Best Practices in Compressor Mounting

by:
James A. Kuly
Chief Engineer
ITW Polymer Technologies
Montgomeryville, Pennsylvania
U.S.A.
[email protected]

7th Conference of the EFRC

October 21th / 22th, 2010, Florence

Abstract
Large reciprocating compressors are found in many industries including gas, oil and petrochemical
production, transmission and storage. Operationally they generate very large gas and inertia forces.
Their mounting systems must manage and transmit weight loads, vertical and horizontal gas and
inertia loads, vertical anchor bolt forces, and the forces of thermal growth. The effectiveness and
integrity of their installation is therefore crucial. This paper addresses the best practices related to
installation techniques, component design, and materials used in the mounting of large reciprocating
compressors including:
Equipment Preparation
Foundation & Mat
Anchor Bolts & Sleeves
Grouting & Chocking
 OPERATIONS
Best Practices in Compressor Mounting, James A. Kuly; ITW POLYMER TECHNOLOGIES

1 Introduction All these modes of vibration have their own natural

frequencies where resonance can occur. In
Large reciprocating compressors are found in a addition, one mode of vibration can be either
number of industries including gas, oil and coupled or connected to other modes and drive
petrochemical production, transmission and them. Finally, vibrations can be transmitted in
storage. Operationally they generate very large gas series or in parallel from one component to the
and inertia forces. Their mounting systems must next. A well designed and constructed foundation
manage and transmit weight loads, vertical and will not only accommodate all of the loads applied
horizontal gas and inertia loads, vertical anchor bolt to it including horizontal gas and inertia loads,
forces, and the forces of thermal growth. The weight loads, anchor bolt loads and loads due to
effectiveness of the mounting system and integrity thermal growth and frame distortion, but it will act
of its installation are therefore crucial. to reduce then effectively pass those vibrations
down to the soil below.
The purpose of the mounting system on a
reciprocating gas compressor is simple. The The complexity of analyzing and mitigating the
mounting system must do three things: negative affects of vibrations in a compressor
1 Position and support the compressor, its installation is difficult and complex. The only way
driver and related equipment. Hold the to properly analyze and design a good foundation is
compressor and driver in perfect alignment with the aid of such tools as Finite Element
while accommodating all of the loads applied Analysis (FEA) and foundation design programs.
to it including horizontal gas and inertia loads, In addition to these tools, there are also many
weight loads, anchor bolt loads and loads due practical design and installation rules of thumb
to thermal growth and frame distortion that should be used. Unfortunately, many of these
2 Effectively transmit the vibration produced are only learned through years of experience. They
by dynamic forces down through the are the small things that are often left off of the
foundation while reducing or eliminating the installation drawings and specifications but have a
harmful effects of those vibrations big impact on the longevity of a foundation.
3 Accomplish items #1 and #2 above for 30
years or more This paper will focus on those rules of thumb
practices or techniques used in compressor
While the purpose of a compressors mounting installation design and installation that directly
system is simple, its construction is not. Reliable, influence the quality of construction and integrity
long-term reciprocating compressor operation of the foundation and how both of these directly
depends on the quality of the design and affect vibration attenuation. It will not address the
construction of the compressor mounting system interaction of the foundation and the soil.
and and the integrity its foundation. Degradation of
the foundation or loss of the mounting systems 2 Best Practices Related to Mitigating
integrity can cause excessive frame vibration and
misalignment, and eventually crankshaft failure. Vibration
To achieve a strong, high-quality yet cost-effective
The primary problem making compressor mounting installation it is important to recognize two very
systems difficult to design and install is vibration. important elements in the design of the mounting
A compressor can vibrate in six different ways or system:
modes three in translation (vertical, lateral, The compressor and its foundation must
longitudinal) and three in rotation (pitching/ form a tightly integrated structure.
yawing, torsional, rocking). Vibration energy travels in the form of waves
down and out through the foundation where
the soil can absorb it. Breaks, cracks or
separations in the integrated compressor /
foundation structure will prevent the vibration
waves from traveling downward.
 OPERATIONS
Best Practices in Compressor Mounting, James A. Kuly; ITW POLYMER TECHNOLOGIES

