CHAPTER 22

COMPRESSOR FOUNDATIONS
Robert L. Rowan, Jr.
Robert L. Rowan & Associates, Inc.

22.1 FOUNDATIONS

The key to rotating and reciprocating machinery reliability is the foundation. One
of the main functions of foundations is to support the machines at a precise ele-
vation, thus allowing the original precision alignment to be maintained over the
life of the machine.
Besides the critical task of maintaining the alignment of the machine, the foun-
dation must supply enough mass to absorb the unbalanced forces that the operating
machine produces. Good engineering input from the manufacturer of the machine
is essential to the designer of the foundation, but equally as important is a geo-
technical analysis of the soil on which the foundation will rest.

22.1.1 Types of Foundations

Reciprocating and centrifugal compressors can be packaged or unitized on a fab-

ricated skid (Fig. 22.1), block mounted (Fig. 22.2), or set on a pile cap foundation
(Fig. 22.3). Large centrifugal machines are also sometimes set on ‘‘table top’’
foundations, which are shaped much like a kitchen table with multiple legs (Fig.
22.4). This style is popular for larger machines and allows the space underneath
to be used for long radius, large diameter piping and auxiliary equipment.
The above types represent practices in the United States. No review, though,
would be complete without mentioning a new option that is starting to be seen in
the United States because of successful installations in Europe. This option in the
type of compressor foundations, is the use of spring supports. The advantages of
this option include good isolation of the dynamic forces, good definition of support
properties and additional possibilities for future modifications or corrections. Spring
support systems for compressor applications will typically have vertical natural
frequencies in the range of 3 to 5 Hz. Horizontal frequencies usually are slightly
less than the vertical frequency. As these values are less than comparable frequen-

22.1
22.2 CHAPTER TWENTY-TWO

FIGURE 22.1 Skid mounted / packaged compressor. (Illustration courtesy of Robt. L. Rowan &
Assoc., Inc.)

FIGURE 22.2 Block mounted compressor. (Illustration courtesy of Robt. L. Rowan & Assoc.,
Inc.)
 COMPRESSOR FOUNDATIONS 22.3

FIGURE 22.3 Pile cap foundation. (Illustration courtesy of Robt. L. Rowan & Assoc., Inc.)
22.4 CHAPTER TWENTY-TWO

FIGURE 22.4 Table top foundation. (Illustration courtesy of Robt. L. Rowan & Assoc., Inc.)

cies for soil or pile supported systems, the spring system typically provides better
isolation of the dynamic forces of the compressor. The springs themselves, usually
steel coil designs, provide well defined stiffnesses both horizontally and vertically.
This advantage simplifies the dynamic analysis of the foundation eliminating the
need to incorporate a range of soil properties in this analysis. By including viscous
dampers in the design, the complete dynamic system can be put together with great
confidence. Finally, the discrete nature of the spring support system permits easy
replacement of the elements if a change to the stiffness or damping characteristics
becomes necessary. Similarly, misalignment from settlement and similar sources
can be corrected at the spring support level.

22.1.2 Design

The detailed design of any of the above foundations is beyond the scope of this
chapter. Unfortunately, there are no established building codes at this time (1996),
but under the auspices of the American Concrete Institute, a committee is working
to develop a report that could eventually become a foundation design guide doc-
ument. Major engineering firms, operating companies, and equipment manufactur-
 COMPRESSOR FOUNDATIONS 22.5

ers that have their own in-house guidelines are represented on the committee. Ad-
ditionally, under the sponsorship of the Pipeline Compressor Research Counsel,
Southwest Research Institute, along with interested industry users of compressors,
much needed data on both dynamic and thermal stresses in foundations is being
developed. With such input data, along with the work of ACI, the design of foun-
dations in the future can be more precise.

