Machinery Components Maintenance And Repair Episode 1 Part 7 ppt

Appendix 3-E Specification and Installation of Pregrouted Pump Baseplates This appendix, or standard procedure, outlines the requirements for specifying and installing pregrouted machinery baseplates However, this standard does not cover the installation requirements for machinery mounted on sole plates A typical application for this standard procedure would be the installation or retrofit of an ANSI or API pump I Purpose The purpose of the standard procedure is to provide specific requirements for prefilling any machinery baseplate, or, in particular, a pump baseplate, with epoxy grout, and machining the mounting surfaces of the baseplate after the grout has cured Additionally, the standard procedure outlines the requirements for installing the pregrout baseplate in the field, utilizing a special grouting technique for the final grout pour This special technique makes use of a low-viscosity epoxy grout for the final pour The technique greatly reduces the field costs associated with traditional installation methods By utilizing this standard procedure, baseplate-mounted machinery can be installed with zero voids, eliminating the possibility of expensive field machining, and reducing field installation costs by 40 to 50 percent 140 Machinery Foundations and Grouting II 141 Specification of Pregrouted Baseplates The underside of the baseplate to be pregrouted must be sandblasted to white metal to remove all existing paint, primer, or scale Any tapped bolt holes that penetrate through the top of the baseplate, such as the coupling guard holding down bolts, must be filled with the appropriate-sized bolts and coated with neverseize to create the necessary space for bolt installation after grouting of the baseplate Anchor bolt or jack bolt holes, located inside the grouted space of the baseplate, must have provisions for bolt penetration through the baseplate after grouting If the baseplate has grout holes and/or vent holes, these holes must be completely sealed prior to grouting All pregrouted baseplates will be filled with catalyzed epoxy grout or a premium nonshrink cement grout Once the baseplate has been filled with epoxy grout, the grout must be completely cured before any machining is performed The machining of the baseplate must be set up to assure that the baseplate is under no stress or deformation Prior to machining, the baseplate must be adjusted and leveled to assure that no more than 0.020≤ of metal is removed at the lowest point The baseplate will have two (2) mounting surfaces for the driver, and two (2) to four (4) mounting surfaces for the driven equipment The flatness tolerance for all these mounting surfaces will be 0.001≤ per ft The finished surface roughness must be no more than an 85P profiled surface 10 The two (2) mounting surfaces for the driver must be coplanar within 0.002≤ The two (2) to four (4) mounting surfaces for the driven equipment must also be coplanar within 0.002≤ The original dimensional relationship (elevation) between the driver mounting surfaces and the driven mounting surfaces must be maintained to within 0.020≤ 11 Once the machining process has been completed, an “asmachined” tolerance record must be taken, and provided with the pregrouted baseplate III General Field Grouting Requirements The epoxy grout utilized for the final field grout pour is a lowviscosity epoxy grout This grout has a special aggregate and has Machinery Component Maintenance and Repair 142 the consistency of thin pancake batter This allows for a very thin final grout pour, with the optimum vertical thickness being 3/4≤ All grout material components must be stored in a dry and weatherproof area in original unopened containers Under no circumstances should grouting components be stored outside subject to rain or under a tarpaulin with no air circulation For optimum handling characteristics, precondition the resin and hardener to a temperature between 64° and 90°F The work area, including foundation and machinery, must be protected from direct sunlight and rain This covering (shading) should be erected 48 hours prior to alignment and grouting, and shall remain until 24 hours after placement of the grout, by which time the grout will have cured and returned to ambient temperature The shading is also to prevent the foundation from becoming wet It is important that the concrete remain dry prior to grouting Grouting shall be scheduled to take place during early morning or afternoon hours depending on the surface temperatures Just before starting the grouting operation, the temperature of the concrete foundation and machinery shall be taken using a surface thermometer Ideal surface temperatures shall be between 70° and 90°F IV Foundation Preparation The concrete must be chipped to expose a minimum of 50 percent aggregate so as to remove all laitance and provide a rough surface for bonding Hand-chipping guns only will be used No jackhammers will be permitted If oil or grease are present, affected areas will be chipped out until free of oil or grease The concrete to be chipped should not extend more than 2≤ outside the “footprint” of the pregrouted baseplate Lowviscosity epoxy grout can be poured only up to a 2≤ depth, and should not extend more than 2≤ from the edge of the baseplate By limiting the chipped area of the concrete to just outside the foot print of the baseplate, simple forming techniques can be utilized After chipping, the exposed surface must be blown free of dust and concrete chips using oil- and water-free compressed air from an approved source Concrete surface