor-cylinder bottle system dynamics. A case study will illustrate this later in the
guidelines.
Table 2-1. Typical Compressor Heights From Under-Surface of Feet to Crankshaft Centerline
Model Height
JGC:D 22
JGU:Z 24
KBB:V 27
These heights in comparison with the height from the lowest point on the driver to the
drivers shaft centerline determine the height differences, which have to be accommodated in the
design of skid and equipment mounting, or the foundation block for a block-mounted system.
As a result, engines on a skid mount are usually supported at their feet or mounting
flange from a pedestal, such as Figure 2-18 shows for a Wartsila engine or Figure 2-19 shows for
a Cat G3616 engine. The pedestal surrounds the well for the sump. Both the engines of Figure
2-14 and Figure 2-17 have mounting feet, and the practice demonstrated in Figure 2-18 and
Figure 2-19 is to support these feet on mounting plates. The mounting plates are set in grout
contained within grout boxes, and the grout boxes are welded to the main beam structure of the
pedestal. It is important that the upper surface of each mounting plate is closely parallel to the
underside of the matching mounting foot. To ensure this condition, the foot and plate are bolted
tightly together before grout is placed and hardens around the mounting plate. This is the most
effective approach and implies that grouting of mounting plates and alignment of mounted
equipment are performed concurrently. If the engine and compressor are to be field installed and
aligned after mounting plates are installed in the shop, then the plates should be carefully shot in
before grout is placed to make them as closely parallel as possible. The mounting plates and
undersides of the feet are typically separated by shims whose thickness is adjustable to achieve
accurate vertical alignment of the engine and compressor. Vibracon steel chocks are also being
used with increasing frequency to mount an engine foot to the horizontal surface of a pedestal or
skid. They enable height adjustment via a screw thread and accommodate misalignment between
The mounting feet have holes for anchor bolts as do the mounting plates and grout boxes.
The Cat GCM and G3616 engines use one-inch anchor bolts.
Figure 2-20. Concrete Well to Accommodate GCM34 Sump for Concrete Block Mounted
Installation of 8180 HP Engine and Ariel JGV6 compressor
The Caterpillar gas engines most commonly used in pipeline applications have the
following heights from the lowest point on the sump to the crankshaft centerline.
Table 2-2. Caterpillar Engine Mode Heights from Low Point and from Under-Surface of
Feet to Crankshaft Centerline
Height from Foot Height from Low
Model
to Shaft C-L Point to Shaft C-L
G3520B 24.99 24.99
G3606 17.72 33.10
G3608 17.72 33.10
G3612 17.73 38.42
G3616 17.72 38.41
GCM34 29.53 49.41
These numbers can be used to establish needed pedestal height for skid mounts, to
establish well depth needed for block mounts, and to decide on minimum pedestal height for the
driven compressor (by comparing the last column above to the height from compressor foot to
compressor shaft centerlinesuch as the values given earlier for three Ariel models).
Thus, for example to run a 6-throw JGU:Z at 900 RPM, an 1120 frame would provide the
likely required power range of 4,000 to 5,000 HP in pipeline service. This motor would stand
four inches higher at the shaft centerline if the bases of the motor and driver were at the same
level. Alternatively, to drive a JGV4 at 900 RPM, the same motor frame would stand two inches
lower at the shaft centerline than the JGV4 if the bases of the two were at the same level on a
skid. These differences may be small enough that they can be accommodated by small height
differences in the mounting feet rather than by adding a pedestal.
Some of the largest Siemens motor drives for pipeline applications were 720 RPM (10
pole) motors, driving JGV6 compressors with significantly more height between feet and
crankshaft centerline than those of the above table, requiring substantial pedestals under the
compressors.
Figure 2-25. Vertical Vibrations on Cylinders 2 and 4 of the Compressor of Figure 2-24
1.4
1.2
Vertical Vibration, IPS
0.8
0.6
0.4
0.2
0
Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4
Figure 2-27. Comparison of 4th Order Vibrations for Cylinders 1, 2, 3, and 4 with Ineffective Head
End Supports at Cylinders 1, 2, and 4
Figure 2-29, Figure 2-30, Figure 2-31, and Figure 2-32 show the mode shapes of
predicted modes with CHG support stiffness of 1E7 lbs/inch, with rigid wedge supports under
the bottles, but with the head end supports removed. These figures show the frequencies for
these four modes are 48.7, 50.1, 53.2, and 53.7 Hz. The modes involve various combinations of
bottle and cylinder motion with the individual cylinders moving in a vertical plane. The
closeness of these four modes to each other and to the peak at 4th order in the measured data
indicates a strong likelihood that one or more of these modes is responding to excitation from the
compressor or from gas pulsation forces but does not explicitly reveal which of the four modes
are involved.
The lower measured vibration of the one cylinder with cylinder head end support in good
condition suggests that, if the cylinder motion could be more effectively and consistently
restrained (which would also push these modes out of this apparently strong excitation range),
then the vibrations would be reduced.
Figure 2-30. Mode Shape for 50.1 Hz Cylinder-Bottle Mode without Head End Support
Figure 2-32. Mode Shape for 53.7 Hz Cylinder-Bottle Mode without Head End Support
40
30
20
10
0
1.0E+05 1.0E+06 1.0E+07 1.0E+08 1.0E+09 1.0E+10
CHG Support Stiffness lbs/in
Figure 2-33. Influence of Crosshead Guide Support Stiffness on Frequency of the
Four Predicted Cylinder-Bottle Modes
The highest frequencies of these four modes are pushed up to 56 Hz with a very stiff
crosshead guide support, but the lowest of these modes remains in the 52 Hz range. In summary,
the crosshead guide supports cannot control these modes sufficiently to eliminate the coincidence
of excitation frequency range and modal frequency range. There is no doubt that the existing
stiff crosshead guide support is a useful part of the structure, but these are heavy cylinders of
approximately 10,000 lbs assembly weight each (Ariel 13DN cylinders), and it is to be expected
that more restraint is required than the crosshead guide supports alone can provide. It would be
necessary to push the lowest of these four modes above 4th order at 1,000 RPM engine speed to
be sure they were clear of this 4th order excitation (i.e., above 67 Hz) with some margin, and no
amount of crosshead guide support stiffness can come close to doing this.
Since the nozzles also provide some support to the cylinders, the influence of bottle
support stiffness was investigated (with crosshead guide support set to 1E7 lbs/inch). Figure
2-34 shows that the highest the wedge support stiffness could elevate these frequencies to be is in
the 49 to 54 Hz rangeagain, not high enough. What happens as the wedges are stiffened is that
bottle vertical squish and some amount of bottle bending introduces flexibility which
dominates the support conditions once the wedges have been made stiff.
Figure 2-35 shows the bottle deformation occurring as part of one of these modesthe
flexibility from bottle ovalization and bending is apparent. Keeping the wedges directly under
the nozzles should help minimize the effect of bending, but cannot avoid bottle ovalization
unless a heavier wall bottle or internal reinforcement is used.
40
30
20
10
0
1.0E+05 1.0E+06 1.0E+07 1.0E+10
Wedge Stiffness lbs/in
Figure 2-34. Influence of Discharge Bottle Wedge Support Stiffness on the Frequency of the Four
Predicted Cylinder-Bottle Modes
100
Frequency (Hz)
80
Mode 1
Mode2
60 Mode3
Mode4
40
20
0
1.00E+05 1.00E+06 1.00E+07 1.00E+08 1.00E+09
Head-End Upper Supt Stiffness (lbs/in)
Figure 2-36. Influence of Cylinder Head End Support Attachment Stiffness on the
Four Predicted Cylinder-Bottle Modes
Figure 2-36 shows by comparison with Figure 2-33 and Figure 2-34 that the head end
support has a much stronger influence in raising the four cylinder-bottle modes than either the
crosshead guide support or the bottle wedge support. Head end supports make it possible to push
all modes well above 80 Hz; specifically, a joint stiffness of 1E7 elevates the lowest of these
frequencies to 88.4 Hz. For a bolted joint, 1E7 should be a practical stiffness value, so pushing
these modes well out of the range of 4th order excitation with head end supports should be readily
achievable. Other restraints (crosshead guide support and discharge bottle wedge support),
although these are important structural members, cannot handle such heavy cylinders alone in
this installation. Figure 2-37 summarizes and emphasizes the comparison of frequencies for the
four modes with and without the head end support with the 4th order excitation range. Figure
2-37 makes clear that only with effective head end supports can the necessary separation
between excitation range and modal frequency range be confidently achieved.
60 Mode 1
Mode 2
50
Mode 3
40 Mode 4
30
20
10
0
1E7 CHG Supprt; Rigid Wedges-No Head End Support Added
Head End Support
Figure 2-37. Need for Head End SupportInfluence on Vertical Cylinder-Bottle Modes and
Comparison with 4th Order Excitation Range
With this modification, the highest vibration on any cylinder occurred at 27.8 Hz with the
engine running at 834 RPM (i.e., 2nd order). The magnitude was 2.3 mils or 0.2 IPS. Thus, the
cylinder head end supports, once properly installed, were very effective and were clearly needed.
Figure 2-38 compares in bar chart format the highest vertical vibration peaks before and after the
modifications, making clear the very substantial reduction in maximum vibration velocity from
1.25 IPS to 0.2 IPS.
1.4
1.2
Before
Vibration, IPS
1 After
0.8
0.6
0.4
0.2
0
Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4
Figure 2-38. Comparison of Cylinder Maximum Vibration Component Before and After
Modifications, which Include Re-Grout of Head End Supports and Added Anchor Bolts
Figure 2-39. Cat G3608 Engine Mount Before Modification to Control Vibrations
and Soft Foot Under Vibracons
Note single plate unwelded to skid supporting two Vibracons. Any imperfections or lack of flatness in either
skid or plate surface can lead to a soft foot or a weak attachment, and the possibility of sliding at the joint.
Vibrations 0.78 IPS.
Even at 0.4 IPS, this vibration remains distinct and emphasizes the need to engineer
a sound structure which both firmly joins the foot to the supporting pedestal without
sliding and which also ensures sufficient rigidity of the entire supporting structure
to keep vibrations under control.
Quantified local excitation forces from the engine are, however, not readily
available or readily calculable. This remains an area deserving further investigation
(i.e., an open question to be the subject of future research).
The option exists to specify a center foot for the G3608 engine; based on these
results, it is strongly recommended to always specify this center foot.
2.5.2.2 Case Study 2: Mounting Joint Motion and Pedestal Flexibility in a Motor
Driven Ariel JGV6 Mounting
Figure 2-42. Crosshead Guide Support and Compressor Pedestal for Motor Driven Ariel JGV6
Figure 2-44. Peak Hold Spectrum Symmetrical Load Step (Load Step 1)
Figure 2-46. Model of Cylinder, Frame, Bottles, and I-Beam Support Structure
In an attempt to reproduce the observed vibration levels at the base mode of the
compressor, a forced harmonic response analysis was performed. Figure 2-52 shows the forced
response prediction at the outboard compressor foot as a function of frequency, with a peak of
0.6 mils. Figure 2-53 presents a predicted vertical profile of the vibration amplitude at the peak
of the response curve in Figure 2-52. Several aspects of this profile are worthy of mention: first,
the amplitude at the center of the frame of 0.72 mils corresponds to 0.45 IPSvery close when
compared to the 0.5 IPS measured at 100 Hz in Figure 2-43; secondly, the relative motion across
the mounting joint is pronouncedmatching qualitatively what is seen in Figure 2-45; thirdly,
the pedestal also exhibits substantial deformation. The term skid top in Figure 2-53 actually
means the pedestal top.
Figure 2-54. Compressor Base Response as a Function of Frequency Under Asymmetric Loading;
Pedestal Stiffness Increased by 4X; No Sliding at Mount
0.25
0.2
Epoxy
0.15 Adjustable
Steel
0.1
0.05
0
Dry-Break Dry-Slide Oily-Break Oily-Slide
Test Conditions
Figure 2-56. Minimum Friction Coefficient for Cast-Iron on Various Other Materials,
from GMRC Technical Report TR97-3 [2]
Figure 2-58. Rugged Support Structure for New 4-Chamber Bottles in More Detail Showing Clamp
Holding Bottle Against Wedges and Long U-Bolts Providing Substantial Bolt Stretch Length
Several of these changes undoubtedly combined to elevate the system mode to over
130 Hz, and the cylinder stretch mode to over 200 Hz as measured in subsequent data. Adding a
stiff suction bottle support puts restraint of the system out at a wide radius for the rotational
system mode and is probably more effective along with the mass reductions in elevating this
frequency than a four-fold increase in pedestal stiffness. Figure 2-59 makes clear a side
benefitmore space available below the floor after the secondary discharge bottle is removed.
