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Project Name: Water Pump Installation 

Completion Date: Pump A – 04/11/2022, Pump B – 17/03/2023

Location: United Kingdom

Type of Project: Installation on existing foundation

Industry: Oil & Gas

Project Overview

The Water Pump Foundation Installation was a successful undertaking, executed by Alphatec Engineering. The project involved the replacement of two outdated pumps from the 1970s with modern, more efficient pumps supplied by Flowserve. 

The installation took place in two phases, with Pump A installed in November 2022 and Pump B in March 2023. The primary goal was to enhance the refinery’s water processing capabilities and improve overall operational efficiency.

Unexpected Difficulties Encountered

Throughout the installation process, Alphatec Engineering faced several unforeseen challenges. The initial difficulty arose when it was discovered that the pump supplier had painted the entire skid, neglecting to clean the underside as required by API RP 686 standards. 

image source: api.org

Furthermore, the corners of the skid had not been rounded off to a 1″ radius, potentially creating stress points. Additionally, adverse weather conditions in November posed difficulties for the installation team.

Overcoming the Difficulties

To address the challenges encountered during the installation, Alphatec Engineering took proactive measures. They removed the paint from the underside of the skid using an angle grinder and flappy disc, ensuring compliance with API RP 686 requirements.

 The corners were also rounded off to mitigate potential stress points, enhancing the structural integrity of the installation. 

To cope with the bad weather conditions in November, the team implemented additional scaffolding and sheeting to protect against rain and maintain the project’s progress.

Lessons Learned

The Water Pump Foundation Installation project provided valuable insights for both the client and the pump supplier. The lessons learned from the initial installation helped improve the second phase. 

In Pump B’s installation, the pump skid’s underside was left unpainted, and the corners were properly rounded off from the outset, demonstrating the benefits of applying past experiences to enhance future projects.

Successes and Achievements

The project was completed successfully and on schedule, with both pumps installed according to plan. The client expressed great satisfaction with the results. 

This project was their first experience using Alphatec 800, an epoxy grout, which they found to be more economical and easier to use due to its lack of temperature restrictions and the non-requirement of heating for curing. 

AT 800 in situ

The successful installation of the new pumps led to improved water processing capabilities and enhanced operational efficiency at the Refinery.

Environmental Impact

The Water Pump foundation Installation not only marked a significant advancement for the Refinery in terms of operational efficiency but also demonstrated a commitment to environmental sustainability. One of the key aspects contributing to the positive environmental impact of this project was the strategic use of epoxy grout for the pump installation.

Compared to traditional cement grout, which often requires multiple regrouting over time, epoxy grout offers a superior and long-lasting solution. By utilising epoxy grout for this installation, Alphatec Engineering ensured a “first-time right” approach, significantly reducing the need for future maintenance interventions. This reduction in regrouting not only saves resources but also minimises the production of waste materials associated with repair and maintenance activities.

Moreover, epoxy grout’s superior durability and resistance to chemical corrosion make it an ideal choice for harsh industrial environments like the oil and gas industry. The prolonged lifespan of the epoxy grout used in the pump installation contributes to a lower carbon footprint by decreasing the frequency of replacement and the associated manufacturing and transportation impacts.

Additionally, the proper alignment and levelling achieved through the use of epoxy grout enhance the pump’s efficiency, leading to reduced energy consumption during operation. This energy efficiency translates to lower greenhouse gas emissions, aligning with broader efforts to combat climate change.

Conclusion

Alphatec Engineering’s successful execution of the Water Pump Foundation Installation showcases their expertise in handling intricate projects within the oil and gas industry.

By efficiently addressing unexpected challenges and implementing proactive measures, the team demonstrated their adaptability and commitment to delivering high-quality results. 

The project’s positive environmental impact, achieved through the use of epoxy grout, further underscores Alphatec Engineering’s dedication to sustainability and responsible engineering practices. 

As the installation served as a learning opportunity for both the client and the pump supplier, Alphatec Engineering continues to set new standards for future projects in terms of efficiency, reliability, and customer satisfaction. For more white papers and case studies, check out our success cases.

A solid and stable machinery foundation forms the backbone of industrial operations, playing a vital role in ensuring optimal performance, productivity, and safety. The significance of foundation stability cannot be overstated, with research revealing compelling statistics and data underscoring its impact. From increased downtime and maintenance costs to compromised product quality and worker safety, unstable foundations can have far-reaching consequences across industries.

