Methods for supporting equipment on a foundation
6.1. Installation of equipment on the foundation is carried out in the following way:
a) with alignment and fastening to permanent supporting elements and subsequent filling of the “equipment - foundation” gap with concrete mixture (Fig. 15, b);
b) with alignment on temporary support elements, filling of the gap “equipment - foundation” and with support when fastening the hardened material of the filling onto an array (without lining, Fig. 15, a).
rice. 15. Support elements for alignment and installation of equipment
and ¾ temporary; b ¾ constant; 1 ¾ release adjustment screws; 2 ¾ set nuts with disc springs; 3 ¾ inventory jacks; 4 ¾ lightweight metal pads; 5 ¾ bags of metal pads; 6 ¾ wedges; 7 ¾ support shoes; 8 ¾ rigid legs
In the first method of supporting equipment, the transfer of installation and operational loads to the foundation is carried out through permanent supporting elements, and the grout has an auxiliary, protective or structural purpose.
If it is necessary to adjust the position of the equipment during operation, topping may not be performed, which should be provided for in the installation instructions.
6.2. When installing equipment using packages of flat metal pads, support shoes, etc. as permanent supporting elements. the ratio of the total contact area of the supports A with the foundation surface and the total cross-sectional area of the bolts A sa must be at least 15.
6.3. When the equipment is supported on a concrete mortar, the operating loads from the equipment are transferred to the foundations directly through the mortar.
6.4. The design of the joints is indicated in the installation drawings or in the equipment installation instructions.
In the absence of special instructions in the instructions of the equipment manufacturer or in the foundation design, the design of the joint and the type of supporting elements are assigned by the installation organization.
Equipment alignment
6.5. Equipment alignment (installation in the design position relative to the given axes and marks) is carried out in stages with the achievement of the specified accuracy indicators in plan, and then in height and horizontality (verticality).
Deviations of installed equipment from the nominal position must not exceed the tolerances specified in the factory technical documentation and in the installation instructions for certain types of equipment.
6.6. Alignment of equipment in height is carried out in relation to working benchmarks or in relation to previously installed equipment, with which the equipment being adjusted is connected kinematically or technologically.
6.7. Alignment of equipment in plan (with pre-installed bolts) is carried out in two stages: first, the holes in the supporting parts of the equipment are aligned with the bolts (preliminary alignment), then the equipment is inserted into the design position relative to the axes of the foundations or relative to previously aligned equipment (final alignment).
6.8. The position of equipment during alignment is monitored using both generally accepted control and measuring instruments and optical-geodetic methods, as well as using special centering and other devices that ensure control of perpendicularity, parallelism and coaxiality.
6.9. Equipment alignment is carried out on temporary (alignment) or permanent (load-bearing) support elements.
The following are used as temporary (alignment) support elements when aligning equipment before adding concrete mixture: push-out adjusting screws; installation nuts with Belleville washers; inventory jacks; lightweight metal linings, etc.
During alignment, the following are used as permanent (load-bearing) support elements that work during the operation of the equipment: packages of flat metal pads; metal wedges; support shoes; rigid supports (concrete pads).
6.10. The choice of temporary (alignment) support elements and, accordingly, alignment technology is made by the installation organization, depending on the weight of individual equipment mounting blocks installed on the foundation, as well as based on economic indicators.
The number of supporting elements, as well as the number and location of bolts tightened during alignment, are selected from the conditions for ensuring reliable fastening of the aligned equipment during the period of its grouting.
6.11. Total area of support for the gulley (alignment) supporting elements A, m 2 , on the foundation is determined from the expression
A£6 n A sa + G× 15×10 -5 , (21)
Where n¾ number of foundation bolts tightened when aligning equipment; And sa ¾ calculated cross-sectional area of foundation bolts, m 2 ; G¾ weight of the equipment being verified, kN.
Total load capacity W, kN, temporary (alignment) support elements is determined by the relation
W ³ 1.3 G + n A sa s 0, (22)
Where s 0¾ pre-tightening voltage of foundation bolts, kPa.