Figure 2-61. Original 3-Chamber Suction Bottle on Ariel JGU6 Driven by Cat G3616
The pulsation study and finite element study revealed the need for modified filter bottles
on suction and discharge, added clamping on the new discharge bottle, and a strong support
structure for the new 4-chamber suction bottle.
The solution designed and implemented was to build a pier and add the originally
specified clamp. In addition, very rugged beam structures were designed and built, one for each
side, which extended under both cylinders on each side and well outboard of the cylinders at
both drive and non-drive ends. This beam structure directly supported the crosshead guides and
greatly reduced the vibration.
The changes may be seen in the pair of photographs in Figure 2-66. The left hand frame
on close inspection shows the beam structure. The right hand photograph of Figure 2-66 shows
the added clamp. Figure 2-67 shows the very rugged beam structure in more detail, together
with the bolts tying the crosshead guides to it.
Figure 2-67. Very Stiff Crosshead Guide Support, which is a Single Structure for Two
Adjacent Cylinders; Installed to Control Cylinder Vibrations Identified with Less Stiff
Individual Cylinder Guide Supports
2.6.4.1 General
Pulsations and associated shaking forces drive piping vibrations. In addition, cylinder
stretch and vertical compression reaction forces at the crosshead bearing can provide strong
excitation at orders of rotating speed. Accurate mechanical modeling of the compressor
manifold is important to achieve reliable predictions and to guide design modifications [14].
Much of this sub-section is based on the related work of White [14], including illustrative
graphics.
Figure 2-70. Details of Model at Joint Between Nozzle and Suction Bottle Showing Shell Elements
Used for Bottle and for Reinforcing Pad
Figure 2-72. Predicted Stress Distribution in Bottle Modeled with Shell Elements
Figure 2-74. Shell Element Model of the System Modeled with Beam Elements in Figure 2-73
Table 2-4. Comparison of Predicted Response Frequencies for Manifold and Piping
Based on Beam and Shell Models
Model Description Beam Model Shell Model
Vertical Scrubber Mode 18 & 33 Hz 11 & 20 Hz
External Choke Mode 27 & 47 Hz 30, 38, 45, & 77 Hz
Suction Bottle Mode 27 & 112 Hz 30, 55, & 75 Hz
Suction (Scrubber Inlet) Mode 56 Hz 38, 51, & 65 Hz
Cylinder Mode 84 Hz 45, 55, & 63 Hz
Figure 2-76. Velocity Spectrum Predicted with Shell Elements (Model of Figure 2-74)
Figure 2-78. Stress Distribution Predicted with Shell Element Model of Figure 2-74
2.6.5.2 Leveling and Aligning the Compressor Frame Free of Bend and Twist
Compressor OEMs in general are aware of the potential for frame bending and twisting
and agree it should be minimized in large separable compressors, but do not have formal criteria,
except for a maximum soft foot measurement. One suggested frame levelness criterion
based on optical measurements is .002-inch difference in height between adjacent bearings,
0.002-inch difference in height between sides of a particular main bearing, and 0.004-inch
difference between highest and lowest readings obtained when taken at both sides of the frame at
each main bearing location (0.008-inch overall has also been mentioned as a criterion for
levelness).
Crank web deflections offer a means to infer alignment of the crankshaft in its bearings,
though are not universally recommended. The widely used Caldwell criterion of 0.00018 inches
per inch of stroke will give a working value in the range of 0.001 to 0.0015 inches web
deflection limit for pipeline separables. The GMRC software Webmap can provide a visual
representation of a crankshafts bent shape, when provided with web deflection data.
There remains a need to define what is tolerable misalignment and twist in terms of the
potential damage caused by measurable misalignment from bearing-to-bearing and within the
frame as a whole. This needs to be the subject of further research.
While any significant soft foot is clearly an unacceptable state of alignment, the use of
this as the sole criterion for alignment of a compressor is incomplete. A widely accepted criterion
for frame alignment is a soft foot pull down limit of 0.002 inches. However, it is reported
anecdotally that in a test on a large frame compressor, one of the feet could be lifted 0.020 inches
before a 0.002-inch soft foot was detected at an adjacent foot. Thus, 0.002-inch soft foot should
be viewed as a necessary but not sufficient criterion for pipeline compressor applications.
Fr1 Fr1
2F
F F
Fr2
Figure 2-82. Simplified Illustration of Forces and Couples Acting on a Compressor Frame
The red F forces represent internal, unbalanced forces generated by compressor action typically these are the
shaking forces from reciprocating motion of pistons, piston rods, crossheads, and connecting rods. The green Fr
forces are the local reaction forces, which must be applied externally by the mounts to equilibrate the internally
generated forces. For an infinitely rigid frame, the green Fr reaction forces are zero. For anything less than a rigid
frame, the green Fr reaction forces are not zero.
The green forces represent reaction forces applied from outside the frame in order to
preserve equilibrium of the frame.
If that frame is truly rigid in bending, the red forces are globally balanced and no external
forces are required to preserve equilibrium; the required green forces are all zero for a rigid
Normal Force, Fn
Figure 2-83. Free Body Diagrams for Two Contacting Bodies Illustrating Friction Forces in
Reaction to Externally Applied Forces
The components of the external forces under consideration act parallel to the contact surface. The friction forces in
reaction to the external forces also act parallel to the contacting surfaces.
Since installations free of oil are uncommon, a conservative value for friction coefficient
would be 0.12.
The desirable design process is:
Get the maximum possible value for the force applied to the mount.
Select the appropriate coefficient of friction.
Determine the minimum normal force, which must be applied to the interface.
Set the anchor bolt force to a safety factor times this minimum.
Choose length, diameter, material, stretch for the anchor bolt to give the required
force.
The fourth bullet stated mathematically is:
Fn = Fs * (Fex/)
where Fs is a safety factor.
The safety factor should take care of the substantial uncertainty in these various steps.
Table 2-5 indicates the root area and achievable normal force for 70% and 80% of yield for
ASTM 193 Grade B7 material bolts of various sizes likely to be encountered in mounting.
Table 2-5. Anchor Bolt Forces (lbs) for Different Sizes and Stress Levels
Normal force for Normal force for
Nominal Bolt American Std. Bolt
70% Yield 80% Yield
Diameter, Inch Root Area, In2
(0.7*105,000 PSI) (0.8*105,000 PSI)
1 0.551 40498.5 46284
1.25 0.89 65415 74760
1.5 1.294 95109 108696
1.75 1.745 128257.5 146580
2 2.3 169050 193200
2.25 3.021 222043.5 253764
Canister bolt products exist designed for 80% of yield, as shown, for example, in Figure
2-84. The anchor bolt is contained within the canister and sealed and, therefore, is protected
against any chemical attack, embrittlement, or stress-corrosion cracking. The product, shown as
an example, can and should be stretched to 80% of yield. The bolt has rolled threads to
minimize stress intensification at the thread root. The design has two-piece spherical washers
under the nuts at top and bottom to provide self-alignment and to minimize any added stresses
due to misalignment. The material of the anchor bolt is ASTM A193 Grade B7 with
105,000 PSI yield and 125,000 PSI ultimate strength.
This canister bolt can reportedly be provided with the RotaboltTM tension-monitoring
device discussed in Section 2.6.6. The above table, therefore, defines for either 70% or 80%
yield the anchor bolt tension to be specified for different size anchor bolts.
The use of 1.75-inch diameter canister bolts which will safely handle 80% of yield, if
appropriately tensioned will apply a 146,600 lbs normal load to each mounting interface of a
JGV6. The interfaces referred to lie between the bottom of the foot and a mounting plate or
between the bottom of the foot and the top surface of any shims used for leveling and between
the bottom surface of any shims and the mounting plate. Using a 0.12 coefficient of friction, this
will hold 17,600 lbs of transverse force. At the current state of knowledge, the specific
maximum transverse load is unknown, but it is to be hoped it is less than this 17,600 lbs.
As another example, the engine block anchor bolts for a Cat G3600 series engine is one-
inch nominal diameter. With 70% yield for ASTM 193 bolt material, the bolt tension to be
specified is, therefore, 40,500 lbs. This can be expected to hold at least 4,860 lbs horizontal
mount load per bolt (note each Cat foot has two bolts giving 9,700 lbs per foot).
A
DIMENSION A = RANGE
OF ADJUSTMENT ABOVE
SEAL AT TOP OF
CANISTER
8 tpi ROLLED THREADS
TM
PER ASTM A-193, AND
GRADE B-7 STEEL
B
3/16" LATERAL
ADJUSRMENT 0 3/16"
D
STEEL HOUSING WITH
SELF ALIGNING
SPHERICAL WASHER E HOUSING
FOR ANGULAR DIAMETER
C
Nut
Foot
Initial
Deflection
X0 Shim
Mounting Plate
Grout
Grout Box
Deflection
after Time t, Xt
Anchor Bolt
Anchor Bolt
Length L
Figure 2-85. Illustration of Anchor Bolt and Compressed Sandwich, Including Grout Layer
Epoxy grout (as opposed to cementitious grout) is needed to provide the strength under
anchor bolt loads. All epoxy grouts are polymeric material and, as such, their properties are
time-dependent and temperature-dependent. Any loaded grout layer does not immediately
deform to a final reduced thickness under load but continues to compress over weeks and
months. Thus, when the mount includes a grout layer, the anchor bolt tension, which comes
from stretching of the bolt, reduces over weeks and months and requires regular retightening.
GMRC undertook a substantial investigation of grout creep properties [3]. A number of chock
and foundation grouts were tested over several months under load, and quantitative data were
obtained which enabled engineering of such grouted joints.
2.6.8.10 Managing Dynamic Forces Acting Between Engine Frame and Mounts
Managing the engine internal forces and their influence on mounting integrity presents a
challenge. In the case of Caterpillar, who provides the majority of compressor drive engines,
discussions of the data needed has been initiated. The need has been demonstrated by Case
Study 1 where it was clear that the adequacy of the engine foot mounting significantly influences
the engine block vibration, and even with a soft foot problem eliminated, the vibrations stayed
distinct (but acceptable). Other anecdotal observations on an 8,000 HP Cat engine showed that
with loss of design tension in the anchor bolt on the engine block mounts, the vibrations became
unacceptable. As a minimum, the need exists to engineer the strength of the tie-down, which can
involve several friction joints (particularly with adjustable mounts) held together by tension in an
anchor bolt. Whatever horizontal forces from individual throws might be transmitted through the
frame to the mount must be held in friction by that mount and the anchor bolt appropriately
tensioned to create that amount of friction at each interface when the coefficient of friction is
multiplied by the anchor bolt force. In other words, the required anchor bolt tension is the
required horizontal force to be held by friction divided by a conservative value for friction
coefficient [0.12 or value specifically established from contacting materials and conditions
maintained (dry or oily)]. There remains uncertainty in some of these mechanics, which needs
further research.
