OpenShift Commons Paris - Choose Your Own Observability Adventure
Re-grout clark bros 4 cyl hyper compressor
1. Re-grout of CLARK-BROS 4 cylinder Hyper Compressor
Assigned by
Dresser Rand, the Netherlands
Sope
Total re-grouting of Hyper compressor foundation
and soleplates
End user
Petrochemical Industry
1
2. Schematic Lay-out of Clark-Bros compressor (2 cylinders only)
Mainframe
Frame extension
Tie Rod
Cylinder
2
3. History
• Previous revision 1990
• Top of foundation was covered with
• Chockfast Red® epoxygrout
• Chocks were grouted with
• Chockfast Orange® epoxygrout
• New anchors 1½” x 8UN were installed
3
4. Scope 2010
I. Investigate present status of foundation
II. Register exact position of mainframe with 3D laser equipment
III. Repair cracks in foundation by epoxy injection
IV. Remove 100 mm from top of foundation in order to create clearance for soleplates
V. Drill all required pockets for new anchors
VI. Make existing 16 anchors suitable for re-use (compress the injected cold-joints)
VII. Design, supply & install soleplates for E-motor and frame extensions
VIII. Align mainframe and soleplates for extensions and E-motor
IX. Grout anchors, mainframe and soleplates (extensions & E-motor)
X. Install BoltSafe® sensors on all anchors
XI. Install / grout new pipe support-anchors
XII. Products used
4
5. I. Investigate present status of foundation
Measurements were taken during a 1 day stop 7 months before TA:
• Vibrations on anchors/feet
• URS on concrete/CFRed – cracks
• Core samples were drilled for:
Compressive strength tests
Oil penetration
De-lamination (non adhesion)
CO2 penetration (carbonization)
• Thorough visual investigation
5
6. I. Results from investigation
Main conclusions:
• Some small areas of delaminated CFRed/concrete
• Penetration of oil was not confirmed
• No serious cracks could be identified
• Vibration levels in general proved to be to be too high
• One (extension) anchorbolt was broken
6
7. II. Register exact position of mainframe with 3D laser before removal
In order to re-connect all piping without tension, it is
important to position the mainframe back into its
exact original position, even without having the
extensions and cylinders attached
• The SOKKIA Total station 0.5 – 3D Laser
equipment is used to measure the original
position of the mainframe & E-motor
• Reproducible fixed points were taken from the
top cover threaded holes
• Targets were fixed on various stable structures
as reference points for later orientation
7
8. III. Repair of cracks in the concrete foundation
Hand injection of delaminated layers with low viscosity
epoxy
8
9. III. Repair of cracks in the concrete foundation
Some cracks were sample-drilled in order to
identify the depth
• This crack did not continue into the
concrete
9
10. III. Repair of cracks in the concrete foundation
However when drilling out the old anchors,
another big horizontal (cold joint) crack was
identified in the concrete
• Additional injections were made
10
11. IV. Remove 100mm from top of foundation for clearance of soleplates
A grout-clearance of 50mm is required under the soleplates for the
new Chockfast Red® grouting
• Including the soleplates thickness 100mm was removed by first
cutting the existing Chockfast Red® into small ‘bricks’ followed by
hydraulic jacking
11
13. VI. Make existing 16 anchors suitable for re-use
Considerations for re-use of the existing anchors
• The anchors installed in 1990 are ca 4000 long; drilled
and grouted into the mat of the concrete foundation
• Taking them out would require a time consuming
drilling-action with very likely a break through into the
ground water
• Initial vibration tests had been performed with the 16
anchors in function
• Not re-using them could give a significant difference
• The (later confirmed) suspicion of the existence of
horizontal cracks in the concrete block make vertical
compression necessary as much as possible
• Adding vertical compression after installation of the
compressor would leave not enough space to introduce
additional anchors afterall
13
14. VI. Making existing 16 anchors suitable for re-use
A guiding piece was designed to
make sure the 1 ½”-8UN thread
was aligned properly to the B7
quality anchor
New thread was cut after the
anchors were cut down to size
VIDEO
14
15. VI. Making existing 16 anchors suitable for re-use
New thread was cut
after the anchors
were cut down to size
15
16. VI. Making existing 16 anchors
suitable for re-use
16 large flanges were grouted in with Chockfast Gray
After cure the nuts were set to 1000 Nm
16
17. VII. Design, supply & install soleplates for E-motor
After removal of the stator (sliding backwards)
• The old soleplates were removed
• The steel shims became visible (frequently corrosion
of the shims create misalignment of the stator)
• And the top-layer was jacked off
17
18. VII. Design, supply & install soleplates for E-motor
After removal of the old
soleplates
• 150mm was jacked off
• The anchors drilled out
• Jackplates positioned
• Shuttering installed
18
19. VI. Design, supply & install soleplates for E-motor
• Soleplates aligned with 3D
laser
• And grouted with Chockfast
Red epoxygrout
19
20. VI. Design, supply & install soleplates for E-motor
Finished soleplates with E-motor installed
20
21. VII. Design, supply & install soleplates for the Frame-extensions
The soleplates for the Frame extensions required a new approach.
