UNIVERSITI TEKNOLOGI MALAYSIA

JALAN SEMARAK
54100 KUALA LUMPUR
TEL : 603-26154931/26154924
TELEFAKS : 603-26932854

INSTITUTE OF NOISE & VIBRATION DIRECT TEL: 603-26154925

To: PETRONAS PENAPISAN MELAKA SDN. BHD. (PPMSB)

From: Professor M. Salman Leong

Fax: Pages: 6

Phone: Date: 3 December 2007

Attention: M Noor Lihin/ Salim Sumormo

PETRONAS PENAPISAN MELAKA SDN. BHD. (PPMSB) COMPRESSOR

VIBRATION INVESTIGATIONS AND FINITE ELEMENT ANALYSIS
SERVICES

We refer to our recent site visit with your staff at the Refinery, and the meeting of 30
November 2007 at our office. We are pleased to forward herewith a Technical & Fee
Proposal for the above services.

We trust that the above are to your requirements, and shall be pleased to clarify any
enquires you may have.

Regards.

DR. M. SALMAN LEONG

Professor and Director of Institute

Proposal for Petronas Refinery Compressors Vibration Investigations 1

PETRONAS MELAKA REFINERY
COMPRESSOR VIBRATION INVESTIGATIONS AND FINITE ELEMENT
ANALYSIS SERVICES

INTRODUCTION

This is a proposal submitted by the INSTITUTE OF NOISE & VIBRATION,

UNIVERSITI TEKNOLOGI MALAYSIA in response to a Request for Proposal a
VIBRATION INVESTIGATION AND ANALYSIS for foundation vibrations of
reciprocating compressors at Petronas Melaka Refinery.

It is our understanding that the structural foundation of the reciprocating compressors had
suffered repeated failure (cracks) attributable to excessive vibrations. It is however need
to be established if the foundation failure was a result of excessive vibrations from the
compressor and piping system, or the excessive vibration induced by material failure in
the foundation (cause and effect).

The objective of this VIBRATION INVESTIGATION AND ANALYSIS is to determine

the nature and root cause of the problem. This work shall include animated visualization
of the dynamic motion (Operational Deflection Shape) of the compressor train, piping
and foundation at pertinent forcing frequencies such that the likely cause of the excessive
dynamic motion could be identified. System and structural resonances shall also be
investigated.

SCOPE OF WORKS

The Scope of Work for the VIBRATION INVESTIGATION AND ANALYSIS shall
include but is not limited to the following:

VIBRATION MEASUREMENTS AND ANALYSIS

1 Undertake visual inspections on the entire compressor train installation with

particular reference to the machine, piping, structural skid and foundation. The
visual inspection shall be carried out with references to structural drawings and
general assembly and layout drawings (to be provided by the Client prior to the
inspections) where available.

2 Undertake measurements on the entire compressor train installation, piping at

appropriate locations, supporting structural skid and foundation under controlled
test conditions. Vibration measurements shall be undertaken using multi-channel
analyzer with multiple accelerometers in three axes simultaneously.

Proposal for Petronas Refinery Compressors Vibration Investigations 2

3 Vibration measurements test conditions shall different flows and/or operating
speeds. Additional measurements shall include transient measurements during a
run up and coast down where feasible.

The vibration measurements shall include FFT vibration spectrum, phase angles
(referenced to a suitable force input location) at a series of controlled operating
speeds where appropriate.

4 If an equipment shutdown can be arranged, undertake an impact excitation test(s)

of the entire compressor installation and connected pipes/ structures (with the unit
not operating) such that resonant frequencies of the installation, pipes and
supporting structure can be identified. Measurements shall be undertaken using
multi-channel analyzer with multiple accelerometers such that mode shapes can
be obtained from the impact tests.

The above requires a temporary shutdown of the unit (and nearby rotating
equipment if possible) for this dynamic testing.

5 Undertake an Operational Deflection Shape (ODS) study using the measured data
to examine the deflection shapes of the compressor train, piping and supporting
structure / foundation under operating conditions.

The purpose of this study is to enable visualisation of the dynamic motion of the
entire machine installation, structure and pipes such that critical areas of forced
response could be identified. This study shall be undertaken using post- vibration
analysis software (MEScope or equivalent).

This Operational Deflection Shape analysis shall provide animated visualization

of the dynamic motion of the compressor train, pipes and supporting structure.
This shall provide a visual insight to the nature of the motion and correspondingly
likely source(s) of the vibration problem.

6 Consolidate findings of the above measurements and analysis with respect to

structural vibration responses correlations with forcing excitations, phase
relationships and Operational Deflection Shapes/Modal Analysis.

7 Review conceptual structural modification options and/or other vibration

reduction measures using results of the Operational Deflection Shape study.

