CHAPTER 1

The Topic and its Background

1.1 Introduction

The liquefied natural gas (LNG) process consists of natural gas production,
purification and liquefaction, ship loading, transportation and subsequent off-loading,
storage, and regasification and, ultimately, injection into gas distribution grid or power plant.
Very large heavy centrifugal compressors are required in the design process for petrochemical
LNG plants, and power plant facilities. Multiple compressor units such as methane, ethylene
and propane compressors, converts natural gas to LNG by cooling the liquid temperature to -
270 degree Fahrenheit. Heavy compressor vibrating machines may be supported by concrete
table top pedestal and, at most cases, by a foundation consisting of pedestal and footing.

1.2 Statement of the Topic

Figure 1.1 Compressor

A reciprocating equipment, compressor, is needed is to be installed in an LNG plant.

The vendor of the compressor has provided a loading data for the equipment including its
dynamic loads. The purpose of this paper is to perform finite element analysis on the mass
concrete foundation to assess its behavior under specified static and dynamic loads.

5
 CHAPTER 3

Methodology

3.1 Objective

This study aims to do the following:

(1) To evaluate the effect of a compressor unit to the mass concrete
foundation supporting it; and
(2) To perform finite element analysis on the mass concrete foundation to
assess its behavior under specified static and dynamic loads.

3.2 Methodology

The procedures carried out in this study are shown in the following diagram.

Identification of Model of the mass Application of Stress analysis and

Parameters concrete by FEM static loads on the member design of
model static analysis

Application of Time history

dynamic loads on Modal Analysis
analysis
the STAAD model

Figure 3.0 Design Methodology for the Study

3.3 Research Design

The researchers modeled the mass concrete foundation in STAAD.pro, a software

developed by Bentley Systems Inc. The static analysis of the foundation for the compressor
is carried out using the Solid Finite Element Analysis. Based on the result of the analysis,
flexural design was performed. Pile supports are modeled as pinned supports in STAAD.pro.
Support reactions are compared with pile allowable bearing capacity.

The dynamic analysis of the foundation for the compressor was also carried out using
the Solid Finite Element Analysis of STAAD.pro. For analysis, STAAD.pro consider modal
analysis and time history analysis. Evaluation of the result for the dynamic analysis was
performed using Microsoft Excel.

7
 150
750
1750

1500
1000

100
Origin (0,0)

FIG. 3.2: SECTION

LONGITUDINAL LOAD
X-DIRECTION

h1 = 1.21 m
7245.33 7354.67

6920.33 6879.67

5795.33 5154.67

4995.33 4829.67

3670.33 3379.67

2820.33 2779.6

1415.33 2304.67
285.33 2129.6
1094.6
LP11,25,29
LP10,24

LP14,30
LP1,15

LP2,16

LP3,17

LP4,18

LP5,19

LP6,20

LP7,21

LP8,22

LP9,23
LP12

LP26
LP28

LP13

LP27

FIG. 3.3: LOAD POINT LOCATION

LATERAL LOAD

Z-DIRECTION

h1 = 1.21 m

2686.67 1963.33

1736.67 513.33

936.67
786.67
LP28~30

LP26,27

LP15~25

LP12,13

LP1~11
LP14

FIG. 3.4: LOAD POINT LOCATION

Where:
h1 = height of centerline of Motor and Compressor Discharge from height of load point
h = yg - yi
h1 = 1.21 m

10
3.5 Model of the Mass Concrete by FEM

A typical solid block of 0.45m x 0.40m x 0.30m (LxWxH) or 0.45m x 0.40m x 0.35m
was used for the mesh.

0.45m

0.40m
0.30m

0.35m

0.35m

Figure 3.5 Typical solid block

The total dimension of the footing was 16.65m x 7.65m x 1m.

Figure 3.6 Finite element model of the foundation

A total number of 4479 solids were used to create the Finite Element Model

11
 Figure 3.7 Isometric View of the Model

3.6 Application of Static Loads on the model

Design Loads are applied at each load points (LP1~LP34) as show on Figure 3.5.
These design loads are placed at the tip of pyramidal shaped solids that are made very rigid
and weightless to ensure subsequent loading effect on the foundation. Configuration of the
loading points are shown on the tables per load item.