A compressor installation must be treated as 2.1.2. If the compressor has to be

a series of interacting structures that move mounted on a skid, two best
and vibrate. Vibration energy actually practices are to run the anchor
deforms the structure as it passes through the bolts to the top of the skid and to
structure. This is because the steel, grout and fill the void spaces inside the skid
concrete are all flexible. Preventing with epoxy grout.
foundation degradation and cracking means These practices act to stiffen the
making sure that all mounting components steel.
work together and none act to harm the other
2.1.2. Design the installation as
components or mounting system. For example,
a rigid structure whose dynamic response will
the design and installation of the anchor bolts
depend only on the dynamic load, the mass of the
should not cause the concrete to crack.
foundation and on soil characteristics. Make the
weight of the foundation 4 to 8 times the weight of
The one best word to describe what it means to
the compressor. The width of the foundation
"form a tight integrated structure" is Monolithic.
should be at least 1.5 times its height.
A monolithic structure is one that is cast as a
massive, seamless, 2.1.3. Keep the center of gravity of the block and
uniform, and rigid mat within 15 to 20 cm (6 to 8 inches) of the
piece. The design vertical centreline of the compressors crankshaft.
objective behind a
2.1.4. Minimize the elevation difference between
compressor installation
the machines dynamic forces and the center of
is therefore to create a
gravity of the machine-foundation system.
monolithic structure that
clamps the series of 2.1.5. Mechanically isolate the foundation block
interacting pieces from any surrounding structures.
together (the
compressor and its 2.2. Best Practices Related to Epoxy
driver to a well Grout & Chocks
designed concrete
foundation) with
enough size and mass to The following are best practices associated with
separate the dynamic response frequencies from the epoxy grout and chocks.
excitation frequencies. This means that the mat, 2.2.1. A non-shrink grout is required between the
concrete foundation, grout and machinery must top of concrete foundation and the bottom of the
become one. compressor and its driver so precise alignments can
be achieved. The use of epoxy grout and epoxy
The following describes the best construction chocks are, by themselves, considered a Best
practices that help reduce the impact of vibration in Practice over the use of cementitious grout
the structure. because of their
Higher physical properties
2.1. Best Practices Related To the Superior bond strength to concrete and
Construction of the Foundation steel
Resistance to cracking
The foundation has the biggest influence on Imperviousness to attack by oil and
mitigating vibration in a reciprocating compressor. chemicals
The following are best practices related to the 2.2.2. The best practice is to cover the
construction of the foundation that have to do with foundation with a full bed of grout then to mount
reducing the impact of vibration. the compressor and driver on individual chocks.
2.1.1. Install the compressor and driver on a The full bed of epoxy grout not only helps to
concrete block foundation. Concrete absorbs support the machinery it seals and protects the
vibration more easily than a steel frame or skid concrete foundation. Because individual chocks are
because its internal molecular structure absorbs separated by a gap, air can easily flow under and
vibration energy. around compressors and drivers. Chocks also allow
the recess in the foundation for the pan to be built
shallower to reduce the weakness in this area of the
block that was prone to cracking.
 OPERATIONS
Best Practices in Compressor Mounting, James A. Kuly; ITW POLYMER TECHNOLOGIES

2.2.3. Individual chocks can be either the 2.3.5. To mitigate horizontal vibration, increase
poured-in-place type or the pre-manufactured the Coefficient of Friction (COF) of the layers. It is
adjustable type chocks. Both are good practice.
The adjustable chocks must be installed on a sole the Coefficient of Friction created by the anchor
plate while the poured-in-place type chocks can be bolts that prevent sideways or lateral vibrations and
placed either directly on top of the grout or on sole movement. Anchor bolts create the Normal Force
plates. that, in conjunction with a high COF creates a very
high Resistive Force that absorbs the shaking force
2.2.4. Poured-in-place chocks can be made from
and prevents movement. A high COF is caused by
either 3-component epoxy grout or 2-component
the intimate fit of epoxy to steel because it fills
epoxy chocking compounds. The best practice
every little scratch, sandblast divot and machining
regarding which product to use is based on size of
mark on the bottom of a compressor / driver.
the chock. With any single chock over 610 mm (24
Resistive Force is found by multiplying Normal
inches) in length or 75 mm (3 inches) in depth it is
best to use an epoxy grout rather than a chocking
compound.