Table 2-6. Full Load Rolling Torques for Cat G3608 and G3616
Engine Compression Speed Rolling torque Max Min
Ratio (rpm) (lb-in) Torque Torque
(lb-in) (lb-in)
th 148,500
4 order
9.2:1 900 th 25,700 357500 41700
8 order
th 21,600
12 order
th 145,300
4 order
th 25,700
9.2:1 1000 8 order 353600 44900
th 21,600
G3608 12 order
th 202,700
4 order
11.1:1 900 th 38,700 433700 1000
8 order
th 18,400
12 order
th 199,000
4 order
th 38,700
11.1:1 1000 8 order 429700 4300
th 18,400
12 order
th 64,200
4 order
9.2:1 900 th 49,000 448000 225000
8 order
th 32,000
12 order
th 62,500
4 order
9.2:1 1000 th 49,000 447000 225000
8 order
th 32,000
G3616 12 order
th 65,300
4 order
th 69,300
11.1:1 900 8 order 513000 256000
th 27,000
12 order
th 62,200
4 order
11.1:1 1000 th 69,300 512000 257000
8 order
th 27,000
12 order
Table 2-8. Cat Large Engine Dynamic Significant Linear and Torsional Excitation Frequencies
Significant Engine
Cat Engine Engine Firing Specifics Orders of Excitation for Firing Order
Linear Vibration
G3606 In-Line, Even Firing Order (120) 1st, 3rd, [4.5] 153624
G3608 In-Line, Even Firing Order (90) 1st, 4th 16258374
1 , 3rd, [4.5], 6th
st
G3612 50 Vee, Odd Firing (50, then 70 & so on) 1 12 9 4 5 8 11 2 3 10 7 6
1 2 5 6 3 4 9 10 15 16 11 12
G3616 50 Vee, Odd Firing (50, then 40 & so on) [0.5], 1st, 4th, 8th
13 14 7 8
Significant Front
Cat Engine Crankshaft Engine
Orders of Excitation
G3606 3rd, [4.5], 6th
G3608 2.5, 4th, 8th
G3612 1.5, 3rd, [4.5] 6th
G3616 0.5, 2.5, 3.5, 4th, 4.5
[ ] These orders are forced excitations of the engine crankshaft due to the engine's firing order
They cause a forced twist of the engine block that directly affects linear vibrations of mounted equipment
This section provides the qualitative, but very significant guidelines for planning and
organization of the project.
It includes the following sub-sections:
Organizations and Their Interfaces (3.1)
Responsibilities (3.2)
End User Due Diligence (3.3)
Needed skills (3.4)
Some of these sections can be viewed as checklists for different aspects of project
organization. The due diligence section can be referred to by the end users project engineer,
with benefit, at all stages of the project.
3.2 RESPONSIBILITIES
This section seeks to emphasize the primary responsibilities of the major stakeholders.
3.2.5 RESPONSIBILITIES FOR FOUNDATION DESIGN AND INSTALLATION FOR FOUNDATION AND
SKID
The responsibilities exist to ensure that a skid-mounted package or a block-mounted
package has a sound foundation appropriate in size, strength, and concrete to ground interface for
the application, and for the specific location. The responsibility further exists to ensure that the
skid is solidly mounted on the concrete block, together with any off-skid items, which must be in
close proximity to the compressor or engine (e.g., discharge bottles).
These guidelines will refrain from characterizing closely to whom all these
responsibilities fall, since a number of different contractual arrangements are possible. The
important message is that these responsibilities exist and are absolutely critical to the success of
the installation. Major corrective action for concrete structures is costly and complex and may
be effectively impossible. The end user must ensure that all the necessary skills to meet these
responsibilities exist on the team, that they will be available when needed, and that appropriate
skills on the end users project team are available on a timely manner to provide oversight of the
most critical functions. The team assembled to design and install the package or components on
Figure 4-2. Compressor Foot of JGD4 Driven by Cat G3616, Mounted on Chock Set in Grout Box
Note anchor bolt stretch length achieved by box structure. Note also vertical jacking screw.
pair of low profile crosshead guide supports. Figure 4-4 shows higher profile A-frame supports
for the crosshead guide, and Figure 4-5 shows a support, which extends between the two
cylinders on each side of an Ariel JGD4 and provides stiff support for low profile A-frame
supports under individual crosshead guides.
Figure 4-5. Stiff Crosshead Guide Structure Covering 2 Cylinders of Ariel JGD4,
Driven by Cat G3608
This structure mounts A-frame immediately under guide to skid. This installation has an elevated compressor frame
because the discharge bottles are mounted on top of the skid instead of on the concrete. It is noted this structure is
also tied back to the pedestal under the compressor frame via I-beams.
Figure 4-6. Crosshead Guide Support for Wartsila Engine Driven JGV6
As discussed, the ability to stagger the height of compressor and driver mount surface is
an advantage of mounting the compressor and driver directly on a concrete block. In general, a
substantial pedestal under the compressor adds risk and a requirement for careful assessment of
dynamic characteristics.
Figure 4-9. Anchor Bolt for JGV6 Compressor Frame Extending Below Skid
Figure 4-10. Box Structure for Achieving Stretch Length for Anchor Bolts
This was retrofitted to reinforce previously installed stretch tube.
4.3.2.1 Minimize Extra Height of Compressor and Its Feet Above the Main Skid
There are several reasons for this, including:
To keep the center of gravity as low as possible and, thereby, to keep the frequency
of modes involving horizontal motion of the compressor and attachments as high as
possible.
To reduce the vertical moment arm for horizontal forces acting at the level of the
crankshaft and cylinders.
To allow the stiffest possible mounting of the crosshead guide support to the skid.
To avoid extra structural flexibility under the compressor.
Figure 2-45, discussed with reference to Case Study 2, showed one consequence of
height on the skid of a motor drive. It presents vibration as a function of level above the bottom
of the foundation, for an installation with a base skid and a pedestal upon which a JGV6
compressor was mounted. There is a clear jump in the vibration from the bottom of the I-beam
structure to the base of the frame; part of this is elastic deformation of the structure and part is
sliding at the interface between feet and mount.
Figure 2-50 (also referred to in Case Study 2) shows a related consequencethe
existence of a vibration mode involving the entire frame-cylinder bottle system on the
compressor pedestal structure at just around 100 Hz.
Factors, which can influence elevation of the compressor, are:
Mounting the bottle on the concrete upon which the skid is mounted, not on the skid
itself.
The combined height of discharge bottle diameter, nozzle length, support pier, and
support wedges under the discharge bottle.
Supporting the bottle on concrete, which is at the same level as the concrete on
which the skid is mounted.
The height of the driver shaft centerline above the lowest point on the driver.
Placing the discharge bottle on the skid inevitably forces the compressor to be mounted
on an intermediate structure on top of the main skid with substantial height. Figure 4-11
emphasizes this point; it shows a bottle mounted on skid and behind it the compressor frame
highly elevated by a pedestal. Thus, a clear recommendation for pipeline applications is to
mount the bottles off the skid and on the concrete foundation as restated below.
Note that the nozzle length and discharge bottle diameter should be either determined by
a pulsation study or should have been confirmed by the pulsation study to be satisfactory.
4.3.2.2 Minimize Height of Any Required Compressor Pedestal and Make the
Pedestal and Compressor Mounting Sound and Stiff
The influence of a driver shaft centerline above the drivers low point (sump bottom for
an engine) is important and cannot easily be worked around in a skid mount, only minimized. If
the driver height exceeds the compressor height by more than a few inches, then a compressor
pedestal will be required, but its height should be minimized and must be carefully evaluated for
its influence on system dynamics. The pedestal must be made stiff enough to avoid the
excitation of undesirable compressor modes. For example, it is not required that the pedestal be
as narrow as the compressor baseextra stiffness can be gained by adding width or by adding
wide gussets or gusseting beams outboard of the pedestal.
4.3.2.3 Allow Anchor Bolts to Terminate Below the Main Skid Level, If Required
Combining the guideline for 20+ inch long anchor bolts with the guideline to minimize
height of any pedestal under the compressor may result in anchor bolts whose lower termination
lies below the top level of the main skid. Figure 4-9 has made clear the feasibility of this skid
design and construction feature. The bid specifications should make clear that this construction
should be considered, if needed, to satisfy low pedestal height and long anchor bolt
requirements.
4.3.2.4 Do Not Mount the Bottle on the Skid Mount It From the Concrete
Even if the discharge bottle is mounted on concrete, the concrete level from which it is
supported can be made lower than the concrete on which the skid is mounted (see Figure 4-12
and Figure 4-13 for staggered concrete levels). This approach may add cost to the foundation,
but, if needed, it removes any constraint on compressor height above the main skid, imposed by
bottle mounting.
4.3.2.6 Always Support Any Outriggers with Grout and Anchor Bolts
Outriggers are horizontal beams, which extend laterally beyond the main skid. If the skid
design incorporates outriggers, they must be grouted and anchor bolted to solid concrete.
Substantial problems have been observed with unsupported outriggers. There should be no
unsupported horizontal structural element (piping excepted). Outriggers can be used to add
lateral stiffening to a skid, and in this case, they clearly need to be rigidly grouted and bolted to
concrete.
4.3.2.7 Fill the Skid with Concrete in the Skid Sections Under the Compressor
The benefits of adding concrete under the compressor are to add weight and resulting
impedance to resist force excitations. It was seen in discussion of Figure 2-1 that concrete added
about 135,000 lbs to a skid whose beam weight was about 85,000 lbs. Such added weight
reduces vibration levels. Figure 4-14 shows installed concrete from the underside of a skid.
The concrete to skid interface should be enhanced with mechanical locks welded to the
inside of the skid structure to be filled with concrete. Concrete can change dimensionally over
time and pull away from the skid beams. The locks help avoid relative motion of the concrete.
Grout can be considered as an alternative to concrete and should reduce the dimensional
changes (at a cost). If the concrete fill does pull away, epoxy can be injected to fill the gap.
4.3.2.8 Design and Build the Skid to Be Level Within Itself to Some Agreed
Tolerance
A nominal criterion to consider for skid levelness as manufactured in the packagers shop
is 1/8-inch deviation over the skid surface. This would be a high standard, with an implied cost
to it, but high standards are appropriate for pipeline applications.
The end users project engineer will benefit from reviewing the following with potential
packagers and with those who will be involved in skid and equipment alignment:
The cost and benefit implications of any specified value for skid levelness as
manufactured.
The relationship of skid levelness criteria to the manufacturing criteria for the
structural beams themselves.
The way in which levelness will be inspected and measured.
The possibility of specifying separate criteria as measured over skid length and over
skid width, as well as for crowning and sagging deviations.
The further possibility to specify the levelness at critical mounting points for driver,
compressor, and vessels.
Recognition that elevations may change as the skid is built up on the shop floor and
equipment is mounted; equipment weight and the means of skid support on the shop
floor will influence these changes.
How skid-manufactured levelness relates to planned procedures and criteria for
installation/alignment of the skid on the foundation and of equipment on the skid.
The need to replicate the shop setup at site on the foundation.
4.3.2.9 Gusset the Skid Beams and Pedestal Beams at Key Support Points
This will minimize distortion and deflection of the beam cross-sections. Figure 4-15
shows main skid reinforcement. Figure 4-16 and Figure 4-17 show reinforcement under the
engine mount pedestals. Gussets for pedestals can extend beyond the flange of the reinforced
beams.
4.3.2.10 Design for Adequate Stretch Length of Any Anchor Bolts on Skid Mounted
Units (20 Inches Minimum)
As discussed under Section 2.6.8.7, the potential for creep leads to a recommendation
that all anchor bolts be at least 20 inches thick for skids. This applies to engine mounts as well
as compressor mounts.
Figure 4-16. Mounting Foot Mounted on Chock Set in Grout Box, With Shims
Between Chock and Foot for Alignment and Leveling
Note pair of anchor bolts and vertical jacking screw. Note also 3 vertical gussets to
reinforce main web of beam at this support location.
Figure 4-18. Freestanding Stretch Tube on Compressor Pedestal for JGV6 Installation Later
Reinforced with Horizontal Plate Mid-Way Down Bay Between Gussets
4.4.2.1 Specify and Confirm Concrete with 4,000 PSI Compressive Strength
Concrete should be specified to meet recommendations of ACI 351 and API 686, which
both call for a minimum of 4,000 PSI compressive strength. Testing should be performed
according to ACI and ASTM standards to ensure the required strength has been reached before
any equipment is mounted on the concrete. Concrete using Portland cement will take at least 28
days to cure.
4.4.2.2 Specify the Pouring of Sufficient Test Cylinders During Foundation Pour
These cylinders should be according to ACI dimensions and conditions. There should be
one for each of 7, 14, 21, and 28 days and some additional cylindersseven or eight total.
4.4.2.6 Set the Concrete Height for Discharge Bottle Mounting as Determined by the
Designs of Skid, Compressor Mounting, and Pulsation Control
The foundation design should allow bottles to be set on concrete outboard of the skid at a
level appropriate to accommodate the combined height of wedges, wedge mounting plate,
discharge bottle diameter, discharge nozzles, cylinder diameter, and at the same time to allow the
compressor center of gravity height to be minimized. This may require the bottle mounting
concrete level to be below the skid mounting concrete level. Section 4.7 further addresses the
details of discharge bottle mounting with wedges.
