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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
Schematic Lay-out of Clark-Bros compressor (2 cylinders only)




                                                 Mainframe
                                                 Frame extension
                                                 Tie Rod
                                                 Cylinder




                                                                   2
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
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
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
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
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
III. Repair of cracks in the concrete foundation


                                         Hand injection of delaminated layers with low viscosity
                                         epoxy




                                                                                                   8
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
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
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
V. Drilling (diamond-) of all pockets for the new anchors




                                                            12
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
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
VI. Making existing 16 anchors suitable for re-use


                                                     New thread was cut
                                                     after the anchors
                                                     were cut down to size




                                                                         15
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
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
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
VI. Design, supply & install soleplates for E-motor



                                                      •   Soleplates aligned with 3D
                                                          laser
                                                      •   And grouted with Chockfast
                                                          Red epoxygrout




                                                                                       19
VI. Design, supply & install soleplates for E-motor

                                            Finished soleplates with E-motor installed




                                                                                         20
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
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
VII. Installation of soleplates in steps

                                 Layout of a frame-extension soleplates

                                 •   Soleplate



                                 •   Grout-anchor

                                 •   Pocket




                                                                          23
VII. Installation of soleplates in steps


                                 A gibkey is mounted into the soleplate with a H7 fitting an spotwelded




                                 •   Grout-anchor

                                 •   Gibkey




                                                                                                      24
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
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
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
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
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
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
IX. Grout anchors, mainframe and Soleplates

                                 Inflated tubing protects grout from running under frame-carter




                                                                                              31
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
XI. Install & grout new pipe support-anchors

                                       Following vibration measurements it was indicated that
                                       some re-designed pipe supports had to be installed




                                                                                            33
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
Final result




               35

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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
  • 12. V. Drilling (diamond-) of all pockets for the new anchors 12
  • 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