can also be vacuumed Machinery Foundations and Grouting 143 Figure 3-E-1 After the foundation has been chipped and cleaned, adequate precautions must be taken to ensure that there is no contamination of the concrete surfaces To prevent debris, loose materials, or parts from falling on the top of the concrete, properly cover the workspace with polyethylene sheet The foundation bolt threads must be protected during the grouting operations As regards the bolts (Figure 3-E-l), which will be tensioned after grouting, care must be taken to prevent the bolt surfaces from coming in contact with the epoxy grout All anchor bolts should have grout sleeves, which must be filled with a nonbonding material to prevent the epoxy grout from filling the grout sleeve This can be accomplished by protecting the anchor bolt beforehand between the top of the grout sleeve and the underside of the baseplate by wrapping the bolt with foam insulation, DuxSeal, or other nonbonding material 144 Machinery Component Maintenance and Repair V Pregrouted Baseplate Preparation Prior to positioning the baseplate over the foundation, the bottom side of the prefilled baseplate must be solvent washed to remove any oil or other contaminants from the surface After the surface has been cleaned, sand the surface to break the glaze of the epoxy grout Vertical edges of the baseplate that come in contact with the epoxy grout must be radiused/chamfered to reduced stress concentration in the grout Vertical jackscrews should be provided at each anchor bolt The jackscrews will be used to level the pregrouted baseplate These jackscrews will be removed after the low-viscosity epoxy cures, generally 24 hours after placement at 78°F Leveling pads should be used under each jackscrew to prevent the baseplate from “walking” while leveling the baseplate The pads will remain in the grout, and must be made from stainless steel The pads must have radius edges and rounded corners to reduce stress concentrations in the grout With the jackscrews and leveling pads in place, level the pregrouted baseplate to 0.002≤/foot for API applications and 0.005≤/ foot for ANSI applications After the baseplate has been leveled, the jackscrews must be greased or wrapped with Dux-Seal to facilitate their removal once the grout has cured Wax is not a suitable releasing agent VI Forming Low-viscosity epoxy grout should only be poured up to a 2≤ depth, and should not extend more than 2≤ from the edge of the baseplate The optimum pour depth is 3/4≤ to 1≤ The best woodforming material for this product is a “2 by 4” Any wood surface coming in contact with epoxy grout shall be coated three times with paste floor wax (Liquid wax or oil is not acceptable as an alternative.) All forms must be waxed three times before the forms are placed on the foundation Do not wax the wood surface that comes in contact with the foundation This may prevent the silicone sealant from sticking to the form board, and forming a proper seal Care should be taken to Machinery Foundations and Grouting 145 prevent any wax from falling on the concrete foundation or the baseplate In most cases, there is very little room between the side of the baseplate and the edge of the foundation To help position the form boards, it is best to fasten the boards together with wood screws or nails One side of the form should leave an opening between the board and the baseplate that measures 1≤ to 2≤ The other three sides should have a separation of 1/2≤ to 3/4≤ The larger side will be used to pour the low-viscosity epoxy grout Forms shall be made liquid tight Silicone sealant that does not cure to a hard consistency is best suited for this application A sealant that remains pliable will facilitate easy removal The best approach is to apply the sealant directly on the foundation, where the front edge of the form will fall, and then press the form down to create the seal Check for cracks and openings between the form and the foundation, and apply additional sealant where needed Allow at least an hour for the sealant to cure before pouring the grout Because of the small depth of the epoxy grout pour, it will be very difficult to use a chamfer stripe to create a bevel around the outside of the form The best approach is to use a grinder after the grout has cure to create a bevel Once the forms boards are in place, a small “head box” can be made using blocks of duct seal To help create a slight head for the grout, build a duct seal dam on the side of the baseplate with the larger opening The dam should be about 3≤ tall, 12≤ long, and form a rectangle by connecting the two short sides direct to the baseplate The end result will be a 3≤ head box that will be used to pour and place all the epoxy grout The best location for the head box is the midpoint of the baseplate VII Grouting Procedure for Low-Viscosity Epoxy Grout The required number of units of epoxy grout, including calculated surplus, should be laid out close to the grouting location The 1/2≤ drill and mixer blade should be prepared for the grouting operation Low-viscosity epoxy grout is a three-component, high-strength, 100 percent solids epoxy grouting compound The resin, hard- 146 Machinery Component Maintenance and Repair ener, and aggregate are supplied in a 6-gallon mixing container One unit produces 0.34 cubic feet of grout Inspection of Work Site Check for: • Proper shading • Preparation of concrete, baseplate, jackscrews, leveling pads • Wood forms properly waxed and sealed • Foundation bolts wrapped and sealed Before Mixing Check for: • Mixing equipment clean • Surface temperature of epoxy grout components (