Erection of Reciprocating Compressors

Standards for Erection of Reciprocating Compressor

o REIE 686 Recommended Practices for Machinery Installation and

installation design
o Pl-618 Reciprocating compressor for petroleum chemical & gas industry
for Erection of Reciprocating Compressor
Latest Revision of the following Documents shall be used for Erection of
Reciprocating Compressor.

o Vendor Drawing
o Foundation Drawing
o Equipment details

Tools and equipment for Erection of Reciprocating

Compressor

Tools and equipment needed should be in good condition and must be

checked by competent person and respective supervisor prior to use in
the plant. Third Party vehicle and equipment inspections and vehicle
stickers required. Saudi Aramco certified where required. These Includes
but not limited to:

o Calibrated engineering level with calibration certificate

o Corrective wrenches all required range
o Crane
o Certified sling and hoists
o Chipping hammer/bush hammer
o Welding Machine
o Compressor
o Calibrated Alignment and Levelling tools (dial indicator, precision
master level, other measuring equipment);
o Final shaft alignment shall be as per Vendor’s recommended method.

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o Low-height rampack jacks
o Chain block
o Vendor-supplied tools, if any
o Rubber mallet

Method Statement for Erection of Reciprocating

Compressor
Equipment Preservation/Protection:

Vendor’s/Manufacturer’s recommendation for equipment preservation

shall be followed.
Equipment Rust Preservation shall be done using applicable
vendor/manufacturer’s documents.
When the equipment arrived at site, shop preservation shall be checked.
Where necessary damage to preservation shall be rectified without delay.

Preparatory Works:

Secure work permit and other applicable approved documents prior to

work commence.

Tools and equipment shall be made operational and available for use.
Ensure tools are color-coded accordingly.

Conduct lifting study & get approved lifting plan.

Prior to the arrival of equipment on site, Contractor / Subcontractor

shall review the manufacturer’s requirement and the requirements of
this specification regarding on site storage of the equipment. These
requirements shall be incorporated to site preservation plan and adhere
to in all respects.

Install barricades to confine the area for authorized personnel only.

Foundation Preparation:

o Confirm acceptances & turnover of civil works foundation/pedestals with

a signed copy of works release notice.

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o After receiving foundation release note, the following points shall be
checked with the latest relevant drawing.
• Distinct position (centre) marking and height (level) marking on the
foundation, It will be referred for alignment work of level and position.
• Size and number of anchor bolt and nuts, position of anchor bolts with
projection.
• Existence of damages and rust of threaded of buried anchor bolts with
projection.

o Using theodolite establish centerline of the equipment unit.

Mark centerline on concrete foundation using paint/ prick punch.
o Trace centerlines of foundation bolt holes with reference to
gridlines. Check Verticality/plumbness of anchor bolt.
o Clean the surface thoroughly by blowing with oil-free from
air compressor.

Centerlines lost due to chipping operations will retrace a new

o Anchor bolts shall be protected properly to avoid damages

during chipping/padding work and keep it up to the equipment
installation.
o The elevation of the chipped top foundations shall allow for at
least 25mm of grout under the base plate as per SAES-Q-005 Concrete
Foundation.
o The bottom of the equipment bases shall be cleaned and free of laitance,
oil or grease.
o In case that leveling jack bolts are not provided on the equipment
base frame, it shall be perform using straight liners on both side of
bolts basically.
o Laitance shall be removed from the surface of the foundation and
boxes by chipping to ensure good adherences of padding and grout
materials
to the surface preparation.

Padding:
o Pads and liners shall be machined flat parallel and larger than the foot
of base frame.
o Pads material shall be in accordance with ASTM A283 Gr. C, D
or equivalent.

