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SSRN-ELSEVIER (2018-2019)

International conference on “Recent Advances in Interdisciplinary Trends in

Engineering & Applications

Design and Analysis of Compressor Base Frame for Weight

Reduction
a,* a a
Sameer Agrawal , Nitin Sherje , Ashish Umbarkar
a
Assistant Professor, SKNCOE, ,Pune-411041, India

Abstract

The compressor base frame also known, as skid is required to carry its weight and the forces to which it is
exposed. The work undertaken is for the compressor base frame (skid). The weight of existing base frame is
much higher than the required, which means it is over designed. It was essential to reduce the weight
ultimately reducing the cost of it. Hence, the work is focused on design and analysis of compressor base frame
to reduce the weight. The weight of existing skid is 4100 Kg and weight of the assembly mounted on it is
9420 kg. The frame has been modified in four different way like I-beams have been replaced by C-channels,
removed the C-channels at some places if not required, reduced the thickness of the plates used to mount the
motor etc. The free vibration analysis has been carried out to check the occurrence of the resonance and also
determined the natural frequencies experimentally using FFT analyzer to validate the results. Similarly, the
stress analysis has been carried out and observed that all the modified frames are safe under the various loads
acting on it. The weight upto 19 % would have been reduced.

Keywords: Skid; Natural Frequency; FFT.

1. Introduction

Compressors are mounted on the Base frame to carry its weight, to maintain its alignment and to assist in
carrying the dynamic loads, which every compressor generates. Compressors base frame needs a effective
design technology to ensure that the base frame as designed performs the required functions, and maintains its
integrity. There is also a need to maximize the life of the compressor base frame under the loads to which it is
exposed.
So the project work is related to the compressor base frame (Skid) on which high speed reciprocating
compressors are mounted. High speed reciprocating compressor has been meeting a market demand in various
applications. Such compressor typically range from 100 to 4700 HP, operating at a speed of 1,000 to 1,800
RPM, and are typically delivered to the side as a skid mounted packages, ready to run. The primary advantage
of skid mounting is portability and ability to perform all necessary integration of engine and compressor,
control system and auxiliary piping on the shop floor with access to the skilled labor and equipment.

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Designing products today offers many challenges they must be stronger, lighter, safer, quieter, or using
new materials. Finite element analysis (FEA) is a powerful technique to simulate the mechanical behavior of a
product. The FEA method has matured to a point where design, meshing, analysis and post-processing are
highly integrated and automated. The project aims at detail FEM analysis of Base Frame. Keeping these
factors in mind design of base frame is carried out ensuring that it will satisfy the desired requirements with
the following methodology adopted
• Building a 3- D model of Base frame using Solid Edge Software.
• Meshing the model by Shell 63 elements in Hypermesh. MPC 184 element is also used for welds.
• To obtain the Rigid body modes and Normal modes in free vibration analysis for base frame (skid)
using Ansys.
• To find out the stresses in existing frame and modified frame using Ansys software for safe design.
• Dynamic response and investigation of critical stresses are found out by incorporating the boundary
conditions at bolting.
• To reduce the weight of skid for given loading conditions.
• The results of the analysis will be design parameters for the skid so that the skid meets the acceptable
limits of the deflection and stress and also has minimum weight.
• To compare the results of free vibration analysis for base frame with the results obtained from
experimentation using FFT analyzer.
• To calculate natural frequency analytically.
• The compressor and its accessory component (bare components) are generally mounted on skid. The
location of compressor and its accessory components are fixed. The following forces are fixed for then
given skid.
• Dead weight of the components
• Dynamic forces due to the crankshaft rotation
• Weights of the component and dynamic forces may vary depending on the application.
The fig.1 is the layout of base frame.

Fig. 1. Layout of base frame

* Corresponding author. Tel.: +91-7743872946.

* E-mail address: [email protected]

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2. Design Loads
2.1. Static Loads
A major function of the base frame is to support static loads (Gravity loads). It has to withstand these
forces while lifting as well as during the working condition of the compressor. The significance of the static
loads is to produce a generally downward compressive load on the base frame. Static loads consist of dead
weight of the bare compressor components. This includes compressor assembly, motor, control panel,
intercooler after cooler etc. Static load also includes the dead weight of the skid structure. For the given
model, the weights of the components are as follows.