2.3. Best Practices Related to Anchor

Bolts

Anchor bolts clamp foundation and equipment

layers together. Their purpose is to prevent
movement of the equipment or separations between
the layers. Separations act as a barrier preventing Force pushing down by the Coefficient of Friction.
vibrations from passing completely through the
foundation to the soil.
2.3.1. To reduce vertical vibration and lessen its
impact, a best practice is to maximize anchor bolt
tension. This may seem like an obvious statement 2.4. Best Practices Related to Frame,
but anchor bolt tension is often arbitrarily limited. Rail, Sole Plate and Foundation
For example, API 686 suggests an anchor bolt
Preparation
stress of only 30,000 psi (207 MPa). If this value is
used, the anchor bolt will be tightened to only 23%
of its Yield Strength. I believe that to be fully Cleanliness of the compressor frame, engine rails,
effective an anchor bolt should be tightened to 60% sole plates or concrete foundation has always been
to 70% of its yield strength. a best practice. There can be no oil in the concrete
2.3.2. The static loading on the epoxy chocks or and all paint, oil, grease dirt, etc. must be removed
grout should be under 6.9 MPa (1,000 psi) to from the frame, sole plates and rail. Cleanliness is
minimize creep. Static loading is made up of a the best way to prevent the various surfaces from
combination of deadweight loading and the loading de-bonding and from sliding due to a low COF.
caused by the tensile stress on the anchor bolts. The following are some additional best practices
This should be a sufficient to firmly anchor the for component preparation the will help mitigate
compressor and its driver. It also provides a 14 to vibration.
16 X Safety Factor to manage any dynamic loads 2.4.1. Sand blast and clean metal frame, sole
before the compressive strength of the grout is plates or rail to SP 6. Do not prime them. Just
reached. remove anything on the surface and give the
2.3.3. Terminate the anchor bolts half way into surface a light texture. This will increase the
the mat. This combined with heavy rebar COF.
connecting the mat to the foundation will help hold 2.4.2. If a primer is required on steel to prevent
the layers together. it from rusting prior to installation, that primer
2.3.4. Increase the portion of the anchor bolt that must be a straight epoxy primer (NO ZINC) and it
is being stretched. The anchor bolts are essentially must be applied no more than 2 to 3 mills thick.
springs that stretch and apply a clamping load. To 2.4.3. Chip off the surface of the concrete
create an effective clamping force, an anchor bolt foundation removing all laitance and expose 50%
must stretch over about 50% of its length. chipped and broken aggregate. This will provide
a structurally solid surface to transfer vertical and
horizontal loads down through the grout and into
the concrete.
 OPERATIONS
Best Practices in Compressor Mounting, James A. Kuly; ITW POLYMER TECHNOLOGIES