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o Pad shall be hot dip galvanized in accordance with ASTM A123 or
coated with zinc rich epoxy primer in APCS-1C of SAES-H-101V as
applicable.
o In general, the distance between pads shall not exceed 800mm. If
the distance becomes more than 800mm, an additional pad shall be
added in
between.
o Pad size shall be selected as per the anchor bolt size as follows:
• Bolt diameter M24 or 1 inch and below Pad width 50mm
• Bolt diameter M30-M48 or 1-1/4 to 2 inches Pad width 75mm
• Bolts diameter M56 or 2-1/4 inches and above Pad width 100mm

o Number of pads shall be determined so the load pressure will be

less than 30kg/cm2.The supporting load can be calculated as per
following formula.
L=W/NxAxB
L: Load supported by liner (kg/cm2)
W: Lifting load of equipment (kg)
N: Number of pads
A: Width of base plate for equipment (cm)
B: Width of liner (cm)

o The length of pad shall be 20 mm to 30 mm longer than the width of

the equipment bases.
o The thickness of the both taper and straight liners shall be at least 10
mm and the minimum thickness of the tapered ends shall be 2 mm.
Adjustment allowance shall be 4 to 6 mm.
o After finishing padding work, following points shall be checked.
• Position of center and elevation line of foundation
• Elevation and position of pads
• Cleanliness of concrete surface
• Condition of anchor bolts

Setting of Liner

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o Prior to the installation of liners and equipment, the liners and
grouting portion of foundation shall be chipped and all concrete laitance
shall be
removed from portion.
o Flat liners shall be installed at the designated position with pads
of cement grout at least seven days before equipment installation. ln
case non-shrink grout material is used; the curing duration shall be
according to the manufacture’s recommendation.
o In case that wedges liners are used the level of padding with a flat
liners need to be adjust to meet with the final equipment elevation.
o Equipment supports are provided with stainless steel (AISI
Standard Type 300) shims minimum 3mm thickness:
• The maximum shim stack height shall not exceed 12 mm thick
• Only one 3 mm (0.125 in.) or thicker shim per mounting foot
is allowed.
• All shims are to straddle hold down bolts and jackscrews.
• Maximum number of shims under any equipment support foot is five
o All mounting surfaces that are not to be grouted shall be coated with
a rust preventive immediately after machining.
o Mounting plates shall not be drilled for equipment to be mounted by
others.
o Anchor bolts shall not be used to fasten drive equipment to the mounting
plates.
o Diametrical clearance between anchor bolts and the anchor bolt holes in
the mounting plates shall be a minimum of 6 mm (1/4 in.)

Lifting of Reciprocating Compressor

o Prior to the installation work, the foundation shall be checked for

the following:
• Location, orientation, elevation and conditions of support foundation
conformed with Project plan drawings
• Level of pads on the chipped surface.
• Completely free from foreign material especially on chipped
surface and anchor boxes.
• Concrete foundation has reached the curing period up until
the compressive strength has reached 70% of the specified strength but
not less than 7 days after placement
o Prior to the installation work, the equipment shall be checked for
the following points.

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 • Compressor skid, Compressor, Cylinder Heads & other
major components are free from any physical damage.
• All components of the system such as relief valves and control valves
shall be identified with a permanently affixed corrosion resistant tag
showing the component identification number referenced to the piping
and instrument diagram.
• Rotation arrows shall be cast in or attached to each major item.
o Prepare lifting location were the crane will be located and position.
o Prepare and set all rigging accessories according to arrangement.
o Checked wind condition, lift shall not proceed when wind velocity
is greater than required of crane.
o Stabilized ground areas where crane will be located and
positioned. Crane mats shall be provided in accordance to findings of soil
bearing
pressure.
o Crane lift & rigging requirement shall refer to approved document.
o The equipment shall be lifted by lifting lugs, lifting trunnion, tailing lugs
or shell not by nozzles.
o Equipments shall be protected by wooden blocks, rubber or
other suitable material that will prevent equipment from damages
caused by sling wire.
o Install reciprocating compressors on top of the foundation as
per approved lifting plan.
o Equipment shall be set and aligned at the proper position,
elevation, levelness and perpendicularity in accordance’s with the
drawing.

Centering of Compressor:

o Leveling of Crankcase Assembly Parts.

o Confirmation of the fitting elevation of the parts
o Level confirmation of crankcase.
1.
a. Measuring places shall be:
b. Machine finished surface of crankcase.
c. Flange surface of cylinder top

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d. Sliding surface of cross guide
e. Measure with precision level, thickness gauge, straight edge, etc.
f. Confirm the setting position with bob weight on the basis of black line of
axial and cylinder centerline on foundation.
g. Measuring time shall be done before and after grouting.