4.5.2.1 Specify Rebar Density of 1% for the Top 3 Feet Under the Compressor and
Engine Mounts
This density can be achieved with #8 on 8-inch centers or with #6 on 6-inch centers.
This is a higher rebar density (2.5X) than recommended for a foundation to support a
skid-mounted unit. This is in recognition that dynamic loads transmitted to a skid, and
distributed by the skid before transmission to the concrete in a skid mount, must now be
directly carried by the concrete. Cracks caused by compressor transverse load on block-mounted
low-speed units were most prevalent near the top of the concrete block, and analysis shows the
top 2 or 3 feet exhibit the highest tensile stresses. The high rebar density inhibits the growth of
cracks, which can start when the dynamic stress reaches a tensile value as low as 190 PSI.
If the #8 rebar for the vertical direction creates a problem for required bending, #6 rebar
may be substituted for this direction.
Reciprocating compressors generate high dynamic loads, which must be withstood by the
concrete block. Even blocks installed in the last 20 years with moderate levels of rebar have
developed cracks under the dynamic loads from the compressor. High rebar density is one of the
design actions, which can mitigate the tendency to crack. Strength requirements of the concrete
block for mounting a medium speed separable compressor should not be greatly different from
those for a slow speed compressor.
4.5.2.2 Below the Top 3 Feet, the Spacing Can Be Doubled in All Three Directions
This is because the dynamics stresses tend to be highest near the top where the loads are
applied.
To aid constructability and to facilitate placement of concrete hoses during the pour,
Windows in the rebar grid (16 x 16) are suggested in regions away from the anchor bolts,
along the center of the compressor. However, the number of such windows should be
minimized.
4.5.2.3 Engineer Anchor Bolts of High Strength Material and Tension Them to
70%+ of Yield Stress
As previously discussed in Section 2.6.8.2, a conservative requirement would be to hold
at least 50% of the local throw force in friction. Figure 2-45 has shown that relative motion can
occur between individual feet and their mounting plate under transmitted compressor transverse
loads, if the horizontal load is not adequately carried by friction.
As a practical manner, the most that can be done in this direction is to specify as high a
bolt strength as can readily be achieved, and to tension the bolt accurately to 70% or more of
yield stress. The bolts should be specified according to ASTM A193 (10), with yield stress of
105,000 PSI (see below for anchor bolts designed to allow stressing to 80% of yield).
4.5.2.5 Design a Grout Layer No Thicker Than 4.5 Inches to Avoid Excessive Loss in
Tension by Creep
This thickness is selected to go with the 4-foot minimum anchor bolt length
recommended above and to avoid excessive creep and excessive thermal distortion or cracking.
4.5.2.6 Engineer and Specify the Grout Support for All Mounting Plates (Chocks) for
Adequate Strength
A minimum grout modulus of 1.5E6 is recommended for 120F. With resulting
compressive strain under 1,466 PSI (146,600 lbs on a 10 x 10 mounting plate) of
approximately 0.1% of the thickness, this high modulus should keep the additional deflection
from creep low as well.
The non-uniformity of loads under a mean pressure of 1,466 PSI, coupled with thermal
loads, demands much higher grout strength than the average applied pressure and at least
10,000 PSI at 120F is recommended.
A
DIMENSION A = RANGE
OF ADJUSTMENT ABOVE
TM
PER ASTM A-193, AND
GRADE B-7 STEEL
3/16" LATERAL
ADJUSRMENT 0 3/16"
This analysis should include independent assurance that the mounts of engine and
compressor meet the recommendations given above for anchor bolts and grouting.
4.5.2.9 Specify That Any Exposed Concrete Surface Be Coated With An Oil Resistant
Coating
Oil leaking on to the concrete should and can be minimized, but it is conservative
practice to guard against oil leaks even so. The oil can carry its own additives or chemicals,
which can damage the concrete or rebar. If cracks occur, any oil, which penetrates the crack, can
generate hydrodynamic pressure and aggravate the working of the crack under dynamic loads.
Coating the concrete will help protect the concrete and the rebar.
Figure 4-24. Siemens Motor Driven JGV6 with Replacement 4-Chamber Suction Bottle Installed
and Rugged Support Structure for Suction Bottle
Note cross-bracing between bottles on each side, also double nozzles for high flow low ratio application.
4.6.2.2 For Pipeline Applications, Ensure Predicted Pipe Stresses Meet ASME B31.8,
While Recognizing the Potential Conflict of Low Thermal Stress and Low
Vibration
The piping must be designed with acceptable thermal, pressure, and weight load stresses,
particularly in the hotter discharge piping. ASME B31.8 [15] is the standard, which must be met
for pipeline compressor stations. However, since one approach to achieving low thermal stresses
is to increase flexibility of the thermally loaded pipe, it is important to confirm that thermal
stress solutions do not aggravate vibration problems, as discussed further in Section 4.8.4.8.
4.6.2.3 All Joints on Gas Carrying Pipe Should Be Either Welded or Flanged
Whatever the Diameter
API 11P exempts some small sizes from this requirementthese guidelines say there
should be no exception, since vibrations can occur in any size pipe and threaded joints are
always vulnerable to vibration.
4.6.2.5 In Meeting ASME Pressure Vessel Requirements for Filter and Manifold
Bottles, Ensure Structural Dynamic Considerations are Also Satisfied
Filter and manifold bottles must satisfy wall thickness and related standards imposed by
the ASME pressure vessel code. However, these standards may not always be sufficient from
system structural considerations. In particular, low-pressure bottles (particularly suction bottles)
may meet code with a wall thickness so thin that it incurs damaging vibrations as a result of wall
flexibility or flexibility at penetrations. Such wall thicknesses should be reviewed from dynamic
considerations, based on shell element FEA modeling, and increased as needed.
The code has requirements for reinforcement at penetrations, but it is sometimes possible
at side and head penetrations of bottles for laterals and choke tubes that the requirements for
material replacement can be met with a pad, which is thin, or with no pad at all. Pad
reinforcement is always recommended from dynamic considerations (see below for dimensions).
4.6.2.6 For Any Bottle Penetration, Weld a Circular Reinforcing Pad to Nozzle and
Bottle with Diameter at Least 1.75 Times the Outer Diameter of the
Penetrating Pipe, Which is Approximately as Thick as the Bottle Wall
The benefit of the reinforcement is to stiffen the joint and to spread any loads induced by
vibration away from the point of penetration.
This guideline represents a larger diameter reinforcement than API 11P, which in its
paragraph 6.3.7 states reinforcement pads shall be at least equal to the cutaway area.
4.6.2.7 Use a Manifold Bottle on Both Suction and Discharge With One More
Chamber Than the Number of Cylinders
Figure 2-68 shows such a suction bottle configuration for a compressor with two
cylinders per side in a finite element model. Baffles create a chamber for each cylinders gas
flow, and then individual choke tubes carry the flow from each cylinders chamber to or from a
common chamber not associated with any individual cylinder.
In this way, each cylinders chamber, in combination with the common chamber, and the
choke tube, which connect the two, form a volume-choke-volume filter just for that cylinder.
Because the flow from only one cylinder must pass through each choke, the choke
diameter is reduced, and the required volume of each chamber is minimized, as is its diameter.
For medium and high-speed compressors, the effectiveness of pulsation control with the
single (Ncyl +1) bottle has been found in SwRI studies to be as good as, or better than, with a
two-bottle system (though the two-bottle system can be more effective for slow speed
compressors).
As discussed in Case Study 2, a smaller diameter bottle has significant benefit in
mounting compressors, whether on a skid or on a block, and there are benefits for both suction
and discharge bottles to be small. For the discharge bottle, we have seen that this helps reduce
the stack-up in height, which must be accommodated between the cylinder and the bottle
wedges. In a block mount, it also allows an increase in width of the block pedestal under
compressor and crosshead guide supports, with specific benefit to the concrete surface area
outboard of the guide support.
For the suction bottle, the reduced diameter helps reduce the overall weight and system
moment of inertia, which has to be carried by the compressor mounting system. The bottle with
(Ncyl + 1) chambers also eliminates the need for a secondary bottle, which would otherwise take
up space and have to be separately mounted. Figure 4-25 shows three different filtering options:
secondary bottles on suction and discharge; secondary bottle on suction with 3-chamber bottle on
compressor with 2 cylinders per side; and 4-chamber bottles for suction and discharge on JGV6
compressor (with 3 cylinders per side).
It is recommended that the end user specify use of such a single filter bottle, unless
specific reasons not to do this can de documented.
4.6.2.8 The End User Should Further Specify that the Resulting Suction Bottle Be
Separately Supported With Its Own Rugged I-beam Structure
Figure 2-3, Figure 4-26, and Figure 2-58 show such support structures and bottle
attachment methods.
4.6.2.11 Robustly Mount All Piping Wherever Possible, Both On-Skid and Off-Skid
Figure 4-27 shows a secondary bottle ruggedly mounted, on-skid, with a low profile. All
spans of piping should be critically evaluated for vibration, both at the design stage and after
installation. Long spans should be avoided; piping should be kept as low as possible; piping
should not be mounted to outriggers or deck plate.
Figure 4-27. JGT4 Installation; Rugged Low Profile On-Skid Mounting of Secondary Bottle
While use of secondary filter bottles is not the preferred approach to acoustic filtering
(primary filter bottles with Ncyl + 1 chambers are preferred), it can be made to work. If
secondary bottles are used, close attention must be paid to their mounting. Figure 4-28 shows a
Figure 4-29 shows a rugged off-skid mount for lateral pipingpart of the original
installation for a JGT4 driven by a G3520B.
Figure 4-30. Cat G3608 Installation Showing Bracket Added to Control Piping Vibration
4.6.2.14 Review All Flange Locations for Convenience of Access After Installation is
Complete
Figure 4-33 presents an example of a flanged pipe joint assembled before the building
walls were installed; after installation of the walls, it proved very difficult to get a wrench to the
flange bolts because of proximity to the wall.
4.6.2.15 Wherever They are Mounted, Vertical Vessels Should Be Robustly Supported
on Thick Plates with Appropriate Bracing
Any vessels on skid should be mounted as directly as possible to full depth skid members
and never to the deck plating.
variation, the shaking forces which result from pulsations, cylinder stretch loads, and uncertainty
in properties such as speed of sound. Methodology and criteria are discussed in Section 4.8.2.
Detailed recommendations for the analytical approach to be used in structural analysis of
piping have been discussed in Section 2.6.4.
4.6.2.17 Stress-Relieve All Welded Joints; Subject All Welded Joints to Non-
Destructive Testing for Flaws
Almost all piping failures occur at welded joints; these are the weakest points and flaws
can be introduced in the heat affected zoneseven of full penetration welded joints and girth
welds on bottles. Stress relief helps eliminate thermally induced stresses in the welded joint.
Inspection helps identify any poorly welded joints or flaws, which remain after stress relief.
The end user should specify both requirements explicitly; examples exist where
inspection was not performed. Specifying stress relief and inspection adds these items to the list
of requirements to be checked as part of the due diligence process.
4.6.2.18 Design Bypass Valve to Be No Less Than One Pipe Size Below the Unit
Discharge Piping
This rule is to avoid overheating during start-up prior to loading. Particularly during the
early starts in the unit, it may be necessary to run for some time on bypass. Excessive flow
resistance in the bypass valve can lead to high discharge pressure and high discharge
temperature. Experience shows that a unit with insufficient valve flow area will trip on high
discharge temperature. This can substantially complicate the start-up checkout process.
Figure 4-34. Skid for Ariel JGT4/Cat G3520 Installation With Grout Showing Anchor Bolt With
Supernut and Jacking Screw for Leveling Skid
Thus, it must be clearly specified that the skid be grouted and anchor bolted for pipeline
applications.
4.7.2.2 Specify the Grout for This Purpose Should Have Appropriate Modulus and
Compressive Strength
1.5E6 PSI for modulus; 10,000 PSI for strength at 120F
4.7.3.2 Specify that Final Alignment of Both Compressor and Driver Must Occur at
Site
Whether or not the driver or compressor are transported to the installation site on skid,
some shifting or change in alignment is inevitable under transportation loads. For pipeline
applications, final alignment should be undertaken at site under the direction of a verifiable
alignment expertwho may be hired for the purpose or may be a part of the supplier team.