22.1.3 Soil Frequency and Vibration

While there have been many technical articles written on theories of foundation
design and vibration, a very comprehensive reference is the work of Prakash and
Puri, Foundations for Machines: Analysis and Design.1 With a good background
in geotechnical engineering, the authors tie together very well the interaction be-
tween the cyclic vibrations caused by the machine with the natural frequency of
the soil-foundation system. Foundations must be designed to avoid the dreadful
consequences of harmonic resonance, which occurs when the frequency of the
vibrating machine matches the natural frequency of the foundation (block and soil).
Prakash and Puri teach that by applying the principles of soil engineering and soil
dynamics with theories of vibration, low tuned or high tuned foundations can be
designed so as to avoid resonance. Their work leads the way to designing foun-
dations for dynamic machines which will have acceptable levels of vibration. Good
engineering at this stage will pay off with a smoother running machine, better
maintenance of alignment, and lower maintenance costs for the replacement of wear
parts (bearing, seals, etc.).

22.1.4 Collection of Data for the Design Step*

While readers of this handbook may not ever be called on to design a foundation,
they may very well be asked to supply data to an engineering design firm working
under its direction.
While the work of ACI committee is incomplete at this stage, probable recom-
mended data collection steps will be as follows:
1. Data gathering
a) Design goal
b) Site factors
c) Sub-soil data
d) Machine data
2. Design criteria
a) Static loads

*Based on preliminary draft of ACI 351-2 Sub-Committee

22.6 CHAPTER TWENTY-TWO

b) Dynamic loads
3. Concrete strength/stresses
a) Compressive
b) Flexural
c) Tension
d) Bearing
e) Fatigue
4. Concrete deflection/deformation
5. Soil strength/stresses
6. Soil deformation/settlement
7. Vibration limits
8. Psychological factors

22.1.5 Materials of Construction

Portland Cement Concrete: Reinforced portland cement concrete is the usual

material of construction for either the foundation proper, or for the mat under a
fabricated steel skid. A mix design, based on locally available ingredients, can be
developed that yields a compressive strength of 4,000 psi in 28 days. The amount
of steel will depend on the tensile and bending loads, as well as thermal stresses.
Many foundations designed over the past 30 years have been under-reinforced, as
evidenced by cracking. Cracking can lead to deterioration of the alignment con-
dition and even catastrophic failure. Extra steel, to increase flexural and tensile
strength is very prudent. Steel, put in initially, does not cost very much, but a
foundation repair later, because of an under-reinforced foundation, is very costly.
Figures 22.5 and 22.6 show a modern design with extra rebar vs. a design done
twenty years ago.
Polymer Modified Concrete: While reinforced portland cement concrete is al-
most universally used today, many older foundations have been repaired using a
more technologically advanced material called ‘‘Polymer Modified Concrete.’’ Sub-
stituting a polymer for the usual water in portland cement concrete, produces an
improved concrete. The polymer, along with fiber reinforcing, produces a very
dense product with low heat of hydration, stronger physical properties in tensile
and flexure, and cures in 24 hours2.

22.1.6 Anchor Bolts

Anchor bolts are a vital link between the compressor and the foundation. Unfor-
tunately, designers often overlook important points concerning anchor bolts, such
as how long and strong they should be and the amount of preload. Anchor bolts,
as well as other parts of the support system, such as sole plates and chocks (to be
 COMPRESSOR FOUNDATIONS 22.7

FIGURE 22.5 Typical perimeter steel reinforcing—era 1960s.

discussed in section 22.1.7), can be one of the principle points of failure on new
construction projects. Failure usually occurs during the first year of operation.
While the number and size of the anchor bolts are set by the equipment man-
ufacturer, their length, configuration, and material of construction are in the hands
of the foundation designer. Figure 22.7 shows good and bad designs.

FIGURE 22.6 Dense steel reinforcing based on current

design practices.
22.8 CHAPTER TWENTY-TWO

FIGURE 22.7 Evolution of anchorbolt designs. (Illustration courtesy of Robt. L. Rowan

& Assoc., Inc.)

Length: Short anchor bolts have historically caused problems in compressor

foundations. Horizontal cracks in the foundation often result. The best practice
today is to make them as long as possible, terminating them in the concrete mat
under the concrete foundation. In this manner, they do not contribute to horizontal
cracking and have the added benefit of adding a post-tensioning effect.
Material: Anchor bolts for any dynamic machine cannot be too strong. Today,
anchor bolts made from steel, conforming to ASTM A-193 with a yield strength
of 105,000 psi, are not much more expensive than steel half as strong. As the need
for high clamping forces for compressors is being recognized, alloy steel bolts to
ASTM A-193 provide the necessary capacity without going to a larger anchor bolt.
Preload: While some compressor manufacturers will specify an initial torque
value for the initial installation, often field experience will show a much higher
(maybe two to three times) clamping force will be required to lower frame
movement/vibration. Unless the anchor bolts put into the foundation to start with
have extra capacity, the machine will not perform as it should, or a costly retrofit
will have to be done.