Measurement of Crankshaft Deflection

• Deflection of crankshaft is measured to confirm that crankshaft

is installed normally and that no abnormal force is applied to
the crankshaft.
• Fit the deflection gauge, which is supplied by MES, between the webs of
crankshaft, read the graduation of dial gauge.
• Measure when the crank pin is at point T, B, Rand L-4. However, when
it is measured at connecting rod , it will be touched the deflection gauge
at certain rotating angle (drawings are shown below) so that it is
measured at 4 places.

In taking the measured record, the indication (+) and (-) of crankshaft
deflection is marked as follows:

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Normally deflection gauge is fitted at one half of journal diameter, but
the cap of connecting rod will be touch the gauge at the time of
measurement so it is

fitted a little outside of regular measuring place for actual measurement.

The measured value therefore is corrected by the following formula.
Deflection

value equals value measured by regular deflection gauge x A/8.

In this case,

A is (270+325)/2 =297.5mm *1),

B is distance between crank pin center and deflection gauge center.

The dimension of “B” shall be measured between the horizontal split
surface
of big-end of con-rod and deflection gauge with convex rule. *1 ):

A=(Piston stroke + Crankshaft diameter)/2.

• Standard value of deflection at the time of installation shall be within:

• 1 / 1000 x piston stroke; 0.027mm Refer to Compressor Technical Data
• Measuring time for crankshaft deflection shall be:

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0 Leveling of crankcase (before anchor bolt grouting).
0 After grouting (after anchor bolts tightening).

0 After connection with driving machine.

• Turning is conducted by temporary turning bar and turning

driver. Before turning, supply oil to each bearing, crosshead guide
and main motor. Especially in case of long-term storage, it is
essential for the above parts to supply.

Measurement of Clearance between Crosshead Guide and

Crosshead

• Measure clearance of rubbing surface of crosshead guide

and crosshead. Confirm · that crosshead rubs rubbing surface
of crosshead guide with a fixed clearance.
• Measure clearance of the following spots with thickness gauge.

0 Measure clearance at spot F and A on cylinder side (CT) and F, A on

crank case side (CB) at top position of piston.
0 Measure clearance at spot F, A on cylinder side (CT) and F, A on crank
case side (CB) at bottom position of piston.

Measurement of Piston Rod Run Out.

• Before and after grouting, measure piston rod movement to upward

and downward, and to left and right at top dead point and bottom dead
point of piston.

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 • Depending on result of the measurement, confirm level of crosshead
guide and cylinder installed.
• Measuring Method

Fit deal gauge on bottom of piston rod outside circumference on

compartment chamber and on side (opposite motor side).
Set dial gauge to O (Zero) at bottom dead point of piston, read dial at top
dead point of piston; and take its record .

o Keep run-out of both up-ward-downward and horizontal direction

within 0.10mm.
• Measurement of Piston Top Bottom Clearance
o Measurement clearance between piston and cylinder cover at top dead
point and bottom dead point of piston.
o Remove each discharge valve cover end and at cylinder bottom cover
end.
Measure clearance from discharge valve hole. While turning of
crankshaft, put lead wire into space between piston and cylinder cover so
that lead wire can
so pressed by piston at top and dead points.
o Measure thickness of lead wire with micrometer.
Refer to Installation Record for standard criteria of clearance. The
clearance is adjusted when assembled in shop.

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 Setting of Cylinder Support

• Installation of Upper Support on cylinder

0 Rigidly fasten bolts between cylinder and upper support.

• Installation of Lower Support

0 Install lower support to upper support with connection bolts for these
supports as shown in refer to chart below. “Upper and lower supports for
cylinder”.
0 Lift lower support until connection bolts touch to upper side of bolt
holes of upper support. At this time, the bolt hole between upper and
lower support becomes as shown in refer to chart below. “Upper and
lower supports for cylinder”.
0 Fasten connection bolt between upper and lower support with torque
wrench.

• Fitting and Grouting of Foundation Bolts.

o Mount foundation bolts to lower support

o Carry out grouting for foundation bolts.
o Adjustment of Cylinder Support.
o After curing of the foundation bolts, set up small jack (W 5/8″) and flat
liner on side of the foundation bolts for leveling. Small jacks and flat
liners are furnished by MES.