4.7.3.3 Specify that the Level of Compressor Feet Should Be Adjustable at Site
This is an important corollary of the preceding requirement. Adjustability is provided
most commonly by shims between the compressor feet and the corresponding, skid-mounted,
mounting plate.
One alternative to shims is a device provided by U.S. Rotech and Mechanical Solutions
called the Epoxy-filled Self-Aligning Mount, illustrated in Figure 4-36. This device consists
of a rectangular box, also termed the bottom plate, with springs between it and a top plate of
similar rectangular size. When inserted under a compressor foot, the springs push the top plate
up against the foots downwards-facing surface. There is a slot for the anchor bolt to pass
through and a hole in the top plate through which jacking screws can pass. Jacking screws from
the foot are used to adjust the foots level by pushing against the bottom plate, while the top plate
remains in contact. When the compressor is satisfactorily aligned and adjusted for height at all
feet, the space between top and bottom plates is filled with grout. When the grout is cured, the
anchor bolt is tightened against the mount.
4.7.3.6 Specify High Strength Anchor Bolts to Attach Compressor Frame to Skid
Use of bolts meeting the requirements of ASTM A193 (standard specifications for Alloy
steel and stainless steel bolting materials for high temperature service) Grade B7 are strongly
recommended and should be specified by the end user to ensure that a less costly and possibly
less strong alternative is not used. Such bolts (with diameter of 2.5 inches or less) will have an
ultimate tensile strength of 125,000 PSI (860 MPa) and a yield strength of 105,000 PSI
(720 MPa).
Double spherical, hardened washers under each nut make the anchor bolt and joint
integrity more tolerant to misalignment caused by small tolerances in bolt or hole location.
4.7.3.7 Nuts Meeting ASTM 194 (11) Should Be Used with ASTM 193 Bolts
4.7.3.10 Specify Tension of Compressor Frame Anchor Bolts to 70% or 80% of Yield
Stress
The interface between compressor and skid or pedestal is a critical joint. Evidence exists
that sliding can occur (as discussed above with respect to Figure 2-45) even in well-engineered
and well-installed installations under the action of forces transmitted from compressor to feet and
feet mounts. Thus, the highest normal force, which can be achieved with the highest practical
anchor bolt diameter, should be specified. As stated by ACI 351.3R-04 (9), the practical limit
for bolt stress is 80% of the yield stress. Past GMRC reports have recommended 70% as a safe
general limit, considering the possibility of stress corrosion cracking. Canister bolts, as
illustrated schematically in Figure 4-22 and by the photograph in Figure 4-23, are designed to
protect the bolt from any corrosive influences, and canister bolt products are available which
recommend bolt stress up to 80% of yield. In summary, 70% of yield is recommended as a
general limit, and with appropriate product selection and engineering, this can be raised to 80%.
The required tension for the anchor bolts in pounds should be explicitly specified.
4.7.4.2.3 Each Mounting Plate Surface Should Be Aligned with the Skid Surface
It is important to ensure that all mounting surfaces are as level as possible in the
specification and implementation of the skid design.
4.7.4.2.4 Make the Separation Between Each Mounting Plate and the Corresponding
Engine Foot Adjustable
Most commonly, the adjustability for compressor feet is provided by shims, as seen in
Figure 4-40 under a G3616. Shims represent a minimum addition of height above the mounting
plate for adjustability, and can be installed in steps as small as 0.002 inches. The high shear area
presented by a shim leads to a shim being a very stiff member, provided the shimmed joint has
sufficient normal forces across it for the friction force to exceed the horizontal force transmitted
by the frame or block to the joint.
For the G3608 of Figure 2-39, the foot is mounted on two Vibracon adjustable mounts.
Some other options for adjustable driver mounting have been listed in Section 4.7.4.1.
and are discussed further in Section 4.7.4.2.5 below.
4.7.4.2.7 Engineer the Highest Holding Force Possible Within Existing Constraints
Even if the horizontal force transmitted to the mount is not known, it is possible to
minimize the potential for slip at the joint by installing the largest diameter bolt at that joint
which the engine foot will accommodate: use the highest grade bolt material available (as per
ASTM A193 Grade B7) with rolled threads; accurately tension the bolt to a high percentage of
the 105,000 PSI yield stress of this bolt material (not less than 70%); and make the bolt
adequately long (between closest nuts) to minimize the opportunities for creep. For skid mounts,
the recommended stretch length is at least 20 inches, and for bolts embedded in concrete, the
recommended minimum stretch length is 48 inches.
4.7.5.1 General
The crosshead guide support is typically located near the joint between crosshead guide
and the cylinder. In particular, with heavy pipeline cylinders, the crosshead guide support is an
essential element in weight support and vibration control.
4.7.5.2.1 Make the Crosshead Guide Support As Stiff and As Strong As Possible and
Minimize the Vertical Separation Between the Main Skid and the Underside
of the Crosshead Guide
Figure 4-6 shows a stout short crosshead guide support for a JGV6 mounted on the skid
by a mounting plate, which sits in a grout box. The support itself is available from the OEM for
JGU and JGV compressors. Figure 4-21 shows a similar A-frame crosshead guide support
mounted on a sole plate grouted into a concrete block for a block mounted JGV6 compressor.
The height separation between skid or block and guide for both these configurations of guide
support mounting is desirably short and stiff.
Engineering the equipment arrangement to achieve such a stiff mounting configuration is
strongly recommended.
4.7.5.2.3 Elevate Cylinder By Shims at the Joint Between Guide Support and Guide,
or Under the Guide Support, to Meet Criteria Established By the
Compressor OEM in Order to Offset the Cylinder Droop Caused By Its
Weight and the Weight of Appendages
Some OEMs provide tables or spreadsheets to assist the shim selection.
4.7.5.2.4 Confirm After Shimming That OEM Specifications for Clearance at Top
and Bottom of Crosshead Guide Bearing are Met
These crosshead bearing clearance specifications should prevail, so adjustments to
shimming should be made to meet these criteria.
4.7.6.1 General
The cylinders of some compressors need head end supports to control their vibrations
and/or to take the weight. This solution on the surface seems to offer significant benefits, and
from the pure question of controlling vertical vibration modes, it probably does. However, the
head end support introduces another critical mounting interface and also can introduce new
vibrations modes of its own, which can be excited by cylinder motion. In addition, care must be
taken to avoid the head end support offering a significant constraint to cylinder stretch motion.
4.7.6.2.1 Design Cylinder Head End Supports to Have a Substantial Mounting Base
The mounting design must include a solid base grouted to the concrete under the base and
four widely spaced anchor bolts with adequate stretch length installed in the concrete and
tensioned against the grout once hardened.
4.7.6.2.2 Do Not Consider Attaching the Head End Support Only to the Skid to be an
Adequate Mounting
Explicit evidence exists that, if the head end support is needed, such inadequate mounting
will lead to an ineffective head end support and high vibration, as discussed in Case Study 1.
4.7.6.2.3 Ensure By Analysis That Even With a Good Base Mount the Head End
Support is Flexible Enough to Avoid Constraining Cylinder Stretch
Basically, this means that the stiffness in response to a force acting perpendicular to the
crankshaft at the top of the support should be significantly less than the stiffness of the crosshead
guide.
Figure 4-41. JGD4 Installation Showing Tuning Mass Added to Head End Support to Change
Natural Frequency from Value Leading to Very High Torsional Vibration of Support
4.7.7.1.2 Ensure Solid Wedges, With Two Side-By-Side Strong Tie-Bolts, Soundly
Supported on the Concrete, Directly Under Each Nozzle and Under Each
Discharge Bottle Clamp
Holding down the discharge bottle can be very important to system dynamic integrity.
Skid mounting the discharge bottle is not recommended, and the wedge configurations in Figure
4-42 also aggravated the associated dynamic problems for such a bottle. This wedge is
inadequate, and it is in the wrong placeit has only one thin tie bolt. It is very narrow; it does
not lie directly under a nozzle; and it is not directly over a structural beam. Figure 4-41, in
addition to the detuning weight discussed above, shows the replacement for the wedge of Figure
4-42. This has two tie bolts instead of one and both are thicker than the original. It is about four
times as long axially and twice as extensive in the direction across the bottle; it is sitting directly
on a beam structural member and directly under a nozzle. Figure 4-43 shows another wide
wedge directly under a clamp, again with 2-well separated tie-down bolts.
Figure 4-44 shows another illustration of good solid wedges located directly under each
nozzle. These wedges each have two tie-bolts and are located on plates grouted directly to the
concrete foundation. The leveling screws for the plate are visible. The plates have not yet been
grouted in place, but when this installation is complete the wedges of this bottle support will be
very robust with anchor bolts tightened against the hardened grout.
In recognition of thermal growth of discharge nozzles, discharge bottle wedge bolts
should be tightened when the compressor is at the operating temperature (as discussed further in
Section 4.10.9).
4.7.7.1.3 Mount Wedges on a Sole Plate Directly Grouted Into the Concrete With
Anchor Bolts
Piers are sometimes used under the bottle wedges, but it should be recognized these add
flexibility. The discharge bottle-mounting configuration shown in Figure 4-44 is preferred to
that of Figure 4-45 for this reason. If circumstances dictate pier mounting, effort should be
applied to achieve stiff piers. Figure 4-46 shows the mounting of retrofit, reduced diameter
bottles on solid stiff piers built up, and butted against the main block to provide the needed
support for the wedges.
4.7.7.1.4 Place Fabreeka Between Clamp and Bottle; Also Between Wedges and
Bottle
Figure 4-43 also makes clear the use of Fabreeka between the wedge and the bottle; this
is not a universally accepted recommendation, but is believed by the author of these guidelines to
be beneficial, if performed carefully. The Fabreeka should be compressed until it is very stiff,
and in the process, it broadens the contact from a line contact to an area contact, so reducing the
chance for fretting damage, if relative sliding motion occurs at the contact point.
Figure 4-43. Close-up: More Rugged Clamp and Wedge on JGD4 Installation
Note clamp and wedge directly on skid cross-beam. Note Fabreeka between wedge and bottle.
4.8.1 OVERVIEW
As previously discussed, it is common for third party designers and analysts to be hired to
support the end user, the packager, or the engineering company involved, most commonly for:
Pulsation analysis and pulsation control system design.
Train torsional analysis and torsional vibration control system design.
Piping and compressor manifold system vibration analysis.
Structural analysis of skid, foundation, and mounted components.
Piping thermal stress analysis.
In general, the responsibilities for providers of these services include:
Define and acquire data needed to prepare model(s) and execute relevant analyses.
Diligently pursue gaps in the needed data.
Manage unfilled gaps in data.
Prepare relevant and accurate models.
Effectively apply appropriate state-of-the-art software tools.
Apply experience and correlations from similar designs to validate predictions.
Identify potential design problems in time for needed changes to be made.
Clearly communicate results to relevant stakeholders, together with significance of
results, assumptions, and sensitivity to assumptions.
Define, analyze, and present appropriate solution options.
Assist in design change decisions.
The following discusses these topics in varying depth, recognizing that other documents
and guidelines address certain types of analysis in considerable depth, which this document will
not seek to reproduce. Harris and Scrivner [18] provide a good overview, with examples, of the
various methods of analysis and design evaluation for integrated design of compressor
installations. The GMRC-SwRI short course [30] provides three days of in-depth technical
instruction on the subject.
This section seeks to focus on how the analysis, associated design/configurational
decisions, and the phenomena that the design analysis seeks to control will impact mounting and
its integrity.
4.8.2.1 General
The time varying flows from reciprocating compressors tend to excite acoustic
resonances and pulsations in attached piping. These phenomena require effective management
supported by detailed acoustic modeling. The details of analysis and of pulsation control are
discussed in more depth in Section 2.6. A pulsation analysis for the specific conditions and
attached piping design is absolutely essential for pipeline applications.
It is almost certain that a digital pulsation analysis will be offered and performed (as
opposed to analog). Since digital pulsation analysis capability has become ubiquitous, the end
user should be assured that the digital tool used is accurate and proven, and that the designers
using it on the pipeline package has relevant experience in pipeline service design (characterized
by low ratios, high flow, a need for high thermal efficiency, and for long life).