Figure 3.8 Load Application

5854 5855

5858 5859 5860 5861 5862 5863 5864 5865 5866 5867 5868
5856 5857

5869 5870

5871
5872 5873 5874 5875 5876 5877 5878 5879 5880 5881 5882

5883 5884

5885 5886 5887

Figure 3.9 Load Points Location

12
Table 3-11 Vertical Load due to Lateral Moment
Load Reference EQ(x) Distance, Moment of Direction
Point Nodes [Fy g] (kN) De Inertia, If of Fy Remarks
(m) (m)
1 5858 5.67 6.920 47.891 UP
2 5859 4.75 5.795 33.586 UP
3 5860 4.10 4.995 24.953 UP
4 5861 3.01 3.670 13.471 UP
5 5862 2.31 2.820 7.954 UP
6 5863 1.16 1.415 2.003 UP
7 5864 0.23 0.285 0.081 UP
8 5865 -0.90 -1.095 1.198 DOWN
9 5866 -1.75 -2.130 4.535 DOWN
10 5867 -2.77 -3.380 11.422 DOWN
11 5868 -3.96 -4.830 23.326 DOWN
12 5869 5.94 7.245 52.495 UP
13 5870 -4.23 -5.155 26.571 DOWN
14 5871 -5.64 -6.880 47.330 DOWN
15 5872 5.67 6.920 47.891 UP
16 5873 4.75 5.795 33.586 UP
17 5874 4.10 4.995 24.953 UP
18 5875 3.01 3.670 13.471 UP
19 5876 2.31 2.820 7.954 UP
20 5877 1.16 1.415 2.003 UP
21 5878 0.23 0.285 0.081 UP
22 5879 -0.90 -1.095 1.198 DOWN
23 5880 -1.75 -2.130 4.535 DOWN
24 5881 -2.77 -3.380 11.422 DOWN
25 5882 -3.96 -4.830 23.326 DOWN
26 5883 -1.89 -2.305 5.311 DOWN
27 5884 -6.03 -7.355 54.091 DOWN
28 5885 -2.28 -2.780 7.727 DOWN
29 5886 -3.96 -4.830 23.326 DOWN
30 5887 -5.64 -6.880 47.330 DOWN
Fy=0.00 Fy = 605.02
31 5854 8.07 0.970 0.941 UP Seal Oil Unit
32 5855 -8.07 -0.970 0.941 DOWN Seal Oil Unit
33 5856 8.07 0.970 0.941 UP Seal Oil Unit
34 5857 -8.07 -0.970 0.941 DOWN Seal Oil Unit
Total Fy=0.00 Fy = 3.76
g
Distance, D (see Fig. 3.3)
h
I = D
i
Fy = Fx * yi * D / I

