fnds_groutofrecip_roteq
TRANSCRIPT
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Foundations &Grouting of
Reciprocating &
Rotating Equipment
Considerations regarding………
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Diversity of GroutingApplications
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Diversity of Grouting
Applications
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The Equipment “System”
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• Equipment
• Mounting System (Optional)
• Grouting System
• Anchoring System
• Foundation System
• Sub-surface condition
Components of an Equipment “System”
“Consider the whole of
the components as amonolithic unit when
designing for optimum
equipment performance”
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Goals when designing an Efficient
Equipment “System”
• Proper selection of components - To meet the client’s
requirements
• Optimum Equipment Performance - Based on system
components selected, designed & their installation
• Costs - Initial installation; long-term operating costs
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Advantages of Epoxy Grout
• Maintains Precise Equipment Alignment
– Positioning critical to efficient performance
– Resistance to downward and some lateral acting loads
on the foundation
What Part Does Epoxy Grout Play in the Equipment “System”?
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Advantages of Epoxy Grout
• Provides a superior interface to the foundation
– Proper damping of equipment vibration• 10 times greater than cement grout
• 30 times greater than steel
– Other dynamic load transference to the foundation for proper absorption & dissipation
What Part Does Epoxy Grout Play in the Equipment “System”?
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Advantages of Epoxy Grout
• Chemical Resistance
– Service longevity of the grout & foundations• Life of the Equipment?
– Protects porous concrete to maintain integrity of thefoundation mass
What Part Does Epoxy Grout Play in the Equipment “System”?
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Advantages of Epoxy Grout
• Cost!………More economical than cement grout
– Material Cost vs. Cost Efficiency……Which is most
important to the client?• Material Cost - One time cost
Or……
• Cost Efficiency – Continual enhanced equipment performancedue to use of epoxy grout over cement grout.
“ Enhanced performance creates decreased maintenance
costs which provides ongoing $ savings for the client”
What Part Does Epoxy Grout Play in the Equipment “System”?
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Characteristics of Epoxy Grouts
What is an Epoxy Grout?
•Thermosetting Epoxy Resin System
•Amide Resin
•Catalyst•Blended Aggregate of Silica or Quartz
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Characteristics of Epoxy Grouts
• High Physical Strengths• Faster Curing & Higher Strength Gain than
Cement Grout
• Shrinkage Nil (< than cement grout)
• Pre – Measured Packaging ( No Water! )
• Approximately 2 to 3 times stronger than Concrete
• Resistance to Chemical Attack
• High Vibration Damping Efficiency
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BEFORE
AFTER
“Cross Linking”
Exothermic Cure
BeforeAfter
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0
20
40
60
80
100
120
140
0 1 2 3 4 5 6 7 8 9 10 11 12
T
em
p
e
r
at
u
r
e
Time (Hr)
Grout Temperature
Peak Exotherm Temperature
Liquid Solid
T
Timeline of the
Initial Cure
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Coefficient of Thermal
Expansion“Rate of expansion or contraction a material is subject
to, according to temperature”
Values
Steel 6.1 x 10(-6) in/in/°°°°F
Concrete 5.9 x 10(-6) in/in/°°°°F
Epoxy Grout 11.2 x 10(-6) to 27.0 x 10(-6)in/in/°°°°F
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Pre-Planning
• Project Requirements
• Drawings & Specifications including:
• Equipment Selection / Foundation Design• Grout Selection
• Project Timing
• Budget Estimates
Preparation & InstallationConsiderations
(From the Engineer’s Point of View)
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Pre-Planning (cont.)
• Contract Bids & Project Awards
• Construction Schedule
• Pre-Construction Meeting
• Contractor, Engineer, Manufacturer’s
Representative, Client’s Representative
• Contactor’s Preparation and Installation Plan
• Engineering Supervision of the
Installation
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Site Preparation
Initial job staging by the contractor allows for alltools, equipment, materials and manpower to be
set up for the equipment installation and grouting.
The work area is isolated to protect surroundingareas and observe safety regulations. When
these tasks are complete, advanced preparations
will begin at the surface of new concretefoundation
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Installation of the Equipment
• Foundation Preparation
• Setting & Alignment Equipment or Base plate
• Forming Preparation – Expansion Joints (if necessary)
• Grout Mixing & Installation
• Grout Curing
• Anchoring System – Installation & Tensioning
Ensure Proper Guidelines are Followed pertaining to:
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Anchor BoltsTheir Effect on Proper Equipment Performance
Definition
While Epoxy Grout resists downward forces produced byequipment deadweight and anchor bolt tension and
provides dynamic load transference to the foundation for
proper absorption & dissipation, the anchor bolts serve toresist the upward and lateral forces imposed by the
dynamics of the equipment
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Anchor Bolt
Factors AffectingEquipment
Performance• Free Stretch
• Anchor Bolt
Maintenance
• Improper
Design &Installation
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Goals Associated with Proper Epoxy Grouting:
“Create an analogous operating system from multiple components
(Equipment/Support System/Anchor Bolts/Grout Cap/Foundation)
capable of performing its function with the greatest cost efficiency
and longevity. Each project situation differs, but the goals remain
relatively constant.
While the information on the subject of grouting and related
subjects can become involved, the basic criteria and considerations presented here provide the basis for successful grouting operations
and proper performance of equipment”
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Pumps
Grouting Guidelines
& Techniques:
h k
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The Two Most Common Causes of Pump Failures in the
Petrochemical Industry:
Mechanical Seals
34.5%
Bearing Distress
20.2%
h kf
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h kf t t
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h kf t t
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Head Box Details
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Upper Form Cover
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Vibration Levels Before and After Proper Epoxy Grouting
Vertical PlaneVertical Plane Horizontal PlaneHorizontal Plane
Before After (Red.)Before After (Red.) Before After (Red.)Before After (Red.)
Pump #1Pump #1 1.40 0.071.40 0.07 (20 x )(20 x ) 0.21 0.080.21 0.08 (2.6 x)(2.6 x)
Pump #2Pump #2 0.19 0.010.19 0.01 (19 x )(19 x ) 0.220.22 0.01 (22 x )0.01 (22 x )
Vibration Readings are in IN. / SEC.Vibration Readings are in IN. / SEC.
(1 inch = 25.4 mm)(1 inch = 25.4 mm)
By using Epoxy Grout, expect a reduction in pump vibration of abBy using Epoxy Grout, expect a reduction in pump vibration of about tenout ten
(10) times that experienced using Cementitious grouts(10) times that experienced using Cementitious grouts
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Skid-MountedMachinery
Grouting Guidelines
& Techniques:
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HS Modular Compressor
Package
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For additionalFor additionalinformation on thisinformation on this
and other conceptsand other concepts
pertaining topertaining to
foundations andfoundations and
equipment grouting,equipment grouting,
contact us at:contact us at:
ITW Philadelphia Resins130 Commerce Drive
Montgomeryville, PA 18936
Website: www.chockfastgrout.com
Email: [email protected]
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For local assistanceFor local assistanceand materialand material
requirements,requirements,
contact your nearestcontact your nearest
ITW PhiladelphiaITW Philadelphia
ResinsResins ChockfastChockfast®®
Product Distributor:Product Distributor:
www.chockfastgrout.com
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