In addition, the organization performing the pulsation analysis should be open to
considering the (Ncyl + 1) filter bottle approach for suction and discharge. The associated
benefits of reduced bottle diameter and effective pulsation control have been discussed in section
2.6.2.
The choice between one and two bottle systems creates close ties between pulsation,
pulsation control, and mounting. It impacts discharge bottle diameter, suction bottle diameter,
bottle lengths, and mounting requirements for one or two suction bottles. Figure 4-25 has shown
this mounting impact of primary and secondary bottle choices. Thus, based on the above
discussion, the key guidelines for pulsation analysis are:
Ensure that a thorough pulsation analysis is performed for every pipeline
application of medium and high-speed reciprocating compressors.
Ensure the organization performing the analysis has a validated design tool and
experience with pipeline compressor system design.
In addition, the preferred prediction algorithms would account for two-way interactive
between compressor valve and piping dynamic flows (as discussed in Section 2.6.2).
4.8.3.1 General
Torsional vibrations have been a significant issue in many high-speed separables. A
number of examples of motor shaft breakage exist and have caused major problems across the
industry. At least in early installations, it was not always recognized by the motor supplier that
the compressor imposes a very high dynamic torque variation on the motor shaft. However,
engine drives are also vulnerable, with excitations from both the compressor and the engine to
contend with. Torsional excitations are experienced by the shaft system and by the mounting
systemboth for the engine and for the compressor, with significant implications for equipment
mounting integrity and system vibrations.
GMRC has developed a guidelines document relating to torsional analysis of separable
compressors. This document was listed in Section 1.7 under the heading of Applicable Codes,
Standards, Specifications, and Guidelines. Section 2.6.3 provides background and summarizes
this torsional analysis guideline. The following presents key guidelines for the present mounting
guidelines document.
4.8.3.3 Specify the Torsional Study Content of GMRC Torsional Guidelines [21]
Section 2.6.3 summarizes this content and the steps involved.
4.8.3.6 Critically Evaluate the Integrity of the Coupling and Its Attachment to the
Shafting Under All Torsional Excitations, Including Possible Overloads
During Start-Up and Shutdown, and Fault Conditions, Based on a Thorough
Transient Analysis
This is particularly relevant to soft couplings.
4.8.4.2 Include the Following Steps in All Piping and Compressor Manifold Analyses
Generate a mass-elastic model of the piping.
Calculate natural frequencies and mode shapes.
Perform forced response analysis for amplitude and stress.
Compare stresses and amplitudes with limits.
4.8.4.4 Model the Nozzles, Pulsation Filter Bottles, Bottle Penetrations With a Fine
Array of Shell Elements to Capture the Essential Flexibility Characteristics of
Reinforced Joints as an Integral Part of the Model as Well as Shell
Deformation Characteristics of Pulsation Bottles
The flexibility of joints between larger and smaller pipe segments (e.g., nozzle-bottle
joints) involves local deformation under bending moments, shear forces, and forces along the
axis of the smaller pipe. Section 2.6.4 discusses modeling requirements and analytical content in
depth. The following guidelines provide the essentials:
4.8.4.5 Use the Nomogram of Figure 4-47 for Piping Not Subject to Detailed
Structural Analysis
It should be recognized that not every pipe in the installation would be the subject of a
detailed structural analysis. Figure 4-47 shows a piping nomogram, which can be used to
estimate natural frequencies of various piping configurations and to relate stress in these pipes to
vibration amplitude.
4.8.6.1 General
For both block-mounted and skid-mounted compressor systems, it is important to assess
the foundation vibration modes on the soil, and their response to shaking forces and moments.
The soil bearing pressure capacity should also be compared with the applied soil loads
and, if necessary, piled foundations should be considered.
Concrete strength near the points of application of dynamic loads is also important.
4.8.6.2.1 Calculate Soil Pressure Loading and Ensure the Adequacy of the Soil to
Carry This Loading
This calculation should account for all the weight of the skid (with added concrete), the
mounted equipment including bottles and their supporting structure, and the concrete and
reinforcing steel of the foundation itself. API 686 recommends limiting the resulting pressure on
the soil to 75% of the soil capacity. Such a limit helps limit settlement and improve the
predictability of dynamic response of the foundation on the soil.
Piping stress analysis establishes that inappropriate loads will not be applied to the
machinery by the piping as the gas becomes hotter. It also establishes that bending and
extensional stresses induced by pipe changes in temperature are acceptable. The available codes
have established criteria for stress and provide the mechanism to report on adequacy of a piping
system.
It should be recognized that code compliance for a piping stress and flexibility analysis
sometimes leads to solutions involving added flexibility; inappropriately applied such solutions
can have a negative impact on piping vibration. Thus, the close integration of the flexibility
analysis and the vibration analysis for a piping system is beneficial in ensuring the avoidance of
such conflicting solutions.
The primary guidelines here are:
For all pipeline compressor stations, perform a piping stress flexibility analysis and
make configurational changes as needed to meet ASME B31.8.
Ensure that solutions considered in order to meet ASME B31.8 code requirements
are also evaluated for their possible impact on piping vibrations.
4.9 INSTALLATION
4.9.3.4 Install Rebar with Specified Diameter and Spacing of Specified Material
For a compressor to be directly mounted on a concrete foundation, with no skid, the
recommended rebar spacing should be #8 (1-inch diameter) on 8-inch centers for the top three
feet of the foundation. This achieves 1% rebar density. To simplify the pouring process, a
limited number of 16-inch by 16-inch windows can be located in the middle of the block, away
from the anchor bolts. No. 6 rebar may replace #8 for vertical direction only to simplify
bending.
This is a lot of steel. It is justified because of the high dynamic loads imposed by a
reciprocating compressor at its frame and CHG support points, when the frame is directly
connected at these points.
For a skid-mounted compressor, the dynamic concrete loads are spread and their
localized intensity is reduced by the skid. As a result, the recommended rebar density is lower
for a skid mount.
4.9.3.6 For Skid-Mounted Units, Place Anchor Bolts with Templates Matched to
Hole Locations in Skid, and in Other Major Items to be Mounted on the
Concrete
4.9.3.7 For Block-Mounted Units, Place Anchor Bolts With Templates Matched to
Hole Locations in Driver, in Compressor, in Crosshead Guide Supports, and
in Other Major Components to be Mounted on the Concrete
The use of a template for anchor bolt location in the foundation is essential practice,
especially for pipeline applications. It ensures that the anchor bolts can be installed vertically,
with minimal misalignment between their anchor location deep in the concrete and the point
where they pass through the feet to the nut. This should be done after the rebar is installed and
before concrete is poured.
4.9.4.1 Ensure a Pre-Grout Job Meeting Occurs With All Relevant Stakeholders
The grouting process is a time critical process, which must keep moving once started. It
requires all those involved know their responsibilities and what action to take in the event of
problemssuch as failure of mixer, leaking from forms, etc. This meeting allows
communication of the plan and backup to the team involved and key stakeholders. Safety is an
essential meeting topic. This recommendation and a number of others in the section are based on
a GMC paper by Rowan [12].
4.9.4.2 Wait 28 Days After Pouring for Concrete to Cure and to Reach Full Strength
The concrete strength should also be established at 4,000 PSI by ASTM testing
procedures before grouting and before any other preparations for grouting.
4.9.4.4 Chip the Top Surface of the Concrete Wherever Grout is to Be Applied
This chipping process is very important and ensures a much higher quality of grout bond.
It should be performed after the concrete is fully cured and meets specified compressive strength;
it should be done soon before grouting with a pneumatic chipping gun, 30 lbs maximum, with a
chisel point; the aggregate should break rather than pop out. A Bush Head should not be
used, and neither sandblasting nor acid etching should be used.
4.9.4.5 Inspect Skid Base for Corrosion, Dirt, or Coating or PrimerRemove Any
Found
The bottom of the skid, wherever it is to be grouted to the concrete, should be clean and
free of dirt, protective coating, or primer. The skid can, and should be cleaned and sandblasted
at site, if any are found on it. Figure 4-49 shows such sandblasting in progress.
4.9.4.6 Glue Expansion Joint Foam to the Chipped Surface at 3 or 4 Feet Intervals
Along Foundation, Oriented Across the Foundation
This approach to expansion joint installation assumes the skid will be lowered into
position with a crane. Smaller skids may be maneuvered on rollers, but it is reasonably expected
that the size for pipeline applications will dictate a crane.
The main purpose of expansion joints in the grout is to minimize grout thermal cracking.
Epoxy grout and concrete have widely differing expansion coefficients and changes in
temperature can set up interface stresses, which will eventually crack the grout, if they are not
limited. While such stresses still occur over 3 or 4 feet, they remain below the level, which will
cause cracking. Figure 4-50 shows expansion joint foam in place before the skid is lowered onto
it. Use of expansion joints has the added benefit of breaking up the grout pour into orderly
segments and allows easier checking that all voids are filled. Expansion joints oriented parallel
to the crankshaft might appear desirable also, but currently such installation remains impractical.
4.9.4.7 Lower the Skid Into Position on the Foundation in Preparation for Leveling
and Grouting Using a Crane
The anchor bolt holes and jacking screw locations for the skid should have been specified
by the skid designer to the foundation designer, as well as to the installer. The installer should
place steel landing plates on the foundation at appropriate locations for each jacking screw. The
landing plates should be cut from circular stock with all sharp edges rounded. The skid should
be lowered on to the foundation so that bolt holes and anchor bolts mate. If there are any
discrepancies in hole locations, the implications and options for corrective action should be
reviewed by stakeholders, including the end users project engineer, before corrective action is
taken.
The skid should be rough leveled using the jacking screws to give between 2 and 3 inches
of separation between skid base and chipped concrete surface. It should slightly compress the
expansion joint foam.
4.9.4.8 Ensure the Main Equipment Items are in Place on the Skid Before Final
Leveling of the Skid
In some cases, with smaller skids, the equipment may already be installed on the skid
when delivered to site. If so, some vertical and horizontal adjustability should remain for
leveling and alignment of compressor within itself, and to the piping and for alignment of the
driver to the compressor.
If either or both of the compressor and driver have been shipped to site separately, the
purpose at this stage is to position them so their weight is appropriately distributed to the skid.
The cylinders and crosshead guides should be attached. The suction and discharge bottles should
be attached to the nozzles but not clamped to their support structure. Alignment and final anchor
bolt tensioning will follow later in the process.
Clean bottom surface of compressor and driver mounting feet to remove any dirt,
paint, primer, or coating prior to placing compressor on skid.
Before leveling the skid, allow it 24 or 48 hours of thermal cycling to reach a stable
state of alignment within itself.
Ensure upwards facing mounting plates in metal surfaces on skid or pedestals at
which mounting feet will be mounted are machined and free of dirt, rust, paint,
primer, or coating.
4.9.5 GROUTING
4.9.5.1 Place Grout So It Flows Under All Mating Surfaces and Fills Gap Between
Skid Base and Chipped Concrete Surface and Between One Pair of
Expansion Joints
Holes in the skid structure will assist the grouting process. If, or where, there are no
holes, a wooden head box will provide the grout flow needed, as shown in Figure 4-51 and
Figure 4-52. To ensure the grout fills the space under the skid from one side to the other, with a
head box delivering grout from one side, as shown in Figure 4-52, the following procedure has
been shown to work:
On the opposite side from the header box, drill a 1-inch hole horizontally through
the wood form.
Placing pulling tool head inside the wood form and screw a piece of -inch
conduit, 3 feet longer than the skid in width is screwed into the tool.
Pour grout into the head box and push the pulling tool horizontally over to the other
side until it is under the head box.
Pull the tool away from the head box. Move grout from one side over to the other.
As the tool is pulled, two blades or wings deploy to form a tee. As the tool is
pushed back again towards the head box, the wings retract so as not to move grout
back from where it came! Figure 4-53 shows such a tool, and Figure 4-54 shows its
use.
Figure 4-53. Grout Pulling Tool [12] Figure 4-54. Grout Pulling Tool in Use [12]
Fill each compartment between the transverse expansion joints completely before
plugging the hole in the wood from the pulling rod and moving over to the next
area/compartment to be grouted. The anchor bolts clearly provide a natural way to
break up the grout pour.