Load 41

21
Table 3-13 Vertical Load due to Lateral Moment
Load Reference EQ(z) Distance, Moment of Direction
Point Nodes [Fy j] (kN) Dh Inertia, Ii of Fy Remarks
(m) (m)
1 5858 12.04 1.963 3.855 UP
2 5859 12.04 1.963 3.855 UP
3 5860 12.04 1.963 3.855 UP
4 5861 12.04 1.963 3.855 UP
5 5862 12.04 1.963 3.855 UP
6 5863 12.04 1.963 3.855 UP
7 5864 12.04 1.963 3.855 UP
8 5865 12.04 1.963 3.855 UP
9 5866 12.04 1.963 3.855 UP
10 5867 12.04 1.963 3.855 UP
11 5868 12.04 1.963 3.855 UP
12 5869 3.15 0.513 0.264 UP
13 5870 3.15 0.513 0.264 UP
14 5871 -4.82 -0.787 0.619 DOWN
15 5872 -5.74 -0.937 0.877 DOWN
16 5873 -5.74 -0.937 0.877 DOWN
17 5874 -5.74 -0.937 0.877 DOWN
18 5875 -5.74 -0.937 0.877 DOWN
19 5876 -5.74 -0.937 0.877 DOWN
20 5877 -5.74 -0.937 0.877 DOWN
21 5878 -5.74 -0.937 0.877 DOWN
22 5879 -5.74 -0.937 0.877 DOWN
23 5880 -5.74 -0.937 0.877 DOWN
24 5881 -5.74 -0.937 0.877 DOWN
25 5882 -5.74 -0.937 0.877 DOWN
26 5883 -10.65 -1.737 3.016 DOWN
27 5884 -10.65 -1.737 3.016 DOWN
28 5885 -16.47 -2.687 7.218 DOWN
29 5886 -16.47 -2.687 7.218 DOWN
30 5887 -16.47 -2.687 7.218 DOWN
Fy = 0.00 I = 80.88
31 5854 6.26 1.250 1.563 UP Seal Oil Unit
32 5855 6.26 1.250 1.563 UP Seal Oil Unit
33 5856 -6.26 -1.250 1.563 DOWN Seal Oil Unit
34 5857 -6.26 -1.250 1.563 DOWN Seal Oil Unit
Total for Motor and
Fy = 0.00 I = 6.25
Compressor
j
Distance, D (see Fig. 3.4)
k
I = D
l
Fy = Fx * yi* D / I

23
 Application of equipment static loads in the Finite Element Model Analysis Static
Loads are assumed to be applied at each Load Points as specified in Table 3-14. STAAD.pro
utilizes a very rigid weightless member to support each elevated loading point, so as not to
affect the modal analysis of the foundation but still capable of distributing the load
appropriately on the element concerned. The member was modeled as a pyramidal shapes
solid.

Figure 3.10 Model of Load Location for Static Loads

3.7.3 Dynamic Loads

As per Loading Data (refer to attachment 1)
Dynamic
Location from origin *
Equipment Rotor Weight Speed Force
Item FLD x y z
No.
(kg) (RPM) (kg) (m) (m) (m)
Compressor
Male Rotor 666 3550 189.50 6.911 4.114 4.450
K-561
Female Rotor 560 2367 106.20 6.810 4.114 4.770
Motor 621 3550 176.70 9.472 4.304 4.414

* Based on the axes of STAAD Pro Dynamic Model

The point of application of all dynamic loads is on the center of gravity of the motor
and compressor as specified in the loading data. Location of the point of application is shown
on the table above.

Figure 3.11 Model of Load Location for Dynamic Loads

25
 Figure 3.12 STAAD syntax for dynamic loads (Case 1 of section 3.7.5)

3.7.4 Criteria for Analysis

At any location, dynamic amplitude shall not exceed the maximum allowable value
as stated below:

5.00 m (0 to peak)
10.00 m (peak to peak)

All natural frequencies below 1.5 times the operating frequency shall be calculated.
The amplitudes of the natural frequencies between 0.35 and 1.5 times the operating frequency
shall be within the allowable values even assuming that due to differences between the
actual structure and the assumed model resonance does occur.

26
 CHAPTER 4

Data Analysis and Results

4.1 Stress Analysis

In this analysis, only two formulations will be considered initially. They are the solid
continuum form and the shell form. They differ in that the continuum form utilizes only
displacement vectors, while the shell form utilizes displacement vectors and infinitesimal
rotation vectors at the element nodes.

Stress transfer takes place within, and on, the boundaries of a solid body. The
displacement vector, u, at any point in the continuum body has the units of meters (m), and
its components are the primary unknowns.

The components of displacement are usually called u, v, and w in the x, y, and z

directions, respectively. Therefore, they imply the existence of each other, u (u, v, w). All
the displacement components vary over space. In stress analysis, the multiple components of
the displacement gradients are combined into alternate forms called strains. The strains have
geometrical interpretations that are summarized in Figure 4.1 for 1D and 2D geometry.