Table 1. Weights of different components

Component Name Magnitude Comment

Compressor 6700 kg Applies at point load on Compressor foundation

After cooler 960 kg Uniformly distributed the support frame
Plummer Block 60kg Applied at point load on the support frame
Control Panel 350kg Uniformly distributed the support frame
nd
Damper for 2 Stage 150 kg Uniformly distributed the support frame
Motor 1200 kg Applied at point load on the support frame
Self weight skid 4100 kg Uniformly distributed the support frame

2.2. Dynamic loads

The forces acting on frame during the operating condition of compressor like inertia forces, gas forces
(vertical and horizontal), and drive torque etc. It is essential to carry out the dynamic analysis of the skid
because most of the failure occurs due dynamic loads only. The couples i.e., turning couple, swaying couple
and galloping couple, which are acting at the C.G. of the compressor, are given. The torque of the motor,
which is required for the dynamic analysis, is also found out.

3. Material Properties

The Fe 410 (steel) is used for whole base frame in which 410 N/mm2 is min tensile strength of the
material. The material properties given in this section are nominal values, to be accepted as characteristic
values in design calculations.

Table 2. Couples and Frequency

Component Name Magnitude Comment

Swaying Couple +210 Kg-m Applied at the C. G. of compressor about Z- axis

+ 140 Kg-m
+46 Kg-m
Galloping Couple Applied at the C. G. of compressor about Z- axis
- 46 Kg-m
+123 Kg-m
Turning Coupling Applied at the C. G. of compressor about Y- axis
- 10 Kg-m
Angular frequency of Motor 155.50 rad/s Applied at the C. G. of compressor about X- axis
Natural Frequency of motor 24.75 Hz For calculation of the stiffness of the springs supports

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IS: 2062-1999 standards are used for material properties. These properties are applicable when 20 mm
<d or t< 40 mm, where‘d’ is nominal diameter of the element and ‘t’ is the thickness of the frame.

Table 3. Material Properties

Component Name Magnitude

2
Density 7830 kg / m
2
Min Tensile Strength 410 N / mm
2
Yield Strength 240 N / mm
Min Elongation 23 %
2
Modulus of Elasticity 2 x 105 N/ mm
Poisons ratio 0.3
2
Modulus of Rigidity 0.769 × 105 N/mm

The above table shows that the stresses in all beams having different lengths are less than the yield
strength, hence the design of all I- beam used in given base frame is safe.

4. Calculations for natural frequency

(1)

Natural frequency of a base frame analytically

(2) Found out stiffness for maximum deformation and minimum

deformation and hence natural frequency for both cases. Then the average of this both values is nothing but
a final natural frequency.

(3) The calculations are made for finding the natural frequencies
for all four case and are compared with the values obtained from analysis

Following are the values of natural frequency obtained for all four cases.

Table 4. Natural frequencies for different cases.

Case Natural Frequency (Hz)

Existing 72.95
Case I 90.232
Case II 50.2369
Case III 65.142
Case IV 63.232

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5. Experimental vibration analysis

The experimental analysis has been carried out to validate the CAE work. The arrangement made for
experimental study is shown in above figure. The natural frequencies have been obtained using FFT
analyzer by giving the excitation at four points to the base frame-using hammer.
The results obtained from the test are plotted in the form of Frequency Vs Acceleration and the pick of
each plot is then compared with the Ansys result to find out the error. The Frequency Vs Acceleration plots
are given below,

Fig.2: Frequency Vs Acceleration for second excitation

Fig.3: Frequency Vs Acceleration for second excitation

Fig 4: Frequency Vs Acceleration for third excitation

Fig.5: Frequency Vs Acceleration for fourth excitation

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In the following table we can see that, ANSYS results are agree with the experimental results.
Table 5. Comparison of result from ANSYS and Experimental result

Mode Ansys (Hz) FFT (Hz) % Error

8 29.014 29.305 1.3

9 48.244 45.89 4.87
10 56.038 57.09 1.84
12 75.925 78.678 3.49

The error is below 10% in every mode. So the software results are accurate and these results are used for
further analysis.

6. Finite Element analysis

The finite element problem results into a system of simultaneous linear algebraic equations to solve
rather than requiring solution of the differential equations. This method yields approximate value of the
parameter of interest in the continuum. i.e. it is a process of dividing a modeled body into equivalent system
of the smaller bodies or units called finite element interconnected at common points, edges, surface known
as discretization. Now, the equations for each finite element are formed and combine them to obtain the
solution of whole system rather than solving problem for entire body in one operation. The solution for the
structure problem is to determine the displacement at each node and stress within each element making up
the structure that is subjected to applied loads. The power and low cost of modern computer techniques
made finite element analysis available to many discipline and companies, which reduce overall time for
product optimization.

6.1. Free Vibration Analysis

Free vibration analysis has been carried out to find out mode shapes of existing base frame and all
modified cases. Total 15 modes are obtained among that up to 6 the modes are rigid body mode and from 7
to 15 the modes are normal modes.
The comparison of frequency from Ansys and analytical method is given in above table which is less
than 10%. Hence the results obtained by Ansys are accurate. The frequency obtained during free vibration
analysis does not match with compressor frequency, hence the resonance is avoided. The mode shapes for
existing frame and all cases are given below.

