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The hydrogen industry is rapidly growing and is expected to play a significant role in the transition to a clean energy future. But, with the increasing demand for hydrogen, there is also an increasing need for safe and reliable infrastructure to support its production, storage, and transport.

The installation of hydrogen compressors is not without its challenges. The high reactivity of hydrogen gas and the potential for hydrogen embrittlement of materials used in the compressor system make it crucial to ensure that the installation is done correctly.

Hydrogen Compressor Installation Recommendations and Directives

What is API RP686?

API RP686 is a recommended practice developed by the American Petroleum Institute (API) for the installation of machinery in refineries and petrochemical plants. It was originally designed for the oil and gas industry. But it has become increasingly important in the installation of hydrogen compressors too.

The recommended practice provides guidelines for the proper installation of machinery in hazardous locations. This helps to ensure the safety and reliability of the equipment. It covers a range of topics including:

• Design considerations
• Foundation design
• Installation procedures
• Commissioning and startup procedures

One of the key benefits of following API RP686 when installing hydrogen compressors is that it helps to ensure the right approach from the beginning. By following the guidelines, potential problems can be identified and addressed before the compressor goes into operation. This helps reduce the risk of costly downtime and repair work. Additionally, it reduces the risk of accidents or equipment failure.

The Machinery Directive 2006/42/EC

The Machinery Directive 2006/42/EC is a European Union (EU) directive. It sets out essential health and safety requirements for machinery placed on the market or put into service in the EU. It aims to ensure that machinery is designed and manufactured to be safe for users. And to protect against accidents and risks to health. 

Installers of hydrogen compressors must also ensure that the equipment is installed correctly. And that any associated piping and electrical systems are designed and installed in accord with relevant standards and guidelines. End-users of hydrogen compressors must also take steps to ensure that the equipment is operated and maintained safely throughout its life cycle. This may involve implementing regular maintenance and inspection programs, monitoring the performance of the equipment, and taking corrective action when necessary.

Key Considerations When Following API RP686 and the Machinery Directive 2006/42/EC For The installation Of Hydrogen Compressors

First, it is important to consider the design of the compressor system. This includes selecting materials that are compatible with hydrogen gas and taking into account the potential for hydrogen embrittlement. It is also important to consider factors such as:

• The location of the compressor
• The design of the foundation
• The type of piping and fittings that will be used

(Image source: Pure energy)

Proper installation procedures are essential. This includes ensuring that the equipment is installed according to the manufacturer’s specifications, that proper alignment is achieved, and that all components are properly torqued and tightened. This helps to maintain the work of the operation over its lifetime. It is also important to perform hydrostatic and leak testing to ensure that the system is operating safely and efficiently.

Commissioning and startup procedures are critical to ensuring the safe and reliable operation of the compressor system. This includes ensuring that all components are properly configured and calibrated, that all safety systems are functioning as intended, and that operators are trained on the proper operation and maintenance of the equipment.

Conclusion

The installation of hydrogen compressors is a critical aspect of the future functioning of your hydrogen compressor. And following best practices ensures efficient and safe operation. 

API RP686 and the Machinery Directive 2006/42/EC provide guidelines for the proper installation of hydrogen compressors. Following them ensures the safety and reliability of the equipment. Proper design, installation procedures, and commissioning and startup procedures are essential to ensure the safe and reliable operation of the compressor system. 

Looking for a team to carry out a grout application for your hydrogen compressor installation? Alphatec Engineering follows these best practices and many others to ensure the safe and efficient working of your machinery – reach out here!

Foundation repair of heavy machinery is a crucial aspect of maintaining the stability and longevity of industrial equipment. Whether it’s due to environmental factors, normal wear and tear, misalignment or faulty design, foundations can crack and shift over time, leading to costly damage and downtime. When it comes to filling cracks and voids in concrete foundations, choosing the right type of grout is crucial.

The most commonly used grouts for foundation repair are cement grout and epoxy grout. But what’s the difference between these two grouts? And which is the best option for foundation repair of heavy machinery?

Should Cement Grout Be Used For Repairing The Foundations Of Industrial Machinery?

Cement grout is often chosen for foundation repair because it is cheap and easy to work with. Depending on the formula used, it can be used in cold and hot temperatures. Because it has a different consistency to epoxy grout, it can flow further and reach smaller spaces and cracks. However, for foundation repair of heavy machinery, cement grout has several disadvantages.

For one, cement grout is porous, which means that it can absorb water and cause further damage to the foundation. This is particularly problematic in environments with high levels of humidity or moisture. Cement grout is also not as durable as epoxy grout and can crack and break over time. This can lead to further damage and instability.

Cement grout is not designed to resist continuous impact loading and the vibrations of heavy machinery. This can cause further damage to the machine and the concrete below. Chemical attacks can also cause severe damage to cement grout, particularly when exposed to substances like oil, salt, and acid.

What Are The Advantages Of Epoxy Grout For Industrial Machinery Foundation Repair?

