A Case Study on Design of Modularized Pump Skid

Chandan Singha*, Sourabh Marakhwar ** and S Jafar Mehdi***

* Structural Engineer
Chandan.Singha@fluor.com
** Lead Structural Engineer
Sourabh.Marakhwar@fluor.com
*** Area Lead Engineer
S.Jafar.Mehdi@fluor.com

Abstract: This paper presents design of modularized pump skid system. The structural steel skid is supporting vertical and
horizontal pumps at the grade level and piping at the upper tier. The vertical pumps are relatively larger in size. During the
early design stage of structural steel skid it has been observed that dynamic performance of vertical pump on a steel skid is
not within acceptable limits hence, as an alternate solution the vertical pumps has been isolated from the rest of skid after
final installation of Module. Although the entire pump assembly has been transported and placed to the final location as a
single module to avoid any field work and to achieve the modularized concept.

Keywords: Pump Skid, Modularization, Dynamic Analysis, Vibration Isolation.

Introduction
In order to reduce time & cost of construction modular construction concept is the present day need. This also has added
benefit of construction safety.
The pump skid under consideration is a modularized structure supporting vertical and horizontal pump at the base level and
piping at the upper tier (See Figure 1). This skid supports two pairs of horizontal pumps & one pair of vertical pumps. The
operating scenario is one of each pair of pumps will be operating at one time while the other is kept as a standby.

Figure 1: Pump Skid with Vertical & Horizontal Pumps

The steel skid is approximately 16m x 7m. The main frame along the width of module is a moment frame. Along the length
of the module set of vertical bracing are provided. Whole structure along with pumps associated piping and cables forms the
module. The main framing columns are supported on piles with column base plate directly welded to the pile cap plate.
Additional piles are provided below the pump supporting beams. The steel along the load path of pumps are all fully welded
to transfer the vibration to the supporting piles.
The vertical pumps are supported on individual pile right below the pumps. This module is transported by PMT (Propelled
Module Transporter) to site and then installed in place by cranes. After installation the vertical pumps its supporting steel is
isolated from the rest of the steel module.

Major Design Consideration

In order to satisfy the overall design, static and dynamic analysis and design have to be performed. Static analysis has
performed using commercially available software RISA 3D. Dynamic analysis was performed using the software SAP 2000.
 A Case Study on Design of Modularized Pump Skid 207

Static Analysis
Static analysis of the module is performed for Onsite Cases (Operating & Empty Condition), Transportation & Lifting Cases.

Figure 2: 3D Model for static analysis of pump module in (Onsite Case)

In Operating & Empty Condition module is analyzed for Wind Load & Seismic Load along with various Vertical loadings
like Live Load, Pipe Operating & Empty Load, Equipment Operating & Empty Load, Snow load etc. From Static analysis
single piles have been provided below each column. Pile location are shown in Figure 2
In Transportation analysis module is analyzed for PMT (Propelled Module Transporter) transport condition. The loading
considered for this case include gravity loads and transportation acceleration & impact loads. See figure 3 for the typical 3D
analysis model.
The main transverse beam at lower level works as transportation beam and is kept on the PMT. The design of transportation
beam is critical for this particular case.

Figure 3: Transport analysis of pump module

For Lifting Case, module is analyzed for Crane Lifting Condition for vertical lift. Lifting lug is provided at top of each
column of module. Typically an arrangement of vertical slings with spreader bars is adopted for lifting of module so that each
of the lifting point observes vertical lift only, and there is no lateral thrust imposed on lifting lugs. Capacity of lifting lug is
designed based on gravity load & Impact loads.

Dynamic Analysis
Below is summery of pump and motor supported on the skid
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Figure 4: Lifting analysis of pump module

For dynamic analysis, based on the pile dimensions, layout together with the geotechnical parameters, the pile impedance
(i.e. stiffness and damping) has been computed for the pile group. The pile impedance for a single pile is computed using the
group pile impedance divided by the number of piles. A structural steel model is established in SAP2000 incorporating the
individual pile impedance at each pile location. The steel members are modeled with frame elements. The pump / motor /
base masses are modeled using dead loads. Modal time history analysis and also steady state analysis are preformed to assess
the dynamic response at the pump/motor.
Results of SAP Output have been checked at the steady state condition. Maximum Vibration Amplitudes checked against the
Pump and Motor limits for both Lower Bound and Upper Bound criteria. Frequency ratios have been checked against
operating speed of each pump. 20 Percent variation has also been considered for soil parameters to account for inaccuracy in
determining of soil parameters.

Challenges
Upon performing dynamic analysis, it is observed that the amplitude of the beams supporting the pumps were higher than the
permissible limits. The reason for high amplitude can be attributed to the large span and thus flexibility of the pump
supporting beams. For the vertical pumps, the amplitude of vibration was way beyond the permissible limits, because for the
very small amount of vibration on the supporting beam, there was large vibration on the upper part of the pumps that is the
motor.
Another concern is on the connection front. Typically bearing type bolted connection are provided. However these
connections are susceptible to higher vibration and fatigue failure.

Figure 5: Model for dynamic analysis of pump module in SAP

 A Case Study on Design of Modularized Pump Skid 209

Final Design
In order to mitigate above stated challenges, following modifications were done to the design.
1) Additional piles are provided below each pump. For horizontal pumps 3 piles were provided below each pump (See
Fig 6). This results in to very much reduction in amplitude.
2) For vertical pumps, a large diameter pile was provided right below the pump base. However the pump dynamic
forces were making the whole structure vibrate. In order to resolve this issue it was decided to isolate the supporting
system of vertical pumps from rest of the structure. Although the pump is transported within the module and
supported on the main steel base frame. Upon installation of module in its final place at site, the connection between
the members supporting pump and the main framing was released so that these are disconnected now. Thus now the
pumps are supported directly on pile instead of the structure and are isolated from it.
3) The bolted connection has been replaced with welded connection on the load path for the pump load. This avoids
use of slip critical connections.

Pile below Horizontal

Pumps

Figure 6: Additional Pile Model

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Conclusion
Utilizing modular construction for pumps and associated piping is possible with little modification to the design. As the case
study presented here suggest that additional piles provided to support the pumps locally, welded connection instead of bolted
and isolation after installation are some of the possible options one has to achieve desired design safety. This approach
completely eliminates concrete and thus is advantageous in the terms of cost and schedule. However in case of relatively
large pumps it may be difficult to satisfy vibration limits thus a proper concrete foundation may be required for such cases.

References
[1] Canadian Standards Association, CAN/CSA -S16 Limit State Design of Steel Structures, 7th Edition, 2009.
[2] Canadian Commission on Building and Fire Codes, National Building Codes of Canada, Volume 1, 12th Edition, 2005, Part 4