6.12. Temporary support elements should be placed based on the convenience of alignment of the equipment, taking into account the elimination of possible deformation of the body parts of the equipment from their own weight and the pre-tightening forces of the bolt nuts.
6.13. Permanent (load-bearing) support elements should be placed as close as possible to the bolts. In this case, the supporting elements can be located either on one side or on both sides of the bolt.
6.14. The equipment must be secured in the correct position by tightening the bolt nuts in accordance with the recommendations of Section. 8 of this Manual.
6.15. The supporting surface of the equipment in the adjusted position must fit tightly to the support elements, the release adjusting screws ¾ to the support plates, and the permanent support elements ¾ to the surface of the foundation. The tightness of the adjacent metal parts should be checked with a 0.1 ml thick probe.
6.16. The technology for aligning equipment using adjusting screws, inventory jacks, adjusting nuts, as well as on rigid concrete pads and metal pads is given in the appendix. 7.
Gravy equipment
6.17. The filling of equipment should be carried out with a concrete mixture, cement-sand or special mortars after preliminary (for joint structures on temporary supports) or after final (for joint structures on permanent supports) tightening of the bolt nuts.
6.18. The thickness of the gravy layer under the equipment is allowed within 50-80 mm. If there are stiffening ribs on the supporting surface of the equipment, the gap is taken from the bottom of the ribs (Fig. 16).
Fig. 16. Scheme of gravy for equipment
1 ¾ foundation; 2 ¾ gravy; 3 ¾ supporting part of the equipment; 4 ¾ stiffening rib of the supporting part
6.19. The grout in plan should protrude beyond the supporting surface of the equipment by at least 100 mm. In this case, its height must be at least 30 mm greater than the height of the main layer of grout under the equipment and no more than the thickness of the equipment’s supporting flange.
6.20. The grout surface adjacent to the equipment must slope away from the equipment and must be protected with an oil-resistant coating.
6.21. The strength class of a loaf or mortar when resting equipment directly on the mortar should be taken one step higher than the class of foundation concrete.
6.22. Before grouting, the surface of the foundations should be cleaned of foreign objects, oils and dust. Immediately before gravy, the surface of the foundation is moistened, while preventing the accumulation of water in the recesses and pits.
6.23. It is not permitted to make gravy under the equipment at an ambient temperature below 5°C without heating the mixture being laid (electric heating, steaming, etc.).
6.24. Concrete mixture or mortar is fed through holes in the supporting part or on one side of the equipment being poured until, on the opposite side, the mixture or mortar reaches a level 30 mm higher than the height of the supporting surface of the equipment.
The mixture or solution should be supplied without interruption. The level of the mixture or solution on the supply side must exceed the level of the surface to be poured by at least 100 mm.
To fill the equipment, you can use pneumatic concrete pumps type S-862 or concrete pumps type SB-68.
6.25. It is recommended to supply concrete mixture or solution by vibration using a storage tray. The vibrator should not touch the supporting parts of the equipment. If the width of the poured space is more than 1200 mm, the installation of a storage tray is mandatory (Fig. 17).
Rice. 17. Refilling equipment using a storage tray
1 ¾ formwork; 2 ¾ supporting part of the equipment; 3 ¾ storage tray; 4 ¾ vibrator; 5 ¾ gravy mixture; 6 ¾ foundation
The length of the tray should be equal to the length of the space to be poured.
Leaning the tray on the equipment being poured is not allowed.
The level of the concrete mixture when pouring with a tray should be approximately 300 mm above the supporting surface of the equipment and maintained constant.
6.26. The surface of the grout must be systematically moistened within three days after completion of the work, sprinkled with sawdust or covered with burlap.
6.27. When using concrete grout, the size of the coarse aggregate should be no more than 20 mm.
6.28. The selection of concrete composition is carried out in accordance with current regulatory documents. The slump of the concrete mixture cone must be at least 6 cm. To improve the properties of the concrete mixture (reduce shrinkage, increase mobility), it is recommended to add the SDB additive in an amount of 0.2 - 0.3% of the cement mass. When introducing SDB, the consumption of cement and water is approximately reduced by 8-10% while maintaining the calculated value of the water-cement ratio. Sand concrete can be used as a gravy.