3 Best Practices to Prevent Foundation remove all sharp corners, points, internal or re-
Degradation entrant corners in the foundation to reduce built-
in stress. In other words, anything that can act as
a stress riser inside the concrete must be softened
In addition to applying Best Practices to mitigate or removed. Instead, round sharp corners and
vertical and horizontal vibration, it is also points. Install a large radius on any internal angles
important to do everything possible to prevent in the foundation. Apply a large radius to
cracks in the foundation and the penetration of oil everything that penetrates concrete. Also, anchor
and chemicals that can degrade the concrete and bolt holes should be round and not square and
allow vibrations to increase. This section contains grout pockets recessed into the concrete
the best practices related to the construction of the foundation should be avoided. Install troughs
foundation and the installation of the machinery around the unit to take away oil.
related to preventing foundation degradation. 3.1.6. Vertical connections - There should be
no vertical connections between different
3.1. Best Practices Related To materials in a foundation. For example, there
Foundation Design & Installation should be not be a vertical connection between
concrete and grout. Connections should be
3.1.1. Concrete specification - The quality of horizontal only. Also, do not install keys or lips as
concrete used in the foundation is extremely they cannot restrain thermal growth forces.
important for ensuring a long successful life of the
3.1.7. Edge-lifting Edge-lifting is a common
foundation. Best practice calls for a minimum
problem on many installations. It is a de-bonding
grade of M25 or M30 concrete. This is concrete
of the concrete just below the epoxy concrete
with a compressive strength of 25 to 30 N/mm2
bond line. It can occur when large there are wide
(3,625 to 4,350 psi) and a tensile strength of 3.2 to
open areas where epoxy grout covers the
3.6 N/mm2 (464 to 522 psi). Use crushed stone in
foundation but does not support any equipment.
the concrete that has angular faces. The bond of
There are three methods of preventing edge-
angular faced stone to the cement paste is better
lifting: 1) Round the outer edge of the concrete
than round stone.
foundation, 2) Pin the edge of the foundation
3.1.2. Tensile strength - A best practice is to using 12 mm () rebar set into a 24 mm (1) hole
increase tensile strength of concrete to at least every 30 cm (12) along the edge of the
1,000 psi using steel fibers. Steel fibers reinforce foundation. 3) Install mechanical anchors in the
the concrete in 3 directions. Steel fibers have a surface of the concrete. These are rebar staples or
high modulus of elasticity and high tensile wickets that improve the bond of the grout to the
strength to withstand excess strain and prevent concrete.
cracking. Because the modulus of elasticity of the
fiber is higher than the matrix (concrete or mortar
binder), it can help carry the load by increasing the
tensile strength of the material.
3.1.3. Concrete curing - Do not allow any
grout to be installed until the concrete is fully
cured. Improperly cured concrete can have its
design strength reduced by as much as 50%.
Good curing practice means keeping the concrete
damp enough and at a uniform temperature long
enough so it can reach its desired compressive and
tensile strengths. The key factors in curing are 1)
shrinkage complete, 2) full tensile strength and 3)
water content reduced. 3.1.8. Rebar specification Best practice is #6
(3/4) rebar on 6 centers. Second best is #8 (1)
3.1.4. Concrete placement and consolidation - rebar on 8 centers due to the increased difficulty
Best practice is to limit the time delay between in placing the concrete. Dense placement in the
layers of concrete to no more than 25 to 30 upper 1/3rd of the foundation block and lighter
minutes. However, breaks in concrete placement density in the lower 2/3rds of the foundation.
of as little as 15 minutes can result in a cold joint Look for and eliminate stress risers that could
separation between layers. Also, do not add water potentially be created in the concrete which could
to the concrete mix at the site as it will reduce the be caused by the ends of rebar. Also, eliminate
compressive strength, the modulus of elasticity, possible stress points in the concrete by installing
and tensile strength of the concrete rebar so it crosses at all internal corners of
3.1.5. Foundation design Best practice is to foundation.
 OPERATIONS
Best Practices in Compressor Mounting, James A. Kuly; ITW POLYMER TECHNOLOGIES

3.2. Best Practices related to anchor bending stress that will be imposed on the bolt
bolts, nuts and washers thread.
3.2.5. Tension monitoring - It is also a best
practice to install anchor bolts with a built-in
The number one reason for foundation failure is tension monitoring device.
cracking, and the number one cause of cracking is
improperly designed and installed anchor bolts. 3.2.6. Anchor bolt length - It is best practice to
Anchor bolts cannot be eliminated so the quality make anchor bolts as long as possible and to
of their installation must be increased and their terminate the anchor bolts half way into the mat.
negative affects must be mitigated. Longer bolts reduce loss in tension resulting from
creep and reduce stress in concrete at their
3.2.1. Anchor Bolt Grade & Materials For termination point. In addition, long bolts separate
reciprocating compressor mounting the anchor the stress area from the source of oil. At a
bolts must be made from 4140 ASTM A193 B7 minimum the anchor bolts should be 1.2 m (48)
material. Nuts should be 2H. in length.
3.2.2. Anchor Bolt Types There are many 3.2.7. Spherical washers The use of
different anchor bolt designs. The primary spherical washers is a best practice. Spherical
difference is the design of their termination or washers allow the tension on the bolt to be spread
bottom end. Free-standing bolts are a best practice uniformly around the anchor bolt rather than on
because they can easily be moved and positioned just one side. This is very important because nut
without putting a strain on the bolt or concrete. face angularity of 1 to 2 degrees can have a
They have advantages over embedded bolts significant effect of the fatigue life of a bolt.
because the holding force is governed by the bolts
tensile strength rather than the concretes tensile 3.2.8. Nuts Anchor bolt nuts should be
strength. If bolts are to be cast into the foundation ASTM A-194 high strength nuts. They must be
do not cast them into the foundation until the lubricated so the torque is not wasted in friction
compressor is set in place. between the threads or between the nut and
washer. Super nuts are a very good practice but
can be expensive.
3.2.9. Bolt torque & tension The nuts on all
anchor bolts should be hand-tool tight while the
grout is being installed. After the grout has
hardened the bolts should be tensioned per the
equipment manufacturers instructions. For a tight
foundation and mounting system, the preload on
the anchor bolts should be as high as possible, but
not higher than 70% of tensile strength of bolt.
3.2.10. Bolt tensioning The only accurate way
to tighten an anchor bolt is to stretch it. Twisting
3.2.3. Anchor Bolt Terminations If free- or torquing a bolt can be very inaccurate because
standing bolts are not used, then any other long torque is often wasted on friction between the
bolt can be used, but as a best practice its threads of the nut and bolt and between the bottom
terminations must be round. This not only means face of the nut and the washer. Therefore the use
that the plate at the bottom of the anchor bolt of a hydraulic bolt tensioner is a best practice. It
should be round, but the plate itself must have is also a best practice to re-tighten anchor bolts
round edges. The diameter of the plate should be after compressor and driver have come up to
3 to 4 times bolt diameter so that the tensile forces temperature.
on the concrete are pushed further out from the
bolt. Also, the thickness of the plate should be 1.5
3.3. Best Practice Related To Anchor
x bolt diameter.
Bolt Holes / Sleeves / Covering /
3.2.4. Free-stretch - No matter the style or type Sealing
of anchor bolt, the bolt itself must be prevented
from touching epoxy grout over the upper half of
its length. This allows the bolt to free-stretch. To Anchor bolt sleeves or covers are a best practice.
accomplish this, the upper half to the bolt must be They cover a length of bolt so it can stretch
wrapped with tape or covered with pipe insulation sufficiently when tensioned. If properly sealed top
foam. Wrapping a bolt also provides the bolt with and bottom, they also protect the bolt from
a large thread clearance which allows the nut to chemical attack, rust and corrosion.
rock slightly on the bolt thread reducing the
 OPERATIONS
Best Practices in Compressor Mounting, James A. Kuly; ITW POLYMER TECHNOLOGIES