Epoxy grout, on the other hand, is made of resin and hardener. It is more expensive than cement grout, but there are many benefits. Firstly, epoxy grout is non-porous and does not absorb water. This prevents future damage to the foundation. Secondly, its durability makes it more resistant to cracking and breaking, making it an ideal choice for heavy machinery foundation repair.

One of the biggest advantages of epoxy grout is its ability to bond strongly with concrete.

Unlike cement grout, which can become dislodged over time, epoxy grout forms a strong, permanent bond with the concrete. This is important for foundation repair of heavy machinery, as the equipment will put a lot of stress on the grout over time. This strong bond prevents the grout from cracking or breaking, ensuring that the foundation remains stable.

Another advantage of epoxy grout is that it is resistant to chemicals like oils, salts, and acids. This is particularly important for foundation repair of heavy machinery, as many industrial processes involve the use of chemicals that can cause damage to concrete foundations. Epoxy grout prevents further damage of concrete foundations that are exposed to such chemicals, making it a long-lasting and reliable option for heavy machinery foundation repair.

Conclusion

When it comes to foundation repair of heavy machinery, epoxy grout is the better option. Its non-porous nature, durability, strong bonding ability, and resistance to chemicals make it the ideal choice for filling cracks and voids in concrete foundations. While cement grout may be cheaper, easier to work with and epoxy grout doesn’t flow as easily as cement grout, it lacks the strength and durability. This is a basic requirement to support heavy machinery over the long term. Investing in epoxy grout for foundation repair can help prevent costly downtime and ensure that your equipment operates reliably and efficiently for years to come.

At Alphatec Engineering, we specialize in providing innovative and effective solutions for complex machinery foundation problems. With our advanced epoxy resin-based grouts and hydraulic leveling systems, we can restore damaged foundations and ensure reliable and efficient operation. If you’re looking for epoxy grout suppliers and heavy machinery foundation repair services, Alphatec-engineering can help you – reach out here!

As machines get older, they can experience a range of problems that can impact their stability and efficiency. One of the main issues that ageing machinery faces is a weakened foundation. Over time, the old foundation of a machine can become unstable due to factors such as wear and tear, changes in the environment, and increased loads. This can lead to a range of problems, from reduced efficiency to safety hazards.

Why is Stability in Machinery so Important?

Stability is crucial for the safe and efficient operation of machinery. An unstable and old foundation can cause the machine to vibrate excessively, which can lead to damage and premature wear and tear, resulting in more frequent maintenance and replacement costs. 

It can also cause parts to become misaligned or come loose, leading to breakdowns and unplanned downtime. Additionally, unstable machinery can be a safety hazard for operators and anyone else in the vicinity. Studies have shown that misalignment in heavy machinery can result in energy losses of up to 10%. 

On the other hand, properly aligned machinery can increase efficiency, reduce maintenance costs, and prolong the lifespan of machinery. For example, a study by the Department of Energy found that properly aligned pumps can reduce energy consumption by up to 7%.

What Problems Can Old Machinery Foundations Have?

Old machinery foundations can experience a range of problems, including 

• cracking
• settling
• shifting

These issues can be caused by a variety of factors, including changes in the soil or environment, exposure to moisture, and wear and tear from the machinery itself. Over time, these problems can lead to a weakened foundation that is unable to support the weight and vibration of the machinery.

What Techniques Can be Used to Stabilise Old Machinery Foundations?

There are several techniques that can be used to stabilise old machinery foundation. One technique for restoring stability to aging machinery is laser alignment. 

Laser alignment involves using a laser beam to measure and correct the alignment of machinery components. By aligning machinery components properly, businesses can improve the stability and performance of their equipment and reduce the risk of breakdowns.

Another technique for restoring stability to ageing machinery is vibration analysis. Vibration analysis involves using specialised equipment to measure the vibration levels of machinery components and identify any potential issues that may be affecting performance or stability. By detecting and addressing these issues early on, businesses can prevent further damage to their machinery and improve its reliability.

As machinery ages, it is not uncommon for the grouting and anchor bolts to wear out or become damaged. In some cases, replacing the grouting and anchor bolts may be necessary to restore stability to the machinery. This process involves removing the existing grouting and anchor bolts, preparing the surfaces, and installing new grouting and anchor bolts. It is important to ensure that the new grouting and anchor bolts are compatible with the machinery and that they are installed correctly to avoid further stability issues. In some cases, additional modifications may also be necessary to ensure the long-term stability of the machinery.

To see this type of work in action, check out the repair of a Sag Mill foundation here.

In addition to these techniques, regular maintenance and inspections are critical for identifying and addressing issues with ageing machinery. By performing routine maintenance and inspections, businesses can catch issues early on and take proactive steps to restore stability and prevent breakdowns.

How Alphatec Engineering Can Help

At Alphatec Engineering, we specialise in providing solutions for ageing machinery and infrastructure. We have years of experience working with a variety of industries, including oil and gas, manufacturing, and mining. Our team of experts can assess the specific needs of your machinery and develop a customised solution to restore stability and efficiency.