6.29. To protect the grout from corrosion in aggressive environments, coatings should be used in accordance with the requirements of SNiP chapter 2.03.11.
Technological equipment is installed and verified by aligning the machine axes with the mounting axes fixed to the foundations for the equipment. The equipment can be installed directly on the foundation without mortar or with mortar, on pads followed by mortar, on metal plates or frames installed and aligned on the foundation using pads secured with foundation bolts and filled with cement mortar. In this case, the dimensions specified by the project between the trajectory of movement of the processed product and the floor level of the workshop must be maintained, for which purpose main longitudinal And transverse axles of machines and tie them to longitudinal And transverse axes of building columns workshops When calibrating process equipment, use basic machine parts.
Basic parts are large, supporting parts of machines (beds, plates, frames, housings), located primarily directly on foundations or other bases (metal structures). The basic parts are installed in the design position, aligned in three coordinates: two mutually perpendicular axes in plan and height. In each unit, two main axes are fixed - longitudinal the entire unit and transverse axis. TO auxiliary axes include the transverse axes of each machine, and in large machines, in addition, the axes of the machine drives.
The position of the basic parts in plan is checked in kind using reference axes made in the form of strings stretched along
* The smaller number refers to heavy materials (sheet steel, beams, channels), the larger number refers to lightweight materials (cardboard, rubber, paints, lubricants)
mounting axes of the unit. The position of the base parts in the vertical plane is adjusted using shoes with wedge jacks located between the supporting planes of the base parts and the surface of the foundation, followed by the placement of metal pads.
Mostly flat rectangular pads are used, less often wedge pads with a slope of 1:20 are used. According to their purpose, linings are divided into installation And adjusting. The first includes linings with a thickness of 5-100 mm, and the second - with a thickness of 0.5-5 mm. Shims are installed on each side of the foundation bolt at the closest possible distance from it (50-100 mm), ensuring their tight fit to the foundation concrete.
The lower support pads are selected depending on the diameter and tightening of the foundation bolts and the weight of the machine. Intermediate pads, necessary to ensure the required height of the machines, take up an area of 30-40% less than the support ones. Experiments have established that the grout, after hardening the concrete, also takes on an external load.
The pads in the bags must be tightly assembled (tacked by welding) and when the bolts are tightened, they must not move when hit with a hammer.
When installing machines using wedges, which make it possible to quickly adjust their alignment in height and in the horizontal plane, the wedges are secured by welding after final alignment (Fig. 3.1, a).
They pour on shoes with wedge jacks (Fig. 3.1, b), on screws resting on hammer-shaped heads (Fig. 3.1, V), Or on linings (Fig. 3.1, d).
High-speed machines are installed on monolithic linings, made from temporary linings with an accuracy of 0.05 mm, and securely fastened.
After aligning the coordinates in plan, the base parts are adjusted in height, leaving an allowance of 1-2 mm for the shrinkage of the pad package, the foundation bolts are pre-tightened, a secondary check is carried out, including a check for horizontality using a control ruler and level, and the foundation bolts are finally tightened. The quality of tightening is determined using a feeler gauge 0.05 mm thick, which should not extend to a depth of more than 5 mm into the joints between the nut and washer and between the washer and the base part, and in special cases, the elongation of the bolt is measured.
The part is poured on one side with concrete mortar using quick-setting cement, grade no lower than 150, without interruption, no later than 48 hours after installing the part. Installation is interrupted until the concrete sets (usually 72 hours).
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Equipment installed on the foundation is verified in two planes - horizontal and vertical. The purpose of horizontal alignment is to install the equipment so that the main axes of the equipment coincide with the main axes transferred from the project to the foundation. To do this, strings are pulled along the marks corresponding to the main alignment axes of the foundation. By lowering plumb lines from certain points of the string to points located on the axes of the equipment, the axes of the foundation and the unit coincide.