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o Adjust level of cylinder with small jack. Carry out grouting for lower
support of cylinder.

Grouting
o Non-Shrink Grout. Following items shall be consider before
grouting execution:
o Prior to grouting, concrete repair have been performed in accordance
with SAIC-Q-1062 as based on SAER-5803.
o Grout shall be mixed as per the Grout Manufacturer’s instructions.
o Foundation preparation shall be in accordance with the grout
manufacturers written instruction.
• Concrete foundations shall be cured for a minimum of 7 days before
surface preparations for grouting.
• Laitance, oil-soaked or damaged concrete shall be removed down to
sound concrete by chipping to the level of sound fractured aggregate or
to a minimum of the top 1 inch (25mm) of the concrete.
• All dust and loose particles shall be removed with clean, dry, oil free
compressed air.
• Grout Formwork, where required, shall be constructed with adequate
strength, rigidity and required dimensions to permit grout placement
and avoid leakage.

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 • A bond breaker shall be applied to the formwork that will be in contact
with the grout.
• After cleaning, the foundation shall be protected with
0.15mm polyethylene sheeting to prevent contamination.
• Concrete surfaces in contact with the grout shall be saturated with
clean water before grout placement. The surface shall be damp but free
from standing water.
• Joints in the grout shall be located as shown in the drawings or
as recommended by the manufacturer.
• Grout shall be placed in only one direction to prevent trapping
air; Grouting shall be quick and continuous to avoid
segregation, bleeding or premature initial set.
• Re-tempering of grout by adding water after stiffening is not permitted.
• If the grout is placed through grout holes, it shall be placed from one
hole continuously until the grout has passed a second hole. A liquid head
pressure shall be maintained at the first access hole until a head pressure
is established at the second hole and continued in a similar fashion until
the next hole.
• Grout shall be mixed, placed and cured in accordance
with manufacturer’s written requirements. The contractor shall
read, understand and comply with the manufacturer’s instructions
as printed on each unit.
• The grout shall be cut back to the lower edge of the base plate by 45°
angle unless otherwise indicated.

Epoxy Grout for Machinery Support.

Following items shall be consider before grouting execution:

o Laitance and oil-soaked or damaged concrete are removed with chipping

hammer to sound fractured aggregate, or to a minimum of the top 1 inch
(25 mm) of concrete.
o Concrete chipping and removal shall not be performed with heavy tools
such as jackhammers as they could damage the structural integrity of the
foundations.
o The minimum grout thickness under any portion of the
base plate/soleplate shall be 25mm Concrete in contact with the epoxy
grout shall be clean, dry and
oil free.
o Formworks for epoxy grout are constructed to be liquid tight
with adequate strength, rigidity and dimensions to permit epoxy
grout placement.

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o Form joints and interface between forms and concrete foundation are
sealed with grout manufacturer’s recommended sealant.
o Maximum depth of pour and length to width ratio shall be as
per manufacture’s recommendations.
o Elevation of the formworks shall be check to ensure that the top surface
of the grout will match the elevation shown on the construction
drawings.
o Three coats of paste wax shall be applied to the inside surface of forms or
other manufacturer recommended procedure for preventing bonding of
the epoxy grout to the formwork.
o Suitable shelter or enclosures shall be provided to protect the foundation
and base plate from direct sunlight, dew, rain or other inclement
weather. During cold weather, adequate enclosure and heating shall be
provided to maintain foundation and base plate temperature with
acceptable range specified by the grout
manufacturer.
o Expansion joints in epoxy grout shall be spaced at a maximum of 48
inches (1.4 m) unless otherwise specified in the contract documents.
o Expansion joints shall be made from closed-cell neoprene
or polyethylene foam board, having a minimum thickness of 1 inch (25
mm) unless otherwise noted in the contract documents.
o Expansion joints shall be fixed into position to prevent movement and
shall be sealed at formwork and at the concrete base to prevent epoxy
grout from passing around or underneath the joint during placement.
• All mounting plate/soleplate outside corners shall have a minimum of
50mm radius to prevent cracking of the foundation grout due to stress
concentration at the corners.
• Baseplate leveling jack screws shall be provided with stainless steel
leveling pads.
• Mounting plate jackscrews shall be liberally coated with paste wax or
grease to prevent grout adherence.
• Mounting plate jackscrews shall be liberally coated with paste wax or
grease to prevent grout adherence.
• Suitable shelter or enclosures shall be provided to protect the grouted
foundations from direct sunlight and weather.
• Foundation and base plate temperature are within the acceptable range
specified by the grout manufacturer until the grout has cured.