4.9.5.2 While Grout is Still Fluid, Demonstrate All Voids are Filled Under Skid
If the grout level visible on both sides of the skid is clearly above the level of the highest
downwards facing surface under which a grout fill is required (main beams, cross beams, and
concrete fill), this provides a satisfactory visible demonstration that the grout must have filled all
voids. Fill holes in concrete remove any doubt that trapped air may be resisting the fill
somewhere.
4.9.6.2 First Level and Align the Compressor Frame Within Itself
The goal of this alignment step is to ensure that the frame is level lengthwise and across,
that the bearings lie in a straight line as viewed from the side and above, and also that there is no
twist of the frame from end-to-end. Early recognition of the potential for and nature of bending
and twisting misalignment in medium and high-speed separables is given in a paper by Raymer,
et al. [17].
Most OEM recommendations for alignment are based on use of a machinists level. This
is good practice, but use of optical alignment with targets mounted on reference surfaces at a
series of points along and across the frame should be seriously considered by end users as the
most accurate alignment method for pipeline installation (when practiced by an expert).
Section 2.6.5 includes further discussion of alignment issues and assessment methods.
4.9.6.3 Supplement Soft Foot Testing with Tests for Acceptably Small Twist and
Bend of Frame
While testing for soft foot may be performed as one of the OEM alignment criteria, it
should be supplemented by tests for twisting and bending of frame using optical and web
deflection methods (see Section 2.6.5).
4.9.6.4 Complete Alignment of Compressor Frame to Earth and Within Itself Before
Tightening Compressor Frame Anchor Bolts
Once the compressor frame is satisfactorily aligned within itself, it should be tied down
by tensioning all its anchor bolts against the shims.
4.9.6.6 Level and Align the Driver Block or Frame Free of Bending and Twisting
This alignment step is very similar to that discussed above for the compressor frame.
Again, there are no formal engine OEM requirements beyond a soft foot limit (0.002 inches for
Caterpillar engines), and a requirement by Caterpillar that one central web deflection be checked
to be within 0.0016 inches. It is also a fact that at this time not all engine frames present a
machined surface to which the engine bearings can be related and which can be used to mount
optical alignment targets for use in alignment. The GCM34 engine block does provide the
necessary access, whereas special arrangements must now be made to provide similar access for
G3600 series engines.
4.9.6.7 Align the Cylinders and Crosshead Guides to the Compressor Frame
The centerlines of the crosshead bearing bore and the cylinder bore should be collinear.
This is the implicit goal of this alignment step. Pipeline cylinders are heavy and their weight can
be a significant cause of vertical misalignment. The OEM typically provides guidance in terms
of the thickness of shim to be placed at the joint between crosshead guide support and the
crosshead guide to offset the weight of cylinder (and weight of unsupported appendages, such as
suction bottles), and specific procedures for applying these shims. Sometimes this guidance is in
the form of software or a spreadsheet.
4.9.7.2.2 Check for Alignment and Parallelism of Discharge Bottle Flanges Before
Final Installation
This check should be performed with the flange nuts installed and slightly tensioned to
hold the bottle in position. The flange faces of bottles and nozzles should be checked for
4.9.8 ENSURE PIPING AND ALL BOTTLE CHAMBERS ARE THOROUGHLY CLEAN BEFORE
INSTALLATION AND OPERATION
The presence of dirt, foreign objects, and other contamination, in the piping and
compressor manifold system is proving a common start-up problem. Special care must be taken
to clean out the (Ncyl+1) chamber bottles recommended in these guidelines.
4.10.1 GENERAL
A carefully executed startup process (summarized below) is as essential to the success of
the installation as any of the equipment selection, design, manufacture, and installation, which
brought the system to this point. Numerous checks of alignment and repeated adjustments are
listed, and these are critical steps in achieving successful long life operation.
4.10.6 CHECK AND RE-TIGHTEN ALL FRAME ANCHOR BOLTS ON DRIVER AND COMPRESSOR
ONCE HOT OPERATING CONDITIONS HAVE STABILIZED
It should be recognized that bolt loosening will occur as a result of initial creep and
relaxation, as a result of changes in temperature which change dimensions of bolts and material
compressed by the bolts, and as a result of decreases in modulus which occur with temperature
(the reduction in grout modulus between 70F and 120F may be as much as 30%, which causes
substantial bolt tension loss).
4.10.7 CONTINUE THE SHORT-TERM CHECK AND RETIGHTEN CYCLE FOR ANCHOR BOLTS
UNTIL CLEAR EVIDENCE OF DAY-TO-DAY REPEATABILITY IS OBTAINED
As has been emphasized several times in the guidelines, the holding capacity of
compressor and drive mounts is a direct function of anchor bolt tension and the friction force,
which it produces. The slipping, which will occur as soon as tension is lost, causes fretting
damage to mating surfaces; and even short-term loss of concrete compression by the anchor bolts
can lead to cracking. Thus, the discipline of anchor bolt tension maintenance, both short-term
and long-term, is critical.
4.10.8 CHECK AND ADJUST CROSSHEAD GUIDE SUPPORT SHIMS UNDER HOT CONDITIONS
These shims should be adjusted as needed to maintain crosshead bearing clearances and
to maintain concentricity between crosshead bearing and cylinder bore under hot conditions.
4.10.10 ADJUST HEAD END SUPPORTS UNDER HOT CONDITIONS, IF THE DESIGN INCLUDES
THEM
The head end supports should be adjusted after frame, crosshead guide, and discharge
bottle wedges have been adjusted hot. It is important that the head end support be effectively
and tightly attached to the cylinder, but it should not cause any changes in hot alignment.
Compressor OEMs generally provide guidance in their specifications for the proper adjustment
of head end supports (or outboard cylinder vibration suppression devices as they may be
called).
4.10.11 ADJUST SUCTION BOTTLE CLAMPS AND WEDGES ONCE STABLE OPERATING
CONDITIONS HAVE BEEN REACHED
These are the tie-downs used between the heavy (Ncyl+1) suction bottles and the frame
structure designed to support these suction bottles. Sound attachment of the suction bottles to
their supports is an essential part of the mounting system. Checking and adjusting this
attachment as needed is as important as the deign effort which led to this support being installed.
4.10.12 RIGOROUSLY CONFIRM THAT ALL WEDGES ON BOTH SIDES OF THE UNIT HAVE
BEEN PROPERLY ADJUSTED, INCLUDING THOSE BELOW FLOOR LEVEL
Wedges below grade will likely be used for block-mounted units, including those under
clamps and under the nozzles. Loose or missing bolts below floor level are more common than
above grade, but equally important to avoid!
The wedge supports are a critical element in the system mountingnot the only one, but
all wedges under clamps and under nozzles are an essential contributor to system integrity as
designed.
4.11.1 GENERAL
Vibration testing is important, but must come at an appropriate time in the start-up
sequence. For vibration testing to be meaningful, the system should have passed all its initial
checks and hot alignments, adjustments, and a number of initial tightening and check cycles for
the anchor bolts. In other words, all mounts should be demonstrably tight and ready to operate,
and units should be aligned as they are expected to run.
4.11.2.1 As a General Guideline, Start-Up Vibration Testing Should Cover All Items
Which Can Impact Integrity and Should Cover a Representative Number of
Test Point Locations and Operating Conditions
Enough test points and conditions should be covered so that subsequent surprises are
minimized. The testing by a qualified expert can add cost, and this cost is influenced by the
range of test conditions required. To the extent possible, the scope of testing should be part of
the end users bid specifications. However, if during design and design analysis issues arise,
which will require more extensive testing than originally planned, this may require further
negotiation.
4.11.2.3 The Start-Up Vibration Testing Process Should Cover the Range of Expected
Operating Conditions
Test conditions for a pipeline compressor should cover the range of speed (minimum to
maximum), loading, and unloading conditions. If single-acting operation is planned, this should
be included in the test condition matrix. If the range of loading or unloading conditions requires
the compression ratio across the compressor to be changed, the appropriate arrangements should
be made to pinch suction or to adjust compression capacity temporarily at upstream or
downstream stations.
Pipeline compressors are mostly large single-stage units. However, storage compressors
may be equally large and can have many of the same needs for integrity, but will likely have
more than one stage; testing for storage compressors should cover each stage combined with the
relevant range of loads and speeds. In addition, pressure differentials to achieve the required
loading may need to be arranged for the storage compressor during the test phase.
4.11.2.6 Based on the Vibration Testing Scope a Test Matrix Should Be Prepared
The step of preparing a test matrix will increase the efficiency of the testing by ensuring
plans are made to achieve all required test conditions. The third party, which will perform the
vibration test, should be involved in the planning process for test points and conditions. At the
same time, the flexibility to add documentary and diagnostic testing as indicated by initial results
should be preserved in the plan.
4.11.3 PERFORM START-UP VIBRATION TESTS ACCORDING TO TEST MATRIX, AND APPLY
APPROPRIATE VIBRATION AND PULSATION CRITERIA
There should be a pre-established and agreed to set of criteria for pulsations and for
vibration (torsional, linear). The criteria may differ depending on the location.
The third party undertaking the testing should be experienced and will most likely have
sound, defensible, criteria to apply to the test results. The compressor and engine OEM may also
have some guidelines for integrity of the equipment they provide. As an alternative, the
following provides some guidance as to levels beyond which some review and/or further
diagnostic evaluation is required:
Skid, engine block, compressor frame 0.4 IPS
Cylinders and piping 1.0 IPS
Pipe dynamic bending strain .. 100 Micro-strain
Pulsations criteria should be based on API 618 design limits (see Section 4.8.2).
For torsional vibrations, criteria should be obtained from References [16] and [21], or
based on specific, defensible criteria of OEMs and service providers.
4.11.6 PERFORM ENGINE TESTING FOR HEAT RATE AND COMPRESSOR TESTING FOR
EFFICIENCY AND CAPACITY, IN ADDITION TO PERFORMING AND EVALUATING VIBRATION
TESTS
These performance tests are not the prime subject of these guidelines, but ultimately, the
reliable and efficient performance of the unit with long-term integrity provides a broad goal of
the compressor installation project and all aspects of this goal are important and related.
The authors wish to express their appreciation to GMRC for management and support of
this important project, and to the generous co-funders: Ariel, Cat, CSI, El Paso, Kinder Morgan,
for making it possible; to Danny Deffenbaugh for his support, encouragement, and endless
availability for project discussions; to Julia Valle who spent so many hours, through numerous
drafts, bringing this documents presentation up to its current, highly professional standard; and
to Ralph Harris, Robert McKee, William Hosek, Benjamin White, and Christine Scrivner of
SwRI who provided their insight, knowledge, and experience whenever asked.
Especially mentioned are members of the advisory committee for the project: Randy
Raymer (El Paso), William Elston (CSI), Tom Stephens (Ariel), David Krenek (Cat),
George McKinney (Augusta), and Stan Borrell (Kinder Morgan), whose unique, first hand,
knowledge and advice has been generously (and frequently) provided whenever requested.
The authors have also been helped immeasurably by many good and generous friends
from the supplier and end user sectors of the industry, including: Richard Frogge, Jim Schulte,
and Joe Moreland of Siemens; Bill Angus and Mark Brackett of Cat; Keith Burley, Mead Weil,
Jim Delaney, Greg Phillippi, Kriss McDonald, and Greg Lortie of Ariel; Jorge Torres, Steve
Bevers, Greg Evans, Rich Browning, Tom Foote, and Doug Schminke of Kinder Morgan;
Matt Peterson, Don Crusan, and Evan Wingate of Nisource; Robert Goodenough,
Harold Herrman, William Couch, Kevin Johnson, Doug Cotter, Mitchell Mauch, Sherry Carr,
Winston Johnson, and Tom Garvin of El Paso; Claus Langer, Dink Green, and Danny Hughes of
Sempra; Bruce Howerton and Paul Mohan of Williams Transco; Pete Harrington of CSI;
Les Moore, Brad Goodwin, Andy Drake, and Eric Payne of Centerpoint; Kenny Gilbert of
Dominion; Bob Rowan and Charlie Rowan of R.L. Rowan and Associates; Eric Amundsen,
Arnold Eisenstein, and Mark Treybig of Panhandle; Gary Tas and Dave Anderson of Dresser-
Rand; Aaron Merritt of Cooper; Jim Pitts of AGL; Whitey Shaffer of Energy Transfer Partners;
Joe Baker of GE/Gemini; Terry Parker of WPS; Brian Howes and Shelley Greenfield of Beta
Machinery Analysis; and Bill Lee of Questar. These individuals and others have taken the time
to bring focused experience and advice to the guidelines preparation, addressing all segments of
the complex mounting and installation process.