The deviation of the main axes of the foundation and equipment should not exceed 30 mm. Having installed the equipment in the horizontal plane according to the design, install and hang the anchor bolts on the nuts, then check the position of the equipment in the vertical plane. The purpose of vertical alignment is to install the equipment strictly horizontally, without changing its position relative to the main axes of the foundation.
Alignment in the vertical plane is performed:
on special jacks (Fig. 4.1, A), installed on the foundation; after the cement mortar has hardened, they are removed;
on leveling (adjusting) built-in bolts 1 (Fig. 4.1, b), supported by the lower, rounded end on a metal lining 2; after the cement mortar has hardened, they are lowered;
on special wedge linings 1 (Fig. 4.1, c), made of steel, with a slope from 1: 30 to 1: 40 so that at any
Rice. 4.1. Schemes for alignment of equipment on the foundation in the vertical plane.
the amount of wedging maintained the parallelism of the surfaces in contact with the foundation and frame of the unit; the surface of the wedges is carefully processed to ensure their good adhesion;
on plane-parallel metal supports 1 (Fig. 4.1, G), of different thicknesses so that you can choose the required height. The horizontalness of the equipment is checked using levels "(spirit levels), in which a division value of 1° corresponds to a slope of 0.1 Mmm. The mechanic's level is made with a fixed working ampoule and an adjustable ampoule.
A frame level is also used (Fig. 4.2), which allows you to simultaneously measure the horizontal and vertical positions of the two surfaces being tested. A special feature of the frame level is the presence of two working ampoules. Characteristics of the levels are given in table. 4.1.
The hydrostatic level (Fig. 4.3) allows you to measure the altitude position of points located far away (up to 150 m) one from the other, and obtain high alignment accuracy (up to ±0.01 mm).
Installation of compressor stations equipped with aviation
Gas turbines.
Block gas pumping units with drive power of 6300 and 16000 kW from aviation gas turbines GPA-Ts-6.3 and GPA-Ts-16, respectively
They are supplied from factories in the form of separate blocks, connected into a single unit at the installation site. Each block is placed in an individual transportable block container. The GPA-Ts-16 unit includes: a turbo unit unit, an oil unit unit, an exhaust shaft support, an automation unit, a ventilation unit, a suction chamber unit, an exhaust shaft unit, an oil cooler unit, including a suction chamber, sound absorbers, a diffuser, an air cleaning device, total weight 140t.
Installation of the gas pumping unit blocks is carried out in the following sequence. First, they install it on the foundation, check and pre-fix the turbine unit block, which is taken as the base one and to which the remaining mounting blocks are centered. Then the suction chamber block with the automation container is installed. The exhaust shaft mounting block is installed on the upper supporting surface of the turbine unit. Then the oil cooler block is installed on the foundation and centered to it. . The last thing to install is the air purification device unit. . This block is preliminarily enlarged from two blocks - noise suppressors and filters and elements of the service area .
Installation of the main (basic) block of the turbine unit is carried out using crawler or pneumatic wheeled cranes or pipe-laying cranes. Local lifting of the turbine unit during alignment is carried out using a rack jack, and checking the horizontal position is carried out using a plumber's level. The tightness of the pads in the set is checked using a feeler gauge.
In the turbine unit, the rotors of the drive power turbine and the supercharger are finally centered at the factory, and the turbine unit itself is rigidly fixed to a steel-concrete slab. In this regard, when installing a turbine unit, only the alignment of the rotors of the drive power turbine and the supercharger, connected by a gear coupling, is checked. The remaining blocks are installed and secured on the turbine unit block and the suction chamber block with the automation container. The blocks are connected through bolted gaskets. All blocks are installed using a truck crane from one parking lot. The blocks are joined with the installation of coupling bolts. A sealing gasket is placed between the supporting surfaces, and then the bolts are tightened. Deviation is allowed no more than 10 mm. Integrated assembly is carried out on a specially designated site. The installation of the block gas pumping unit is completed by installing the suction and discharge pipes of the centrifugal blower. The installation of the pipes is carried out immediately before the installation of the supercharger piping begins.