After grouting works following items shall consider:

• The grout shall be checked for voids after the grout has cured. Any

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voids shall be filled according to epoxy grout
manufacturer’s recommendations.
• After the void grout has cured, the base plate shall be recheck to ensure
that all voids are filled with grout. Any voids still exist shall be rectified.
• Exposed expansion joints shall be sealed with the epoxy
grout manufacturer’s recommended sealant.
The final level of the epoxy grout is flush with the top horizontal chamfer
edges built into the formwork.

1st Alignment of Main Motor

Lifting of Main Motor

• The main motor shall be lifted horizontally and set carefully on

the foundation using crane and wire rope that have enough strength. On
the lifting of motor, take care that crankcase and other equipments are
not damaged in these jobs.

Temporary Alignment Procedure between Driver and

Compressor.

• Tools for temporary of alignment.

• For measurement of eccentricity of coupling use dial indicator with
magnet base or mechanical attachment.
For measurement of parallelness of coupling, use inside micrometer or
dial gauge with magnet base.

Measurement of eccentricity of coupling.

• Surface of the setting position of dial indicator and measuring surface

of the dial indicator shall be cleaned.
• To measure at four points (top, bottom, right and left) which divide the
circumference of coupling equally and are marked temporarily as 1,2, 3,
and 4.
• Dial indicator shall be set.
• Eccentricity shall be measured at four points by turning the crankshaft.

Measurement of parallelness of coupling.

• Parallelness of coupling shall be measured by measuring the

gap between coupling clearance at four points (top, bottom, right
and left) that are marked. Prior to, measuring the parallel ness, it
is important that the gap between couplings should be adjusted to obtain
the correct magnet center position of main motor.

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• Level of driver unit shall be confirmed at the same time.
0 Level of driver unit shall be measured at the machined surface of base
plate of motor by using the sprit level.
0 Level shall be confirmed in parallel direction and right angle direction
of shaft.
• Temporary alignment of main motor shall be confirmed before setting
anchor bolts.
0 Temporary alignment shall be done according to tolerance at final
alignment.
0 Tolerance at final alignment.
o Eccentricity of coupling is within 10/100 mm.
0 Parallel ness of coupling is within 5/100 mm.
0 Leveling of driver unit is within 30/100 mm.
0 The dropping value of crankshaft coupling by putting flywheel should
be considered.

• In connecting the main motor with compressor, confirm that

the magnet center and air clearance of the main motor are
within tolerance. Adjustment of the motor is made in accordance
with operating manual.
2nd and Final Alignment of Main Motor
• Procedure of 2nd and final alignment shall be done according to the
“Temporary Setting and 1st Alignment of Main Motor “by tightening the
anchor bolts and jacking up the motor with small jackscrews.
• Tolerance at 2nd and Final Alignment
0 Eccentricity of coupling within 101100mm

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0 Parallelness of coupling within 5/100mm
• After 2nd alignment, motor base plate shall be grouted.
• After confirming the final alignment and connecting the coupling of
main motor and compressor deflection of crankshaft shall be confirmed
within standard value. Standard clearance shall be referred to
“Installation Record”.