Figure 4.1 Geometry of normal strain (a) 1D, (b) 2D, and (c) 2D Shear Strain

28
Table 4-11. Internal Blocks Derivation of design stresses (service)
Axis ft v v fy v fmax v max
2 2 2 2 2 2 2
(kN/m ) (kN/m ) (kN/m ) (kN/m ) (kN/m ) (kN/m ) (kN/m )
147.77 32.63 6.47 154.66 32.63
59.17 47.84 3.94 85.84 47.84
59.83 56.64 12.08 93.97 56.64
x
27.24 102.00 6.81 116.53 102.00 154.66 102.00
27.12 70.69 15.46 85.53 70.69
56.06 29.21 33.98 72.08 33.98
11.08 32.63 16.79 38.64 32.63
177.14 47.84 33.80 189.24 47.84
103.48 56.64 17.99 128.46 56.64
y
49.59 102.00 15.77 129.77 102.00 189.24 102.00
59.17 70.69 79.40 114.32 79.40
9.10 29.21 16.41 34.11 29.21
14.24 16.79 6.47 25.35 16.79
69.51 33.80 3.94 83.24 33.80
99.45 17.99 12.08 102.60 17.99
z
39.61 15.77 6.81 45.13 15.77 105.28 79.40
45.40 79.40 15.46 105.28 79.40
0.49 16.41 33.98 34.22 33.98

Table 4-12. Footing Blocks Derivation of design stresses (service)

Axis ft v v fy v fmax v max
2 2 2 2 2 2 2
(kN/m ) (kN/m ) (kN/m ) (kN/m ) (kN/m ) (kN/m ) (kN/m )
247.74 36.43 5.68 252.98 36.43
24.11 149.68 90.64 162.21 149.68
24.11 149.68 90.64 162.21 149.68
x
183.23 331.33 77.83 435.37 331.33 435.37 331.33
13.18 132.72 90.48 139.48 132.72
45.87 89.59 110.83 136.12 110.83
38.97 36.43 72.29 94.36 72.29
427.00 149.68 348.60 622.28 348.60
427.00 149.68 348.60 622.28 348.60
y
293.60 331.33 70.94 509.19 331.33 622.28 394.46
344.84 132.72 394.46 602.92 394.46
46.35 89.59 57.50 115.71 89.59
136.50 72.29 5.68 167.67 72.29
199.06 348.60 90.64 462.06 348.60
199.06 348.60 90.64 462.06 348.60
z
16.39 70.94 77.83 86.45 77.83 471.12 394.46
140.84 394.46 90.48 471.12 394.46
9.86 57.50 110.83 115.87 110.83

Figure 4.3 Stress components in 2D (left) and 3D

32
 Figure 4.4 Graphical representations of 3D normal strains (a) and shear strains

For normal operations (1.2[DL + EL(E) + PL(E) + EL(O) + PL(O) + TL] + 1.6[LL +
J + I] + 0.5[Lr] ) normal stress results (xx) and (zz) are shown in Figures 4.5 and 4.6,
respectively. Shear stress result (zx) is shown in Figures 4.7. For other stress contours, refer
to Appendix A Stress Contours and Distribution

SXX
MPa
<= -2.51
-2.32
-2.13
-1.94
-1.75
-1.57
-1.38
-1.19
-1
-0.814
-0.626
-0.438
-0.250
-0.062
0.126
0.314 Y
X
>= 0.502 Z

Figure 4.5 Stress contour for (xx)

33
SZZ
MPa
<= -2.67
-2.48
-2.29
-2.1
-1.91
-1.72
-1.53
-1.34
-1.15
-0.963
-0.773
-0.583
-0.393
-0.204
-0.014
0.176 Y
X
>= 0.366 Z

Figure 4.6 Stress contour for (zz)

SZX
MPa
<= -0.350
-0.307
-0.264
-0.221
-0.178
-0.135
-0.092
-0.049
-0.006
0.037
0.081
0.124
0.167
0.210
0.253
0.296 Y
X
>= 0.339 Z

Figure 4.7 Stress contour for (zx)

34