Recycle Gas Compressor: Foundation Repair and More

Alphatec Engineering was engaged by Couronnaise de Raffinage in Rouen, France, to repair the foundation of a Burton Corblin gas compressor.

This 164 ME 250 single-cylinder compressor, driven by a 45 kW electric motor at 500 rpm and installed in 1977, was affected by improper grouting, leading to oil leakage, weakened concrete and deformed anchor bolts.

Features

Client

Couronnaise de Raffinage

Final user

Shell Petit Couronne Refinery

Project

Foundation Repair, Anchor Bolts Replacement, Redesign of Crosshead Support Base, Regrout

Equipment

Burton Corblin Gas Compressor, 164 ME 250 Single Cylinder

Work period

11–21 July 2005

Location

Petit Couronne, Rouen, France

01 Identified Challenges

The initial installation suffered from flawed grouting practices. Lubricating oil infiltrated the gaps between the anchor bolts and the grout, and the concrete under the crankcase had lost its compressive strength.

Inadequate anchorage, including shimming with thick steel plates resting on compromised concrete, resulted in vibrations that ultimately led to a sheared crankcase bolt and severe cracking of both the crankcase and crosshead casing.

02 The Strategy

Alphatec Engineering’s solution focused on three main areas:

Repairing the foundation by removing damaged grout and concrete.
Replacing the faulty anchor bolts with Grade 8.8 fully threaded rod, ensuring a proper grouted embedment.
Redesigning the crosshead support base by installing a new soleplate to facilitate future maintenance.

The process involved a careful dismantling of the compressor from its foundation, followed by extensive cleanup and repair of the structural substrate before reassembly.

03 The Repair

The compressor was disconnected from the motor and lifted from the foundation to allow access for the removal of the compromised grout. With accurate dimensional assessments, new holes were drilled for the replacement anchor bolts, and the existing oil-soaked concrete was chipped away.

New Grade 8.8 bolts were installed, with the upper portions isolated to allow for an adequate stretch length. The entire assembly—including the crosshead support, soleplates, and motor bases—was regrouted using ALPHATEC® 800 Epoxy Grout.

After curing overnight, the bolts were tightened to 50% of their yield strength, and the foundation’s top surface was capped with epoxy grout to prevent future oil ingress.

04 Conclusion

The complete remediation turned a precarious setup into a secure and well-aligned installation. The new soleplate and carefully regrouted anchor bolts, coupled with the protective epoxy cap, not only restored the foundation’s integrity but also prepared the compressor for enhanced, reliable performance.