Setting of Flywheel
• Preparation for Flywheel Setting
° Cleaning of the setting surface of flywheel on crankshaft coupling, main
motor coupling, and the bolt holes.
° Cleaning of flywheel surface (both sides) and the bolt holes.
0 Before sliding of main motor, confirm the electrical personnel to
protect for main motor is necessary or not. If necessary, appropriate
electrical protection to be carried out.
0 Remove LO in plugs of bearing housing, and fill in LO with appropriate
quantity.
0 Make match marks for relative position (at four corners of main
motor) between main motor and sole plate by using center punch and
steel compass. So it is easy to install the main motor at regular position
for restoration.
0 Set the dial gauges at main motor front and rear, left and right side
(total 4 points) on the main motor base plate.)
0 Remove all of shims between main motor and sole plate to avoid the

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damage during motor sliding work. Make clear identification for
mounting positions of shims before removing.
0 Slide main motor around 25mm to anti coupling side, which is relative
amount between end plate of main motor and crankshaft coupling to set
the flywheel.
° Fix main motor with jack-bolts in front and rear, and left and right
corner not to move main motor.

• Setting of Flywheel.

Set the dial gauges to crankshaft coupling, horizontal and vertical, to

confirm the drop and horizontal moving amount of crankshaft for
flywheel weight after setting.
Hang the flywheel vertically and fit to crankshaft coupling.
With two bolts, tighten up flywheel to crankshaft coupling.
Loosen the flywheel lifting wire.
Confirm the drop and horizontal moving amount of crankshaft coupling
by fitting flywheel weight.

0 Lift up the flywheel again to return the vertical and horizontal amount
of dial gauges “zero” position. Refer to attached sample picture.

• Connecting of Flywheel and Main Motor Coupling.

0 Restore main motor on regular position sliding on base plate and

insert shims removing before main motor sliding. Confirm the regular
position by the match marks and the dial gauges setting before main
motor sliding.
୤ Confirm the magnet center of main motor.
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0 When the main motor position and magnet center are acceptable,
tighten the coupling bolts with hydraulic oil pressure. Oil pressure is
noted on the attached tightening torque list. Order of tightening coupling
bolts in indicated in next sketch.

0 After tightening bolts with hydraulic pressure, tighten the lock nuts of
coupling bolts.
0 After tightening lock nuts, measure deflection of crankshaft. Measure
upper clearance of guide bearing and main bearing with thickness gauge,
and confirm any no irregular contact.

0 If fine adjustment is necessary, carry out the adjustment again with

measurement of crankshaft deflection by moving main motor position
and shim combination.
°ଶ Fit flywheel cover.
• Setting of Pulsation suppressor.
°ଶ Fitting of discharge pulsation suppressor.
0 Before fitting of the discharge pulsation suppressor, clean the
connecting flange.
0 Measure the clearance of surface between the connection flange and
cylinder flange and adjust it so that the error is within 0.1 mm.
0 Tighten the cylinder flange and discharge pulsation suppressor
through packing uniformly with tightening bolt.
°ଶ Fit the support for discharge pulsation suppressor
under the pulsation suppressor through adjusting liner.
Suspend the foundation bolt on the support.
0 Stay for the support is set between the foundation and the support,
using small jack provided by MES.
°ଶ For grouting of support, a wooden frame is made on

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the foundation.
• Fitting of the suction pulsation suppressor.
°ଶ Clean the packing seat of connecting flange and
the cylinder.
0 Hang up the pulsation suppressor horizontally.
°ଶ Confirm the fitting direction of the pulsation
suppressor with general arrangement drawing.
0 Slowly bring the pulsation suppressor to cylinder connecting part.
0 Slightly tighten the flange on the cylinder and pulsation suppressor
through packing.
°ଶ Fit the support for suction pulsation suppressor under
the pulsation suppressor through adjusting liner. Suspend
the foundation bolt on the support.
a. Measure the clearance between the flange of the pulsation suppressor
and the cylinder in longitudinal and vertical direction of the pulsation
suppressor at four places and adjust the clearance so that the difference
in within 0.1 mm, using small jack provided by MES.

0 Uniformly tighten the flange tightening bolts for the pulsation

suppressor with the bolt.
0 Bury the foundation bolt in the ground with non-shrink Grouting
material.
0 After the curing of grout, tighten the foundation bolt.
0 Grout the discharge pulsation suppressor support with non-shrink
grout.
0 Tighten the foundation bolt after the curing of grout and remove the
wooden frame.
0 After tightening the foundation bolt, slack the tightening bolt of
adjusting liner between the support and pulsation suppressor and
confirm that there is no clearance. Tighten the bolt for tightening of the
pulsation suppressor once again.

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