Table 6. Comparison of frequencies by Ansys and Analytical method.

Natural Frequency Natural Frequency

Case % Error
Analytically Method by Ansys

Existing Frame 72.95 80.251 8.9

Case I 90.232 85.587 5.15
Case II 50.2369 56.038 6.50
Case III 65.142 59.91 8.03
Case IV 63.232 58.245 7.88

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Fig 6: (a) Max. Deformations for existing, (b) Max. Deformation for Case-I base frame

Fig 6: (c) Max. Deformation for case-II, (d) Max. Deformation for case-III

Fig 6: (e) Max. Deformation for case-IV

Fig.6: Mode shapes

6.2. Dynamic force study for critical stress analysis

The following activities should be included:
• Forces generated by reciprocating compressors create stresses in the skid. Dynamic structural analysis
is required to find the stresses and ensure that the stresses are under guidelines for all planned
operating conditions.
• The skid stiffness and mass at the skid mounting location has to be considered.
• Evaluate all computer model mesh sizes to ensure accuracy of the dynamic analysis.
• Recommend modifications to the structural design.

6.2.1. Information required for skid and structure analysis

• Weights and Center of Gravity of all equipment
• Compressor skid drawing and platform/topside steel drawings with details
• Unbalanced forces and couples for all installed equipment on platform/topside
• Design loads for the lifting analysis
• Mounting details.

6.2.2. Boundary Conditions:

To predict dynamic behavior of any system, the systems around the model have to be considered and
simulated mathematically. It contains forces, constraints, reactions applied by external system on the
system under consideration. In the terminology of FEM it is called ‘Boundary Conditions’.
• The constraints are applied to the frame at bolting position where the frame is fixed to the foundation.
• The basis layout of the skid should not be changed during the optimization.

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• The skid should hold at the point where the extrusions are given for holding it at the time of analysis
for overhanging frame

6.2.3. Load Application:

Fig.7: Load application

The load application for dynamic condition is given in following figure, the various loads are applied
at C.G. of compressor and it’s supporting accessory.
The constraints are given at the bolting where the frame is fixed on the foundation block and the loads
are applied to find out the stresses in the base frame for dynamic condition. The dead weights are applied in
case of non-rotating members and couple & torque is applied in case. Three different couples i.e., swaying,
galloping and turning couple are acting at the C.G. of compressor shown in above figure. These couples are
the couples acting about the three different axis i.e, x,y,z-axis. The other loads like weight of damper
pulley, weight of after cooler, weight of control panel are applied at their C.G point. The torque and the
weight of the motor are applied at the C.G. of motor.

(a) Plot for existing frame (b) Plot for Case-I

(c) Plot for Case-II (d)Plot for Case-III

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(e)Plot for Case-IV

Fig.8 Stress Pattern for the dynamic Load Consideration on the Base frame

From fig.8(a) it is observed that the analysis is carried out for existing frame in which maximum von
2 2
mises stress value is 122.206 N/mm which is less than the yield strength of material i.e., 245 N/mm ,
hence the design is safe. The maximum deformation in frame is 0.1893mm. The existing base frame is then
modified and further analysis is carried out to find out the critical stresses in modified.
From fig.8(b) is for first case in which pipes are removed which are used in frame for lifting the frame
during transportation and the analysis is carried out to find out the von mises stresses in skid. The maximum
2 2
von mises stress value is 134.201 N/mm , which is less than yield strength (245 N/mm ), hence the design
is safe. The critical stress region is found at the bolting position where the frame is fixed on the foundation
block.
From fig.8(c) is for second case in which some I-beams are removed and some beams are converted into
C- Channel by keeping the pipe as it is and analysis is carried out to find out the stresses in the skid. After
the analysis it is observed that the critical stress region is found at the bolting position where the frame is
2
fixed to the foundation block. The maximum von mises stress value is 154.179 N/mm which is again less
2
than the yield strength i.e., 240 N/mm , hence the design is safe. Maximum deformation in the frame is
0.2399 mm. The fourth case for the modification in the frame is explained further.
From fig.8(d) is for third case, it is the combination of first case and second case in which all pipes are
removed and some beams which are found stiff after free vibration analysis are removed and some are
converted into C- channel. The analysis is then carried out for this new layout and it observed that max von
2
mises stresses are 176.839 N/mm less than the yield strength, hence the design is safe.
The above explain cases are when the skid is mounted on foundation block, but during transportation the
dead weight of compressor and its operating accessories like motor , intercooler, control panel etc is acted
upon the skid and it is behaves like a overhanging beam. So it is essential to consider this condition also,
hence the analysis is carried out for overhanging skid in the next plot.
The above plot is for IV case in which modified frame discussed in third case is suspended by holding
the frame at four corners and the analysis has been carried out. The maximum Von mises stress is 183.482
2 2
N/mm which is again less than yield strength i.e., 240 N/mm , hence the design is safe. The maximum
deformation is 0.2851 mm.