Many people mistakenly believe that the purpose configuration of expansion joints is usually based
of a bolt sleeve is to allow the compressor installer on the grout used and the extremes of weather and
to easily bend the anchor bolt for alignment the thermal cycling expected. The larger the
purposes during compressor installation. This is expected difference in seasonal temperatures the
not true. Pushing an embedded anchor bolt puts a closer the expansion joints should be but is
strain on it as well as the surrounding concrete that typically either 1.2 m (4 ft) square or 1.8 m (6 ft)
could lead to cracking. For this reason it is a best square.
practice NOT to embed any anchor bolts until the
3.4.2. Well sealed - Expansion joints must be
compressor is set in place and aligned.
well sealed at the bottom so they cannot allow any
3.3.1. Corrugated anchor bolt sleeves are a liquids to pass down next to them.
best practice because they
have an ability to give under 3.5. Best Practices Related To
compression rather than to Alignment Tools
drive themselves up into the
grout or down into the
concrete. In any event, Some sort of jacking device must be used to
anchor bolt sleeves should be position the compressor and driver. There are
cut off even with the top of many different types of jacking devices and all
the concrete. If they are (except nuts on anchor bolts under the mounting
allowed to stick partway up plate) are acceptable IF they are removed
into the grout, they will completely from the grout. Jacks, wedges, shims,
eventually crack the grout. and blocks of any shape or size must never be left
3.3.2. Not too close to the edge - It is good inside the grout. Cracks are guaranteed if they are.
practice to keep bolts and pockets as far as 3.5.1. Jacking screws - The best practice here
possible away from the sides of the foundation is to use jacking screws (d) and back out the screw
30 cm (12 minimum) completely after the grout has cured. This can be
3.3.3. Well sealed the top and bottom of the done if the threads of the jacking screws are
sleeves should be well sealed to prevent them coated with non-melt grease. Jacking devices that
from filling up with oil or water. are isolated and grouted around must have a
second pour to fill in the space where the jacking
3.3.4. Wrap bolt threads - The bolt threads screw was located. This is costly and
sticking up above sleeve must be covered using unnecessary. The best practice is to use jacking
foam backed tape or foam pipe insulation. This screws with non-melt grease on their threads. This
prevents grout or chocking compound from going is more cost effective as it allows the entire area to
up into the bolt hole on the compressor and be grouted at one time.
preventing the bolt from moving or stretching.