Contact us today to learn more about our services and how we can help you revitalise your old foundations.

I’m Giles Goldsbro, the technical director of Alphatec Engineering. Alphatec Engineering has a unique history that started in Japan in 1977. At that time, I had been working with construction epoxies for a few years while I was still at Exxon Chemicals. I realised that there was a thriving epoxy grout business in North America focused on natural gas engine compressors, but there was nothing like that in Asia. 

Giles Goldsbro, Technical Director, Alphatec Engineering

While exploring business opportunities in Asia, we discovered that the epoxy grout market was not yet established. But, we identified diesel engine driven generator sets as a potential alternative with similar challenges. We decided to venture into this market and quickly realised its potential for growth. Our experience in working with diesel engine driven generator sets led us to expand our focus to include other types of reciprocating and rotating machinery, as well as hydrogen compressors, among others.

Today, our expertise lies in pairing machinery with concrete, whether it be a concrete foundation or an industrial structure primarily made of reinforced concrete. This specialisation defines us, and we continue to offer customised products and services to meet the unique needs of each client.

 What Is Alphatec’s Main Activity?

 Alphatec Engineering is a company that specialises in resin and grout installations of machinery foundations, as well as the repair of machinery foundations. 

Our core expertise lies in the use of grout to effectively connect machinery to concrete foundations, whether it be a standard concrete foundation or a reinforced concrete industrial structure. Essentially, we address machinery problems by addressing the foundation they sit on.

Grout is a type of mortar that is specially formulated to provide a secure, stable, and durable connection between the machinery and the concrete. This is crucial because it ensures proper alignment of the machines, which in turn prevents vibration, excessive wear and tear, and other issues that can lead to premature failure of the machinery.

Aside from our grouting services, Alphatec Engineering also offers a range of other products and services. For example, we provide solutions for repairing cracks and other damages in concrete foundations, which can extend the lifespan of the machinery and prevent more severe issues from arising. Additionally, we offer specialised coatings that protect machinery from corrosion and other types of damage.

At Alphatec Engineering, we are dedicated to providing high-quality solutions for machinery foundation challenges, ensuring that our clients’ machinery operates optimally and reliably for long-term performance.

What Does Alphatec Engineering Specialise In?

Alphatec Engineering specialises in offering comprehensive solutions for machinery installation and repair. Our focus is on providing customised products and services that are tailored to meet the unique requirements of each client. With our expertise in this field, we have earned a reputation as a trusted partner for businesses across diverse industries, such as manufacturing, energy, and many others. We pride ourselves on delivering reliable and high-quality solutions that help our clients achieve optimal performance and efficiency for their machinery installations.  

What are Alphatec Engineering’s Star Products? 

In addition to providing solutions for machinery foundations, our product range is designed to provide effective and durable solutions for machinery installation and repair. And we have the expertise to tailor our products to meet the specific requirements and expectations of our clients. With our high-performance grouts and polymer systems, we ensure that machinery foundations are properly supported, repaired, and protected, helping our clients achieve optimal performance and longevity for their machinery installations. Our key products include: 

• ALPHATEC® 800, a high performance, aggregate-filled epoxy grout with superior mechanical and chemical properties. This grout material has been specifically formulated to support heavy machinery on concrete foundations, and when used correctly, will ensure the transfer of static and dynamic loads into the inertia block. 
• ALPHATEC® 110 is a three-component polymer grout system consisting of modified epoxy resin, chemical hardener, and blended aggregate. It is especially formulated for rapid curing. In the last few years, ALPHATEC® 110 has been used successfully in major refineries and petrochemical plants throughout Europe during winter shutdowns. 
• ALPHATEC® 342 is a two-component polymer grout injection system consisting of modified epoxy resin and chemical hardener. It is specially formulated for moisture and oil tolerance, and shows exceptionally good bond to wet, submersed, and oil-soaked concrete. It is widely used for the repair of water-soaked concrete foundations for presses, rolling mills, and rails, as well as for the repair of underwater or immersed structural concrete. It also performs well in the repair of all types of rotating machinery foundations, where oil contamination is inevitable. 

Would Alphatec like to collaborate?

 At Alphatec Engineering, we are committed to supporting the growth of green businesses and advancing sustainable technologies. We recognise the vital role that hydrogen and wind energy play in this effort, and we are actively seeking to expand our capabilities in these areas.

We are proud to provide specialised services and solutions to support the development and maintenance of renewable energy infrastructure. We believe that investing in these technologies is not only good for the environment, but also presents significant economic opportunities for our clients and partners.

Research and development are essential components of our business, and we are committed to staying at the forefront of innovation in our industry. To this end, we are interested in forging partnerships with universities and research institutions to enhance our capabilities and expand our knowledge base. 

In particular, we are seeking to build our research capabilities in areas such as fatigue resistance, where we recognize the need for more advanced testing techniques. By collaborating with academic partners, we hope to not only improve our own products and services, but also contribute to the broader advancement of our industry.

If you would like to find out more, collaborate or see if we have the right service or product for you, reach out here!