8 Report and Documentations of the above site measurements, post site data
reduction and vibration analysis, and recommendations for remedial measures.

Proposal for Petronas Refinery Compressors Vibration Investigations 3

FINITE ELEMENT ANALYSIS

9 Review structural and piping drawings for the RC structure, and all attached
piping for information to build up a computational Finite Element Model. The
FEA model shall consist of 3 dimensional solid elements where appropriate to
represent the compressor block, piping, structural skid and foundation.

10 Assign material and constraints input for the FEA model, including compressor
interfacing with concrete plinth.

11 Undertake normal modes analysis to determine natural frequencies and mode

shapes for the compressor train, piping and structural skid/foundation system.
Results shall be checked against measured data of natural frequencies and mode
shapes identified in the vibration measurement for the compressor train. The
FEA model shall be fine tuned, and if necessary with adjustments to material
properties and constraints such that computational results are fairly similar to
actual measured results. Results shall include animation of the natural modes to
be compared against existing measured modes.

12 Based on measured acceleration levels in the compressor, determine likely force

and moment reactions acting on the compressor train and foundation. With these
forcing estimates, undertake a forced harmonic response analysis of the FEA
model (whose normal modes had been validated). The vibration response as
predicted from this FEA analysis shall be checked against actual measured
vibration levels on the structure at all locations of interest. If necessary,
refinements to the forcing functions shall be undertaken to further fine tune the
FEA model and forcing functions to represent existing conditions.

13 From the FEA model whose dynamic motion is validated, obtain stress profiles
for the entire structure and foundation in particular. Stress generated from
combined static and dynamic loadings shall be reviewed and assessed against
likely failure modes and acceptable threshold levels. Acceptance limits shall be
based on Petronas Technical Specifications, where applicable, and/or Euro Codes.

14 Based on the above model, further FEA analysis shall be undertaken with
particular emphasis to stress concentration points/stress risers and if necessary
cracks located at strategic locations at hold down bolts locations to validate likely
failure modes and locations.

15 Undertake repeat FEA analysis for cases involving forcing input that’s detuned
from existing natural frequencies and/or with structural modifications and
foundation redesign where appropriate. The FEA model shall also be used to
consider any structural modifications to the piping systems and/or structural skid
and foundation.

16 Report and Documentations of the above analysis.

Proposal for Petronas Refinery Compressors Vibration Investigations 4

DELIVERABLES

Deliverables of the VIBRATION INVESTIGATION AND ANALYSIS shall be a formal

REPORT documenting the vibration measurements, vibration deflection shapes, and
analysis. Recommendations and solutions for vibration induced failure mitigation shall
also be included as appropriate.

INFORMATION AND DOCUMENTS REQUIRED FOR STUDY

The following documents and information shall be required:

- Equipment layout drawings for the equipment installation including all

connected pipes;
- Structural drawings showing the supporting structures, skids, and platforms
for the compressors installation;
- Information relating to operating speeds and process loading conditions.
-

MANPOWER

Personnel proposed for this VIBRATION INVESTIGATION AND ANALYSIS are as

follows:

SPECIALISTS Ir Dr M. Salman Leong

(Professor/Principal Consultant)

ENGINEERS Tan Chek Zin

GuaiYeu Kae.

The Principal Consultant shall be Professor Ir Dr M. Salman Leong from the Institute of
Noise & Vibration, Universiti Teknologi Malaysia. He has more than 25 years
experience in Mechanical and Structural Vibrations. His experience includes vibration
analysis, modelling, predictions, measurements and assessment. His experience includes
petrochemical plants, offshore platforms, power generation plants, and heavy industrial
facilities. Assistance on site for vibration measurements and off site data reduction shall
be provided by the Engineers.

The Institute and Professor Salman Leong in particular had similar experiences in
troubleshooting and resolution of foundation and bearing pedestal failures of turbo-
machines. Similar work for structural vibrations and Finite Element Analysis were also
recently undertaken on a Petronas facility with Petronas Global Solutions.

Proposal for Petronas Refinery Compressors Vibration Investigations 5

PROFESSIONAL FEES

Professional fees are charge on a lump sum basis based on estimated man hours required
for this Project:

Professional Services

i Vibration Measurements and Analysis

Scope of Work Items 1 to 8 RM 45,000.00

ii Finite Element Analysis

Scope of Work Items 9 to 16 RM 35,000.00

Total Fees RM 80,000.00

iii Reimbursements
Out of pocket expenses for travelling
and accommodation. RM 1,500.00

Any extension of work to the above consultancy brief shall be to prior mutual agreement,
and charge at RM400.00 per man hour for a SPECIALIST and RM 180.00 per man hour
for an ENGINEER.

Proposal for Petronas Refinery Compressors Vibration Investigations 6