3.4. Best Practices Related To

Expansion Joints
The use of expansion joints is a best practice.
Expansion joints serve 2 purposes 1) they
prevent the concrete and epoxy grout from coming
apart due to the difference in thermal expansion
and contraction rates
and 2) they guide
flow of grout into
areas of limited size.
Using expansion
joints will ensure that
the epoxy grout
flows everywhere it
is needed and that it 3.5.2. Round landing plate - Another best
will stay in place practice is to have the jacking screw touch down
once there. on a relatively thin, round, landing plate with
rounded edges. This provides a stable place for
the jacking screws to rest that will not add any
3.4.1. Proper
stress risers to the grout.
layout - Proper
spacing and
 OPERATIONS
Best Practices in Compressor Mounting, James A. Kuly; ITW POLYMER TECHNOLOGIES

Bond the round landing plates to the surface of the 3.6.5. Chock Overpour The overpour is not
concrete with a fast setting epoxy paste. just the place where the chocking compound is
poured in place. The overpour also plays a vital
3.6. Best Practices Related To Epoxy role in the curing of the chocking compound. It is
Grout & Chocks the place where the chocking compound can
expand up into and contract down from so the
epoxy in it must remain cool and liquid. This is
Only epoxy grout and epoxy chocking compound done using metal dams placed no more than 19
are discussed in this section as their use is mm (3/4 inch) away from the mounting foot. The
considered a Best Practice over cementitious overpour should be along the long side of the
grouts. It is important to first differentiate mounting foot. It can also be on the opposite long
between an epoxy Grout and an epoxy Chock side but it should never extend around the entire
or Chocking Compound. Epoxy grouts are mounting foot.
mixtures of resin, hardener, and aggregate. 3.6.6. Foam strip - Install a foam strip around
Because of the aggregate, grouts have the the mounting foot or sole plate to take up a small
consistency of lumpy oatmeal. However, the amount of shaking movement without causing the
aggregate also allows the grout to be poured in chock or grout to crack.
large, thick sections because it absorbs the
exothermic heat created by the resin and hardener.
Epoxy chocking compounds have no aggregate. 3.7. Best Practices Related To Coating
As a result they get much hotter and must be and Sealing the Foundation
poured in small blocks typically around individual After the compressor and driver have been grouted
anchor bolts. Chocking compounds have a and/or chocked in place and the forms removed,
smooth and creamy consistency. prepare the exposed concrete surfaces under and
3.6.1. Eliminate stress risers in grout and around the installation by following these best
chocks. Stress risers are created when re-entrant practices.
angles are cast into the grout, equipment mounting 3.7.1. Concrete preparation - The surface of
feet or sole plates with sharp corners instead or the foundation must be firm, free of any laitance
well rounded corners are installed in the grout. or efflorescence, clean, free of any adverse
Also, screw threads, welding slag, sharp edges, moisture conditions, have an appropriate surface
and points of any kind increase the stress in both profile, and be fully cured before coating. Newly
grout and chocks which can lead to cracking. poured concrete must age at least 30 days at
3.6.2. Manage temperatures of the grout and temperatures over 70F before coating. Form
chock to eliminate over heating. Over heating can release agents, sealers, curing compounds, salts,
cause high thermal stresses that can lead to hardeners and other foreign matter will interfere
cracking. High temperatures also cause an over with adhesion and must be removed. Shot-
expansion of the epoxy followed by an over blasting, mechanical scarification, suitable
contraction that can lead to soft foot problems. chemical means, or sandblasting should be
employed to prepare substrate. The surface profile
3.6.3. Manage depth of pour The larger the of the concrete should be CSP-3 to CSP-5 meeting
mass of epoxy chock or grout, the more ICRI (International Concrete Repair Institute)
exothermic heat it generates and that too can lead standard guideline #03732 for coating concrete,
to a larger than expected expansion then producing a profile equal to 60-grit sandpaper or
contraction in the epoxy. For this reason the depth coarser. Moisture vapor transmission should be
of pour is important. For most epoxy grouts the 1.4 kg (3 pounds) or less per 93 square meter
maximum depth should be no more than 30 cm (1,000 square feet) over a 24 hour time period, as
(12). The depth of most epoxy chocking confirmed through a calcium chloride test, as per
compounds should be about 5 cm (2). ASTM E-1907. All surface irregularities, cracks,
3.6.4. Grout / Chock level - Most installation expansion joints and control joints should be
drawings show the level of grout or chock at the properly addressed prior to application.
same level as the bottom of the mount. This is not 3.7.2. Concrete coating Mix and apply an
correct and should not be done. The grout/chock epoxy primer and a 2-part, 100% solids, epoxy top
level should always be 12mm to 24 mm (1/2 to 1) coat over the concrete areas not covered by epoxy
above the bottom of the mount. This puts a head chocks or grout. This will protect the surrounding
pressure on the epoxy surrounding the mount areas from oil penetration.
which in turn puts an upward force on the epoxy
under the mount. This upward force ensures that
any contraction in the epoxy has little or no effect
on the alignment.
 OPERATIONS
Best Practices in Compressor Mounting, James A. Kuly; ITW POLYMER TECHNOLOGIES