• After detailed discussions it was approved to install a soleplate
under each extension mounted into the concrete with 2 grouted
anchors and 2 gibkeys to resist horizontal forces
• The extensions are mounted with 4 studbolts
21
22. VII. Installation of soleplates in steps
Layout of a soleplate with 2 anchors and
gibkeys
• Per anchor 2 holes were drilled in an
-8- shape
• One 125 – 1500 deep
• One eccentric 60 – 750 deep
• This smaller hole allows the anchor
glue Chockfast Red to flow
smoothly into the pocket
22
23. VII. Installation of soleplates in steps
Layout of a frame-extension soleplates
• Soleplate
• Grout-anchor
• Pocket
23
24. VII. Installation of soleplates in steps
A gibkey is mounted into the soleplate with a H7 fitting an spotwelded
• Grout-anchor
• Gibkey
24
25. VII. Installation of soleplates in steps
The gap between anchor and gibkey is closed with kit in order to avoid
epoxy to enter in-between anchor and gibkey, which otherwise would
influence stretching of the anchor
• Stretch length of anchor
• Gibkey
• Kit
• ‘Passage’ along the gibkey allows the Chockfart Red to pass the
gibkey
25
26. VII. Installation of soleplates in steps
First the anchor is grouted with
Chockfast Red
• The anchor needs to be fixed in
order to align the extensions also
along ‘z’ axis
• Grout blocks air-passage through
the tube as soon as the correct
level is reached
• The tubing functions as ‘level-
control’
26
27. VII. Installation of soleplates in steps
Next the Gibkey is grouted with Chockfast Gray
• Chockfast Gray has a lower viscosity, applicable
for the smaller clearance between gibkey and
pocketdiameter
• Cured Chockfast Red
• Horizontal displacement is blocked
27
28. VII. Installation of soleplates in steps
Last step is to grout the soleplate with Chockfast Red
• ‘new’ Chockfast Red layer
• Existing (old) Chockfast Red layer
28
29. VII. Installation of soleplates in practice
Assembly of the soleplates with
gibkey, anchors and stud-bolts
The Bolt-Safe sensors are
installed
The ‘level-tube’ is checked
The soleplates are installed with
the prepared anchors hanging
‘loose’ in the pockets
29
30. VIII. Align mainframe and Soleplates
Thanks to precise 3D Laser
alignment of the frame-extension-
soleplates, the frame was re-
installed at an accuracy of ± 0,5 mm
30
31. IX. Grout anchors, mainframe and Soleplates
Inflated tubing protects grout from running under frame-carter
31
32. X. Installation of Bolt Safe sensors
Bolt Safe sensors were installed under each nut
of both soleplate-anchors and the stud-bolts of
the frame extensions
With the hand-held read out attached, the
sensor gives the real compressive force exerted
by the nut in kN
This clamping-force is checked on a regular basis
32
33. XI. Install & grout new pipe support-anchors
Following vibration measurements it was indicated that
some re-designed pipe supports had to be installed
33
34. XII. Products used
Chockfast Red® 3 component epoxy grout
Chockfast Gray® 2 component epoxy grout
Chockfast Orange® 2 component epoxy grout
BoltSafe® anchor tension sensor type CMS
34