7. Results and discussion

The dynamic response of base frame has been studied by considering different boundary conditions. The
maximum stresses obtained by analysis are compared with the yield stress of a material for checking the
frame for safe design. The critical stress region is identified near compressor bolting place. The comparison
for existing frame and different cases is given in following table. From table it is observed that the
maximum von mises stress for each is less than the yield stress of the material.

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Table 7. Comparison of Von mises stresses with yield strength.

Von mises Stresses

Yield Stress
2
Case Minimum Maximum (N/mm )
2 2
(N/mm ) (N/mm )

Existing Frame 0.563 E – 04 122.206 240

Case I 0.853 E – 04 134.201 240
Case II 0.598 E – 04 154.179 240
Case III 0.554 E – 04 176.839 240
Case IV 0.67 E – 04 183.482 240

The design of frame has been provided by company which is designed as per IS standards The
compressive stress in I- section has been calculated which is 184 N/mm2 less than the yield stress of a
material, hence the dimensions taken for I- section as per IS-808 grade are correct.
Cost reduction is a crucial issue now days for every industry to survive in market. Hence the company
has also given an opportunity to study the various aspects, which would involve in the cost reduction of
base frame. The existing base frame has been modified to reduce the weight by keeping same the location
of compressor and its supporting accessories. The modified frames are then analyses to find out critical
stress regions in static and dynamic condition for safe design. The results obtained in terms of weight and
maximum stress would have been compare to find out the optimum condition. The comparison is given in
the table.

Table 8. Comparison for stress and weight for different cases.

Maximum von mises stress Weight Percentage weight

Case ( MPa) ( Ton) reduction

Existing Frame 122.206 4.022

Case I 134.201 3.3661 16.30
Case II 154.179 3.9365 2.12
Case III 176.839 3.2806 18.43
Case IV 183.482 3.26141 18.91

For a drastic weight reduction by more than tens of percent, however, extensive structural studies are
necessary. The pipe in structure for holding the frame during transportation does not play any role in
increasing the strength of frame has been removed. The stiff I-beams observed during vibration analysis has
been removed from the places where the components are not supported by I beams and some I beams which
does not support much more load has been converted into C-channel.
The analysis is done on all these modified frames and obtained the results for weight and stresses shown
in table no 8. From table it is observed that the maximum weight is reduced in case IV, which is 18.91%
and 760 kg and maximum von mises stress, is 186.482 MPa, which is less than yield stress.

8. Conclusion

In the finite element analysis, the natural frequencies of the base frame were found out which are verified
by experimental results conducted using FTT analyzed. It is given in Tables 3 that the FEM results are in
good agreement with the experimental results. The results of modal analysis were also verified by analytical
method as shown in Table 4, it has been observed that the difference in the result of both the methods is
below 9%.

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In this study, dynamic response of base frame has been evaluated under different boundary conditions using
FEM. The maximum von mises stresses found out for each case are below the permissible limit, shown in
Table 5. Hence it is concluded that the designed frames existing as well as modified are safe and achieved a
weight reduction up to 19 %.

References

Smalley A. J., J. S. Mandke, R.D. Drummod,( December 1993) Reciprocating Compressor Foundation: Loading, Design, Analysis,
Monitoring &Repair. GMRC Gas Machinery Conference,TA93-1

Harrel Jr. John P., P. Joe Pantermuehl. Ralph E. Harris,.(October 4- 6,2004), Foundation Design for an 8,000 Hp High Speed
Reciprocating Compresoor, ,GMRC Gas Machinery Conference, pp.1-12 , Albuquerque, New Mexico.

Patel A.H., Pandya S.R.,Design and Finite Element Analysis of base frame for power transmosion, Journal of Engineer,Dec2006:vol
3:86-96.

Grenald Group, Vibration Analysis of Gas Lift Compressor Foundation, 27 Oct 2008;1: File no 2008-TD-8262:Doc.No.HF112499-
0217-ANL:2-34.

Rao Singiresu S., Mechanical Vibrations, Fourth Edition, Pearson Education, 2004.

S. Seshu, Introduction to Finite element Method, Tata Mcgraw Hill, pp.295-303, 2002.

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