Compressor Skid Installation and Grouting at Petrochemical Plant

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Project Overview

 

The petrochemical plant required a comprehensive installation and grouting of two compressor skids to ensure optimal alignment and stability.

This project involved concrete plinth preparation, anchor bolt installation, and precise application of epoxy and cement grouts.

The team was tasked with executing this in a high-pressure industrial setting, meeting stringent quality and safety standards.



Features

Client
Petrochemical Plant
Project
Skid Installation and Grouting
Equipment
Two Compressor Skids
Work period
Autumn 2024
Location
Hungary

 

The Problems

 

The existing concrete plinths required meticulous preparation, including scabbling and cleaning, to create an adequate bonding surface for the grouting process. The issues included:

  1. Non-functional equipment (e.g., compressors and pumps).
  2. Tight project timelines.
  3. Limited site resources and technical delays.
  4. Complex pouring conditions, especially under the skid pockets.

 

The Challenges

 

  • Logistics: Material movement, equipment setup, and scheduling required constant adjustments due to equipment failures and site conditions.
  • Coordination: Aligning multiple teams for tasks like torqueing anchor bolts and scaffold erection demanded precise communication.
  • Technical Difficulties: Pouring grout under skid pockets and ensuring leak-free forms in constrained spaces required innovative techniques.
  • Weather Impacts: Rain during pours posed additional challenges, risking grout contamination and delays.

 

The Solution

 

The team implemented a systematic approach:

  1. Thorough site preparation, including scabbling and cleaning concrete plinths.
  2. Strategic use of hand tools and smaller mixers to adapt to tight working conditions.
  3. On-the-spot troubleshooting.
  4. Efficient material management to minimise waste and delays.

 

The Procedure

 

Day 1-3: Initial plinth preparation, including scabbling and cleaning. Anchor bolts were wrapped, greased, and positioned. Skids were lifted and aligned with jacking screws in place.

Day 4-5: Anchor bolt grouting and formwork installation. Dry packing was applied to avoid leaks before epoxy grouting began.

Day 6-7: Epoxy grout poured in stages, followed by form removal and site cleanup. High-pour areas handled with precision.

Final Day: Jacking screws were capped off, and materials were moved back to storage.

 

Conclusion

 

The project concluded successfully despite numerous challenges. By adapting to unforeseen issues, such as equipment failures and weather impacts, the team completed the installation and grouting of both compressor skids on schedule.

The result was a stable, high-quality foundation that met all client specifications. The success highlights the importance of flexibility, teamwork, and technical expertise in complex industrial projects.