3.7.3. Seal mounting feet - After the grout or References

chock cures, seal around the mounting foot or sole
plate with a sealant that will prevent oil from 1. Prakash, S. and V.K. Puri, Foundations for
penetrating underneath and causing the COF to Vibrating Machines, Journal of Structural
decline. Engineering, April May 2006

3.7.4. Seal Expansion joints Remove 12 mm 2. ACI 351.3R-04 Foundations for Dynamic
(1/2) of the top and end of the expansion joints. Equipment, Reported by ACI Committee
Pour liquid expansion joint sealant into this space 351, James P. Lee, Chair and Yelena S. Gold,
to prevent oil from penetrating underneath. Secretary
3. Shear Strength of Steel Fiber Reinforced
The depth of the sealant should be only half as Concrete Beams Without Stirrups, Yoon-
wide as the expansion joint. Keun Kwak, Marc O. Eberhard, Woo-Suk
Kim and Jumbum Kim, ACI Structural
3.7.5. Drip pans - Install drip pans under the
Journal, Technical Paper Title No. 99-S55
equipment with drain piping and troughs around
http://faculty.washington.edu/eberhard/publica
the unit to take away oil.
tions/kwak-eberhard_aci-journal_jul02.pdf
4 Acknowledgements 4. Smalley, A.J., P.J. Pantermuehl, R.M. Lewis
and E.A. Johnson, Design of Reciprocating
The author would like to acknowledge the Compressor Mounting Systems and
invaluable verbal contributions by the following Foundations for Integrity and Reliability,
experts to the content of this paper: 1996 PRCR Gas Machinery Conference, 1996
Mr Tom Hoekstra, EMHA Technisch Bureau 5. Mandke, Javant S. and Anthony J. Smalley,
B.V., Ridderkerk, Holland, Parameter Studies for Enhanced Integrity of
[email protected] Reciprocating Compressor Foundation
Mr Mark Huggins, Engineered Industrial Blocks, Pipeline and Compressor research
Products, Aylesbury, Bucks, U.K., Council Technology Assessment, September
[email protected] 1994.
Mr Lothar Idler, Marine-Und-Industrie- 6. Bhatia, K.G., Foundations for Industrial
Montage Gmbh, Hamburg, Germany, Machines, D-CAD Publishers, 2008
[email protected]
Mr Bernard Mirabaud, Polyresine, Boissy 7. Smalley, A.J. and P.J. Pantermuehl,
LAillerie, France, [email protected] Foundation Guidelines, Gas Machinery
Research Council Report No. TR-97-2,
Mr Piero Arduino, Wartsila Italia S.P.A., January 1997
Genova, Italy, [email protected]
Mr Ramon Zubiaga Garteiz Jr., Sintemar, 8. Smalley, A.J., Crankshaft Protection:
Vizcaya, Spain, rgz.sintemar.com Guidelines for Operators of Slow Speed
Integral Engine/Compressors, Gas Machinery
Research Council Report No. TR-97-1,
5 Conclusion January 1997
The only sure way to actively manage vibrations 9. Recommended Practices for Machinery
in a compressor and foundation system is by Installation and Installation Design,
understanding the entire system as whole using American Petroleum Institute, Practice 686,
FEA and working to effectively control all aspects April, 1996.
of the installation at the design stage. However,
all this work can be for nothing if the simple yet 10. Harrison, Don, The Grouting Handbook,
crucial best practices for installing the compressor Gulf Publishing Co. Houston, TX, 2000
and driver are not followed. The above paper was
not intended to be a complete list of Best
Practices. Installation Best Practices should be
accumulated, confirmed and applied by every
company involved in reciprocating compressor
foundation design and installation.