Foundation issues contribute to machinery downtime, resulting in significant financial losses for organisations. Unstable foundations can also be responsible for maintenance expenses. But beyond financial implications, the impact of foundation instability extends to product quality and worker safety. Machinery operating on unstable foundations is more prone to excessive vibrations, misalignments, and premature wear, leading to a decrease in product quality standards. This not only affects customer satisfaction but also raises safety concerns for workers who operate in close proximity to these machines.

By implementing industry best practices supported by expert research, organisations can mitigate risks, minimise downtime, and maximise the efficiency and longevity of their machinery.

Machinery Foundation Stability 

The significance of machinery foundation stability cannot be overstated when it comes to ensuring the overall performance, reliability, and longevity of industrial equipment. A stable foundation is essential for maintaining proper alignment and functionality of the machinery, as it provides a solid base to support its weight, absorb vibrations, and counteract external forces.

When the foundation of machinery is stable, it forms a secure platform that effectively supports the equipment’s weight. This prevents excessive stress and strain on the machinery, allowing it to operate smoothly and reducing the risk of failures. Proper alignment is crucial for the machinery to function as intended, avoiding issues such as increased friction, vibration, and premature wear, which can lead to reduced efficiency and higher maintenance costs.

Proper alignment is key for machinery foundations

A stable foundation plays a vital role in minimising vibrations generated during machinery operation. By absorbing these vibrations, the foundation prevents their transmission to other components and surrounding structures. This helps to maintain the structural integrity of the machinery, reduces the likelihood of damage, and extends its operational lifespan.

Foundation Design and Construction

According to industry experts, proper foundation design is essential for machinery stability. It involves considering factors such as weight distribution, dynamic forces, and anticipated loads of the machinery. Structural engineers utilise industry standards and structural analysis methods to design foundations that can withstand operational demands while minimising the risk of settlement, cracking, or uneven load distribution.

To ensure machinery foundation stability, the use of high-quality construction materials, such as reinforced concrete or steel, is crucial. Adherence to established engineering practices, including proper reinforcement placement and adequate curing processes, enhances the durability and integrity of the foundation.

Quality Construction Materials and Techniques

In the realm of foundation stability, the careful selection of high-quality construction materials and reliable techniques is paramount. When it comes to using epoxy grout, industry experts recognize its significance in enhancing the strength and durability of foundations. Epoxy grout offers exceptional bonding properties, high compressive strength, and chemical corrosion resistance, making it an ideal choice for various foundation applications.

Mixing AT800 Epoxy Grout

Proper installation techniques play a crucial role in maximising the benefits of epoxy grout. Strategic positioning of epoxy grout involves filling voids, anchoring machinery, and providing structural support within the foundation. This strategic placement helps distribute the loads and forces exerted by the machinery, significantly reducing the risk of cracks, settlements, or uneven load distribution.

In addition to precise positioning, following established engineering practices is vital for achieving optimal results with epoxy grout. Accurate mixing ratios, proper surface preparation, and meticulous application are essential steps to ensure a strong bond between the epoxy grout and the foundation. Adhering to manufacturer guidelines throughout the process is crucial for achieving the desired level of strength, stability, and longevity.

Contact Alphatec Engineering today to ensure your machinery foundations future!

Industrial processing plants rely heavily on machinery to carry out essential operations. Over time, the wear and tear on machinery can lead to decreased performance, increased downtime, and costly repairs. 

However, by implementing proper grouting techniques, you can significantly extend the lifespan of your plant’s machinery. In this blog post, we will explore the importance of proper grouting and provide practical tips to help you maintain and enhance the longevity of your equipment.

Understanding the Significance of Proper Grouting

Proper grouting plays a vital role in the maintenance and longevity of machinery in industrial processing plants. It goes beyond a simple construction step and involves using specialised materials to create a stable and durable foundation for equipment. By employing the correct grouting techniques, you can effectively prevent common issues that can arise during operation.

One of the primary benefits of proper grouting is the mitigation of vibrations. Machinery in industrial settings often generates significant vibrations during operation, which can lead to various problems. Excessive vibrations can cause accelerated wear and tear, leading to premature failure and decreased performance. Proper grouting techniques can effectively dampen these vibrations and ensure smooth and stable machine operation.

