Large Custom Compressor Frames Fabrication
Compressor frames and industrial skids form the foundational backbone for massive gas compressors, turbines, and heavy rotating equipment. Because they endure continuous, heavy-duty vibration, these frames require flawless structural integrity, strict dimensional stability, and perfectly co-planar mounting surfaces.
Openex specializes in the heavy fabrication and machining of large, custom-built compressor base frames. By keeping the entire manufacturing lifecycle in-house—from thick-plate cutting and AWS-certified welding to massive thermal stress relief and final CNC gantry milling—we ensure that your rotating equipment aligns perfectly in the field, eliminating the risk of bearing failures or shaft misalignment.
Compressor Frame Manufacturing Specifications
We custom manufacture heavy-duty base frames and skids to your exact blueprints. Below are our general facility capacities:
| Maximum Dimensions | Lengths up to 25,000 mm (25 Meters) |
|---|---|
| Maximum Weight | Up to 250 Tons |
| Materials Processed | Carbon Steel (A36, Q345, S355), High-Strength Low-Alloy (HSLA), Stainless Steel. |
| Machining Tolerances | Co-planar mounting pads milled to tight flatness tolerances (down to ±0.02 mm depending on scale). |
| Testing & NDT | Magnetic Particle Inspection (MPI), Ultrasonic Testing (UT) on full penetration welds, Laser Tracker Alignment. |
The Manufacturing Process
Building a frame that supports high-vibration rotating equipment requires a strict, multi-step engineering process:
We utilize massive plasma and oxy-fuel cutting tables to process thick carbon steel plates and I-beams. Our experienced fitters ensure precise joint preparation (bevelling) before tack welding.
Full penetration welds are critical to prevent cracking under vibration. We utilize submerged arc welding (SAW) and robotic flux-cored arc welding (FCAW) to lay massive, high-integrity weld beads.
Heavy welding introduces intense internal stresses that will warp the frame over time. We place the entire welded assembly into our massive on-site heat treatment furnaces for Post-Weld Heat Treatment (PWHT) to ensure permanent dimensional stability.
Once stress-relieved, the frame is moved to our 25-meter CNC Gantry Mills. We machine the compressor and motor mounting pads in a single setup, guaranteeing perfectly flat and co-planar surfaces for flawless equipment alignment.
Finally, the frame enters our state-of-the-art steel grit blasting booths to remove mill scale, followed by marine or industrial-grade epoxy painting to withstand harsh environments.