Epoxy Grouting Four New IHI BOG Compressors

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Alphatec was brought in by Premonor S.A. to install epoxy grout for four brand-new BOG compressors at Fluxys facilities. Fluxys is a Belgium-based company, mainly acting as a natural gas transmission system operator. The project required epoxy grouting for the four compressors, with a capacity of 12600 kg/h each plus the frames and their motors.

 

The Problem and Solution

 

The mechanical assembly of four BOG compressors required precise alignment and surface preparation for grouting. 

 

To address these challenges, we supplied and installed Alphatec®800 epoxy grout for the compressors and followed a step-by-step plan that included isolating each anchor bolt with PE foam and sealing the formwork with epoxy putty to prevent leaks during the pour process.





Features

Client
Premonor S.A.
Final user
Fluxys, LNG Gas Terminal
EPC
UTE F.D.B Zeebrugge Felguera IHI-Balzola
Project
Grouting BOG Compressors, New Installation, Fifth Tank Expansion Project
Equipment
4 x BOG IHI Compressors: Model 32HF-4N-CM
Work period
June 2017
Location
Zeebrugge, Belgium

The Procedure

 

Once the surface preparation was completed using a blower and vacuum to remove debris and dust, and the mechanics installed & adjusted the compressors and the motors, we set up formwork for each frame. We then installed and aligned the compressors and their frames accurately, following the manufacturer’s instructions. The alignment process involved ensuring the compressor base and the motor were level and in line with the compressor.

After the compressors were installed and aligned, we began isolating each anchor bolt with PE foam to prevent contact with the grout. We then sealed the formwork with epoxy putty to prevent leaks during the pour process.

Next, we poured the Alphatec®800 epoxy grout through one point to avoid the formation of cavities under the bed. It was crucial the grout was poured carefully to ensure that there were no air pockets, as this could compromise the structural integrity of the compressor.

After pouring the grout, we allowed it to cure for 24 hours until it reached its maximum strength of 100 MPa of compressive strength. During the curing process, it was essential to maintain a consistent temperature and humidity level to ensure proper curing of the grout.

After the grout had cured, we inspected the grouted area for confirmation of product application. A second top layer of 25-30mm of Alphatec®800 was then poured to cover all exposed concrete, acting as a protective coat and oil barrier.

Finally, we ensured that all grouted areas were finished, avoiding sharp edges and a levelled seal between the concrete-epoxy grout layers. This process involved removing any excess grout and ensuring that the surface was smooth and even.

In conclusion, by following this step-by-step process, we were able to supply and install Alphatec®800 epoxy grout for the four BOG compressors at Fluxys facilities, ensuring precise alignment and surface preparation for grouting, and ensuring the structural integrity of the compressors.

 

Conclusion

 

At Alphatec Engineering, we understand the importance of having a strong and reliable foundation for your machinery. That’s why we provided Premonor S.A. with our top-of-the-line ALPHATEC® 800 epoxy grout for the mechanical assembly of their four BOG Compressors. Our team of experts meticulously prepared the concrete surfaces, secured the anchor bolts, and poured the grout with precision to ensure maximum stability and protection against unwanted vibrations.

Our commitment to using high-quality products and attention to detail sets us apart from the competition. We prioritise the long-term performance and durability of your machinery, ensuring that your investment is protected. When you choose Alphatec Engineering, you can trust that you’re receiving the best foundation services in the industry. Contact us today to learn more about how we can help you with your machinery installation needs.