Restoring Grout on CMD Gearbox, Auxiliary and GE Induction Motor

In Autumn 2015, Alphatec Engineering partnered with Votorantim Cimento in Temara, Morocco, to restore the grout on a CMD gearbox, auxiliary unit, and GE induction motor in a critical clinker crusher system.

This project was crucial for ensuring smooth and reliable cement production by addressing misalignment and vibration issues.

Features

Client

Votorantim Cimento

Final user

Asment Temara Plant

Project

Injection Foundation Repairs, Regrout & Realignment, Polyssius Mill Drive Train

Equipment

CMD Jumborex JC30SP 4000 HP @ 985 RPM, GE Induction Motor, Auxiliary turning gear box

Work period

30 Sep – 14 Oct 2015

Location

Temara, Morocco

01 Challenges and Objectives

Misaligned installation

The initial installation, post-2007 gearbox replacement, revealed that the baseplate was not level or correctly positioned.

Vibration issues

Faulty grouting led to excessive vibrations, impacting the efficiency of the Polysius mill drive train and the GE induction motor.

Foundation integrity

The presence of cold joints and cracks in the foundation reduced load distribution and permitted oil intrusion, further compromising the overall stability.

02 Technical Approach and Execution

Our team began by carefully removing the faulty gearbox with hydraulic jacks and guided it along specially installed rails to gain access to the problem areas.

Three 3.5-meter injection holes were drilled around the foundation, allowing for the effective injection of Alphatec® 342 epoxy resin. This resin sealed cracks and cold joints over a one-meter radius, preventing oil penetration and creating a homogenous, structurally sound foundation.

Subsequently, Alphatec® 800 epoxy grout was applied to re-establish a secure base for the equipment. Utilising Alphapads® for fine levelling and laser alignment, the gearbox, auxiliary unit, and GE induction motor were then accurately reinstalled, ensuring optimal performance and reduced vibrations.

The application of a specially formulated green epoxy grout, with enhanced flow and edge filleting, further ensured uniform load distribution and minimised stress concentrations.

03 Results and Impact

The meticulous regrouting and realignment restored stability to the entire system, significantly reducing vibration levels and thereby extending the service life of the equipment.

With the foundation now acting as a unified whole, the clinker crusher system resumed smooth operation, ensuring consistent production and improved operational efficiency, a testament to the effectiveness of our high-performance epoxy grout solutions.