2. Pantermuehl, J. P. and Smalley, A. J., Friction Tests Typical Chock Materials and Cast
Iron, GMRC Technical Report No. TR97-3, December 1997.
3. Smalley, A. J., Epoxy Chock Material Creep Tests, GMRC Technical Report No. TR
97-5, December 1997.
4. Smalley, A. J. and Harrell, J. P., Foundation Design, presented at the GMRC Gas
Machinery Conference, Austin, Texas, October 1998.
6. API 11P, Packaged Reciprocating Compressors for Oil and Gas Production Services,
Second Edition, November 1989.
7. API 686, Recommended Practices for Machinery Installation and Design, First Edition,
April 1996.
8. API 618, Reciprocating Compressors for Petroleum, Chemical, and Gas Industry
Service, Fifth Edition.
10. ASTM A193, Standard Specifications for Alloy Steel and Stainless Steel Bolting
Materials for High Temperature Service.
11. ASTM A194, Standard Specifications for Carbon and Alloy Steels Nuts for Bolts for
High Pressure and High Temperature Service.
12. Rowan, C., Epoxy Grout Installation Techniques for Skid Mounted Equipment,
presented at GMRC Gas Machinery Conference, October 2000.
15. ANSI/ASME B31.8, Gas Transmission and Gas Distribution Piping Systems.
17. Raymer, R. R., Goodenough, R., Harris, R. E., Smalley, A. J., The Criticality of High-
Speed Separable Alignment, presented at the GMRC Gas Machinery Conference, Salt
Lake City, Utah, October 2003.
18. Harris, R. and Scrivner, C., Integrated Design Approach for Reciprocating Compressor
Installation, tutorial presented at the GMRC Gas Machinery Conference in Tucson,
Arizona, October 2004.
20. Finley, W. R. and Burke, R. R., Proper Specification and Installation of Induction
Motors, IEEE/PCIC 1995 Conference Record.
22. Pantermuehl, J. and Smalley, A. J., Compressor Anchor Bolt Design GMRC Technical
Report, TR97-6.
26. Mandke, J. S. and Troxler, P., Dynamics of Compressor Skids, PCRC Technical
Report, TR92-2, March 1992.
28. Sureh, A., ONeill, M., and Pincus, G., Design of Structures and Foundations for
Vibrating Machines, Gulf Publishing Company, 1979.
29. Richart, F. E., Jr., Hall, J. R., Jr., and Woods, R. D. Vibrations of Soils and
Foundations, Prentice-Hall, 1970.
S Service
ID Installation Details
CC Capacity Control Method(s)
DE Problem or Observation Related to Design/Engineering
T Problem or Observation Related to Transportation
I Problem or Observation during installation
SC Problem or Observation Related to Startup & Commissioning
IO Problem or Observation Related to Initial Operation
EO Problem or Observation related to Extended Operation (3Yrs+)
CA Corrective Action
C Comment
R Recommendation
Considerable Force from a Back Hoe & Dozer needed to pull on bottle Flange to make up the Joint I
After 1 Year Motor Shaft Fractured due to torsional fatigue; After Torsional Study Inertia Rings installed on
Crankshaft to detune IO, CA
Unit was found to be out of alignment & was regrouted on the skid IO, CA
The next Year 2 suction bottle nozzles cracked in the gusset welds; bottles were removed & repaired IO, CA
Initial Alignment should have bee verified by Company Inspector before releasing installation contractor R
Should not have attempted to commission unit without torsional vibration study R
7000 HP Motor Drive
JGC6 P Successful Installation Confirmed by Follow-Up Site O&M Contact I
Motors Shipped Separate; Disassembled Cylinders & Primary Bottles T
Single Point of Contact w/Packager Helps, streamlines, reduces cost C
Cat 3616 & Below should be Skid Mounted; R
You have to do the Engineering & Program Mgmt Right! DE
Very bad Pulsations; Orifice Plates Installed to dampen Vibrations; -> Decreased Compressor Efficiency SC
High rate of Compressor Valve Failures; IO
Problems Not Due to Mounting C
Cat 3616 (4750 HP) W Mainline Transportation S
800 to 1000 RPM; ratio 1.1 to 1.5; Utilization 90% OC
RPM, Volume Pockets, and Head End Deactivation CC
Package checked at fab Shop - Compressor frame not in alignment on skid; shipped with Frame not
premanently aligned; Skid Grouted in Place, then frame was precision aligned P&I
Initial Start-up was vibration Free SC
No problems Reported during initial or extended operation IO
Units had higher than expected vibration and pulsation. Much of the vibration has been tied to
bottle design. Infinite step capacity control also contributes to high vibration. SC
It took considerable time to identify and understand the vibration patterns and how to operate
around the worst conditions. IO
All units have been realigned on the skids. The units have been aligned so that the crank shaft is
straight, but the frame is not necessarily level. EO, CA
Could any of the problems encountered have been influenced by the choice of Mounting*, or
mitigated by a different mounting approach? - No. Even though these units are skid mounted,
the size dictated that the final installation had to occur on site. The skid, driver and compressor
frame were all shipped separately to the location and final assembly occurred on site. Lesson
learned, any skid mounted unit, whether mounted in the shop or on site, the frame must be
properly aligned on site. Soft foot is not an acceptable method. The skid design must provide a
means of making precision alignment adjustments of the frame in the field. Provisions for
mounting bolt stretch must be provided to achieve proper clamping forces. C
Two of these units have had the pulsation bottles replaced. During the replacement, the
compressor frame was precision aligned and leveled. It is too soon to reach conclusions, but
early indications are that the new bottle design has greatly reduced vibrations on the unit. Piping,
frame, and skid vibrations are at much lower levels than the initial installation. EO
Contractor did not adequately level the skid during initial Installation; compresssor frames were mounted
on skids using soft foot to check for alignment I
Units had higher than expected vibration and pulsation. Much of the vibration has been tied to
bottle design. SC
It took considerable time to identify and understand the vibration patterns and how to operate
around the worst conditions. IO
All units have been realigned on the skids. The units have been aligned so that the crank shaft is
straight, but the frame is not necessarily level. EO, CA
Could any of the problems encountered have been influenced by the choice of Mounting, or
mitigated by a different mounting approach? - No. Even though these units are skid mounted,
the size dictated that the final installation had to occur on site. The skid, driver and compressor
frame were all shipped separately to the location and final assembly occurred on site. Lesson
learned, any skid mounted unit, whether mounted in the shop or on site, the frame must be
properly aligned on site. Soft foot is not an acceptable method. The skid design must provide a
means of making precision alignment adjustments of the frame in the field. Provisions for
mounting bolt stretch must be provided to achieve proper clamping forces. C&R
No significant problems. The engine was shipped from Rostock Germany to New Iberia, La via
LASH barge, then trucked from Port of Iberia to the job site. T
Significant engineering studies performed by Tech Transfer to ensure foundation, mounting, sole
plates, and other mounting issues were properly designed. The unit is not operational at this
writing so there has been no physical verification of the adequacy of the design. DE
Installation is ongoing. No significant issues with installation to date other than the Geislinger
coupling had to be machined in the field to provide clearance for Caterpillar flywheel mounting
bolts. I
Startup & Commissioning not complete as of this writing SC
Added Comments after Commissioning: There are many skid mounted units in our industry with
marginal torsional, vibration, and pulsation characteristics which often result in long term headaches for
the operator. The block mounted Cat/Ariel installed at JISH appears to be a very stable unit that should
cause little trouble during the operating life of the unit. Vibrations and resulting shaking forces are certainly
within acceptable levels. Adequately designed and sized pulsation bottles and secondary volume bottles
have resulted in good pulsation response. The driver is mounted on vibracons so I am interested in how
they perform over the long haul time will tell. C
I think the extreme service of 700 psi suction and 3325 discharge conditions would be difficult for a skid
mounted unit not to mention the need to ship the driver and compressor as separate pieces to be
installed on a skid in the field. Adequately designed pulsation bottles and volume bottles might be more
difficult on a skid mount. I think the block mount will result in a better installation for the long haul than a
skid mount for this size unit.. C
4500 HP Reliance
Motor driven Ariel JGD6 P "Complex"; Storage; Market Flow Transportation; or Combination S
1200 RPM (Fixed); single and 2 stage Operation (See Figure) OC
Pocket Unloaders CC
A shim pack coupling was used between Driver and Compressor ID
Foundation block was mounted on a thick (3 Foot) concrete sub-floor; Block about 33 feet long & 14 foot
wide at widest under compressor; 10 feet wide under motor and 9 feet wide near end; Block height varied
between 2'6" and 3'4" to achieve same level senterlines of motr and compressor. ID
Compressor and motor mounted on a common skid; skid in 3 sections; center section under the
compressor filled with concrete; included holes through the concrete to assure grout flow to space
between skid concrete and block; the entire skid was grouted to the block ID
Skid I-beams were 2'6" tall; Motor also had a 7" platform. ID
Suction Bottles had extra weight and length abd required extra support; were supported off the concrete
block - as were the discharge bottles ID
Skid was set below floor grade; IE they had a grade floor at the level of top of skid ID
Mounting design Objective was to get skid, block & sub-floor stiff enough to transfer loads DE
SwRI did pulsation & Mechanical Vibration study and piping thrermal study DE
Serious Torsional Problems; failing oil pump drives at end of shaft; Ariel worked hard to solve problems
and went well out of their way; they came up with a modified chain drive for the oil pumps SC&CA
Other Minor Vibration Problems; but expect that such minor things will require tuning on most installations SC
To control suction side vibration they ended up tieing the suction bottle suppoprts on the two sides
together with a brace. SC&CA
Ran into rod reversal problems and associated bearing failures as a result of transitioning between
operating states; have learned how to operate around these problems IO
A cearer definition is needed for the content of a torsional study to avoid the problems experienced C&R
With such a complex operation it is necessary to consider not just steady operating condiitons, but how to
transition between them and avoid such problems as rod reversal C&R
With this complex a system & operation not having the added complexity of a VFD or infinite step
unloaders was a benefit C&R
General P If you install medium or high speed compression for mainline you have to do it right C&R
(Panel of Experts) Skid Mounting has benefits: It gets as much as possible done in a shop with a single point of contact C&R
With Block Mounting you have to do much more in the field & Organize people to do it C&R
Separables have narow frames - the skid spreads the footprint so the concrete has a better ability to
handle the dynamic loads without high tensile stresses C&R
Even if you do block Mount you need a "Mini-Skid" for the Oil System C&R
The panel's past Experience in the 1980s with block mounting high speed separables says do not do it
again C&R
Also never skid Mount an integral! R
The skid needs to be filled with 5,000 or 6,000 PSI grout; with this weight you start to approach the
characteristics of a concrete block C&R
The skid needs to be wide enough to spread the load C
Put the skid (and discharge Bottles) below floor grade; this combines floor mass with the skid mass; it
also gives you a floor level at or near the height of the top of the skid C&R
You need to allow for a good size crane for future maintenance & lifting of heavy components C&R
The decision whether to put bottles on the skid or separately support them is situation specific C
Suction Pulsation Bottle Vibration led to cracking; Bottle wall thickness met pressure requirements, but
Various-2 W was too thin from structural considerations SC
A thicker walled bottle solved the problem CA
Various-3 W Vibrations occurred on a unit which had been studied for pulsations SC
The problem turned out to be single acting operation which had not been considered in Study SC
High Vibrations have occurred because needed bottle suppoprts called for and supplied by the packager
Various-4 W were not installed or were allowed to become loose I
Wrong Assumptions made about compressor and cylinder Configuration in absence of data led to high
Various-5 W vibration of compressor manifold system and cylinders. DE
Addition of a very heavy crosshead guide support cured the problem CA