Another critical aspect is the prevention of misalignment. Misalignment can occur due to various factors, such as uneven loads, temperature variations, or inadequate foundation support. Improper alignment can lead to increased stress on machine components, resulting in decreased efficiency and potential damage. Proper grouting provides a solid and level foundation, reducing the risk of misalignment and allowing machinery to operate optimally.

Structural damage is yet another issue that can be prevented through proper grouting. Heavy machinery exerts significant forces on the surrounding structures, which, if not properly managed, can lead to cracks, fractures, or even collapse. By using the appropriate grouting materials and techniques, the forces generated by the machinery can be evenly distributed, minimising the risk of structural damage and ensuring the safety of the entire plant.

Choosing the Right Grouting Materials

Selecting the appropriate grouting material is a critical step in maximising the lifespan of your machinery and ensuring optimal performance. Various types of grouting materials are available, each with its own unique characteristics and advantages. Understanding these materials and their applications will help you make an informed decision when choosing the right grouting solution for your specific machinery needs.

Epoxy Grout

Epoxy grout is a popular choice for industrial processing plants due to its exceptional strength and durability. It offers excellent load-bearing capacity, chemical resistance, and vibration-dampening properties. 

Epoxy grout is particularly suitable for heavy machinery, high-impact areas, and environments with exposure to chemicals or extreme temperatures. It provides a secure and stable foundation that effectively absorbs vibrations, minimises misalignment, and prevents structural damage. Alphatec Engineering offers a range of high-quality epoxy grouts specifically designed for industrial applications including ALPHATEC® 800 High-Performance Epoxy Grout, ALPHATEC® 141 Underwater Curing Epoxy Grout, ALPHATEC® 130 Epoxy Grout for High Temperature and various others.

Cementitious Grout

Cementitious grout, also known as non-shrink grout, is commonly used for machinery installations. It is a cost-effective option that provides good compressive strength and stability. Cementitious grout is suitable for lighter machinery and applications where high chemical resistance or vibration damping is not required. It is easy to mix and apply, making it a popular choice for various industrial processing plants.

Polymer Grout

Polymer grout is a versatile option that combines the benefits of epoxy and cementitious grouts. It offers excellent chemical resistance, flexibility, and adhesion properties. Polymer grout is suitable for a wide range of machinery and environments, including those exposed to chemicals, moisture, and thermal variations. It provides effective vibration absorption and enhances the overall stability and performance of machinery.

Regular Maintenance and Inspections

Performing regular inspections allows you to identify signs of wear and tear, loose connections, leaks, or any other abnormalities. By conducting visual inspections and using advanced diagnostic tools, you can detect early warning signs of potential failures. This proactive approach enables you to take corrective actions promptly, preventing further damage to the machinery and reducing the risk of unexpected breakdowns.

Monitoring various parameters such as temperature, vibration levels and performance indicators can provide valuable insights into the health and condition of your machinery. Implementing a robust monitoring system allows you to track trends, detect anomalies, and take necessary preventive measures. By closely monitoring the machinery’s performance, you can identify areas that require attention and schedule maintenance.

Collaboration with Grouting Experts

When it comes to proper grouting of your machinery, collaborating with grouting experts can provide significant benefits. Grouting is a specialised process that requires expertise and knowledge of various factors such as materials, techniques, and specific machinery requirements as well as engineering.

Working with experienced grouting professionals, such as Alphatec Engineering, ensures that you receive tailored solutions that meet the unique needs of your machinery. With their expertise, they can recommend the most suitable grouting materials and techniques to ensure optimal performance and longevity of your machinery.

Collaborating with grouting experts also provides access to specialised equipment and tools required for proper grouting. These professionals have experience in executing grouting projects efficiently and effectively, minimising downtime and disruptions to your operations. They follow industry best practices and adhere to strict quality standards, ensuring that the grouting process is carried out correctly and to the highest standards of excellence.

In industrial settings, managing heavy machinery plays a crucial role in ensuring smooth operations and maximising productivity. A well-defined Machinery Asset Management Strategy (MAMS) is essential for optimising the performance, reliability, and lifespan of machinery in a plant. 

What is A Machinery Asset Management Strategy (MAMS)

A Machinery Asset Management Strategy (MAMS) encompasses a comprehensive set of systematic approaches, processes, and practices specifically designed to effectively handle the entire lifecycle of heavy machinery within a plant. It involves strategic planning, regular maintenance, proactive monitoring, and informed decision-making to ensure that machinery operates at its peak performance, achieves maximum uptime, and minimises operational risks.