22.1.7 Support Systems

Figure 22.8 shows a range of options on how to support a gas compressor from
the older method of full bed grouting, to the latest technology of adjustable support
 COMPRESSOR FOUNDATIONS 22.9

FIGURE 22.8 Types of compressor frame support systems. (Illustrations

courtesy of Robt. L. Rowan & Assoc., Inc.)

systems. Adjustable supports are the system of choice today, because they eliminate
a potential problem of poor initial alignment which happens from time to time with
full bed grouting. Adjustable systems also allow the optimum hot running condition
to be achieved as the frame can be re-aligned to correct for the alignment changes
that occur as the machine heats up during its first 100 hours of operation.

22.1.8 Grout

Since the introduction of epoxy grouts for gas compressor grouting in 1957, the
use of cementitious grouts mixed with water has virtually stopped. Epoxy grouts
are stronger, resist oil and many chemicals, and perform well in dynamically loaded
situations.
While grout need not be stronger in compressive strength than the concrete
underneath, a good grout will be tough enough to take impact and cyclical loads
from the dynamic machine it supports. For that reason, compressive strengths above
5,000 psi and tensile strength above 1,000 psi are all that are required. Higher
compressive strengths are not necessarily better if the product is brittle and cracks
excessively in service. Almost all good machinery grouts can crack, so expansion
joints are required. The expansion joints should be strategically placed so cracks
will not develop in the prime load transfer area adjacent to the anchor bolts.
22.10 CHAPTER TWENTY-TWO

FIGURE 22.9 Section view, looking from the flywheel end towards the oil pump end. (Illustra-
tion courtesy of Robt. L. Rowan & Assoc., Inc.)

22.1.9 Repair of Foundations

Almost every foundation 20 twenty years old and designed with only minimal steel
reinforcing is a candidate for replacement or repair. Common repair techniques
include removing the top 24 inches to 30 inches of grout and concrete, cutting off
and up-grading the anchor bolts, adding a heavy rebar layout in the excavated area
and post-tensioning the repair to old remaining concrete.
What to use for the post-tensioned repair described above is extremely important.
If the job schedule will allow 21 to 28 days, portland cement concrete is the best
choice. If a 24-hour curing product is needed, then a polymer modified concrete
should be used. Either product will have a modulus of elasticity of at least
4,000,000 psi, and will have negligible creep at typical compressor foundation
temperatures. What should not be used as a deep pour repair material to replace
the removed concrete is the epoxy grout material that is used as the final cap on
top of the foundation. Epoxy grouts are just that—a grout designed to be used in
2 to 4 inch thicknesses. Epoxy grouts, as a class of material, have a modulus of
elasticity ranging from under 1,000,000 psi up to 2,500,000 psi, with the lower
range being the most prevalent. This means epoxy grout will compress under load,
two to five times more than concrete. Additionally, some epoxy grouts creep enough
at typical foundation temperatures to cause equipment misalignment. There have
 COMPRESSOR FOUNDATIONS 22.11

been catastrophic machine failures as a result of deep pours of epoxy grout. A new
compressor foundation should not be designed with a 14-inch thick upper pour of
epoxy grout nor should an older concrete foundation be repaired that way.
Besides up-grading the anchor bolts, an adjustable support system is also added
to allow easier realignment. Figure 22.9 shows a typical foundation repair design.

22.2 REFERENCES

1. Prakask, Shamsher, and Vijay K. Puri, Foundations for Machines: Analysis & Design,
Wiley Series in Geotechnical Engineering.
2. Rowan, Robert L. & Associates, Inc., Re-Grouting Reciprocating Gas Compressors, 5
Year Repairs vs. 20 Year Reliability Criteria, 1:12 Grouting Technology Newsletter.