At its core, MAMS aims to optimise the utilisation and efficiency of machinery by implementing proactive maintenance schedules, conducting routine inspections, and employing advanced monitoring technologies. By adhering to manufacturer guidelines and industry best practices, plant operators can extend the lifespan of machinery, reduce the frequency of breakdowns, and avoid costly downtime.

Furthermore, MAMS facilitates strategic planning to align machinery usage with production demands, enabling better resource allocation and minimising idle time. It also entails effective spare parts management, ensuring timely availability and reducing the risk of unexpected delays.

Another crucial aspect of MAMS is continuous monitoring and data-driven analysis. Real-time data collection using sensors and advanced analytics enables operators to detect anomalies, anticipate potential failures, and make informed decisions for preventive maintenance. This proactive approach helps identify underlying issues before they escalate into major breakdowns, thus maximising reliability and minimising unplanned downtime.

By implementing a robust MAMS, organisations can achieve several benefits, including improved equipment performance, increased reliability, extended machinery lifespan, reduced maintenance costs, and enhanced safety and compliance. Ultimately, a well-executed MAMS optimises overall operational efficiency and contributes to the long-term success of plant operations.

Benefits of Implementing Machinery Asset Management 

Implementing a comprehensive Machinery Asset Management Strategy offers several advantages for plant operations.

Enhanced Equipment Performance

A well-executed Machinery Asset Management strategy or system ensures regular maintenance, calibration, and monitoring of machinery, optimising its performance and minimising downtime. By implementing preventive maintenance schedules, plant operators can proactively address potential issues, identify inefficiencies, and fine-tune machinery to operate at its peak performance. 

This results in improved overall equipment effectiveness (OEE), increased production output, and better quality control.

Improved Reliability

By employing proactive maintenance practices, such as predictive maintenance and condition monitoring, potential breakdowns and failures can be detected early, reducing unplanned downtime. 

MAMS allows for the implementation of advanced monitoring technologies like sensors and data analytics, which enable real-time data collection and analysis. This enables operators to detect anomalies, monitor equipment health, and address potential issues before they lead to catastrophic failures. Consequently, machinery reliability is improved, leading to increased uptime, reduced disruptions, and enhanced overall operational efficiency.

Extended Equipment Lifespan

Effective asset management practices, including routine inspections, timely repairs, and equipment replacements, can significantly extend the lifespan of heavy machinery, maximising return on investment. 

A well-implemented Machinery Asset Management strategy ensures that equipment is properly maintained, lubricated, and calibrated, preventing premature wear and tear. By adhering to manufacturer guidelines and best practices, plant operators can avoid costly breakdowns, reduce the frequency of major repairs, and extend the operational life of machinery.

Cost Reduction

Optimised maintenance scheduling, spare parts management, and efficient resource allocation through MAMS can help reduce maintenance costs and minimise production losses due to equipment failures. 

By establishing clear maintenance plans, operators can avoid unnecessary expenditures, optimise the use of spare parts, and minimise equipment downtime. Additionally, implementing cost-effective maintenance strategies, such as condition-based or reliability-centred maintenance, enables targeted interventions, reduces unnecessary maintenance activities, and maximises cost savings.

Enhanced Safety and Compliance

A well-maintained and properly functioning machinery fleet ensures a safer working environment for plant personnel. MAMS includes regular safety inspections, adherence to safety protocols, and compliance with regulatory standards. 

By implementing safety measures, such as lockout/tagout procedures, routine inspections of safety features, and comprehensive training programs, the risk of accidents and injuries is minimised. MAMS also aids in meeting regulatory requirements and industry standards related to equipment operation and maintenance, ensuring compliance and mitigating legal and operational risks.

Conclusion

A well-implemented Machinery Asset Management Strategy (MAMS) is vital for effective management of heavy machinery within a plant. Alphatec Engineering, a trusted industry leader, specialises in heavy machinery foundation rehabilitation, offering valuable solutions to enhance machinery performance and prolong its lifespan.

With their expertise in foundation engineering and rehabilitation, Alphatec Engineering can assist organisations in addressing the structural integrity of machinery foundations. By conducting thorough assessments and utilising advanced techniques, they can identify and rectify any underlying issues that may impact machinery performance and reliability.