Alignment is aimed at correcting the location of various components in the equipment - mechanisms, parts. It is necessary that all these parts meet certain standards. There is a certain reconciliation algorithm. First of all, a geodetic support network is created and control is carried out over it. Next, the performance is monitored and the equipment under study is photographed along with the created network. This is necessary in order to determine whether the technology and its elements comply with the geometric parameters. After the control is completed, geodetic documentation is compiled and diagrams are developed.
In order for all measurements to be carried out accurately and efficiently, they must be carried out with appropriate equipment. Also, a lot depends on the qualifications of the specialists performing geodetic reconciliation. To get the right results, contact Guild Engineering. Here you will be fulfilled reconciliation of process equipment both at the installation stage and during repair and dismantling work on devices. The foundation for this equipment will also be analyzed for its correctness, strength and geometric compliance.
Geodesy supports the installation and dismantling of equipment at industrial sites. And do not underestimate geodetic research, since unprofessional alignment of process equipment can further affect the implementation of the industrial process. Executive geodetic survey allows you to control the quality of work, as well as the condition of the equipment. Such a survey allows you to detect all deformations in time, as well as take all necessary measures to prevent them.
During geodetic reconciliation, the following processes are carried out:
- work on the creation and control of a geodetic reference network;
- work aimed at monitoring the quality of operation of technological equipment. The compliance of the geometric parameters of the equipment, as well as its individual elements, is monitored;
- desk work, which is carried out on the basis of data obtained during measurements. Such work includes the preparation and maintenance of executive documentation.
When carrying out geodetic alignment of technological equipment, with the subsequent preparation of a report and recommendations for bringing it into the design position (turning and moving the support rollers to ensure the straightness of the furnace axis), surveyors of the Guild Engineering company use specialized equipment that allows you to obtain the most accurate data in a short time .
Equipment alignment (installation in the design position) is carried out in terms of height in plan and horizontally. Deviations of installed equipment from the design position must not exceed the tolerances specified in the factory technical documentation and in the installation instructions for certain types of equipment.
Alignment in height is carried out either relative to working benchmarks, or relative to previously installed equipment, with which the equipment being calibrated will be connected kinematically or technologically.
Alignment in plan (with pre-installed bolts) is carried out in two stages: first, the holes in the supporting parts of the equipment are aligned with the bolts (preliminary alignment), then the equipment is brought into the design position relative to the axes of the foundation or relative to the previously aligned equipment (final alignment).
Rice. 92. Temporary (a - d) and permanent (e - h) support elements for alignment and installation of equipment: 1 - release adjusting screws, 2 - lock nut, 3 - foundation bolt, 4 - supporting part of the equipment, 5 - foundation, 6 - support plate, 7 - fastening nut, 8 - disk washer, 9 - mounting bolt, 10 - lightweight metal pads, - stock jacks, 12 - packages of metal pads, 13 - wedges, 14 - rigid supports, 15 - support shoes
During alignment, the position of the equipment is controlled using control and measuring instruments and optical-geodetic methods, as well as with the help of special centering and other devices that ensure control of perpendicularity, parallelism and coaxiality. The equipment is verified on temporary (alignment) or permanent (load-bearing) support elements, depending on the type of joint and the alignment method. Supporting elements are installed between the foundation and the supporting part of the frame.
As temporary support elements (Fig. 92, a-d) when aligning equipment before filling it with concrete mixture, use, for example, push-out adjusting screws 1, adjusting nuts 9 with disc washers 8, inventory jacks 11, lightweight metal pads 10. Permanent support elements elements (Fig. 92, e-h) (packages of metal pads 12, wedges 13, support shoes 15, rigid supports - concrete pads 14) also work during the operation of the equipment.
The choice of the type of temporary (alignment) support elements and, accordingly, the alignment technology depend on the mass of individual equipment mounting blocks installed on the foundation, as well as on economic indicators. The number of temporary support elements, as well as the number and location of bolts tightened during alignment, must ensure reliable fastening of the aligned equipment before it is grouted.
The support area S of temporary (alignment) support elements on the foundation is determined by the formula S≥6nF+0.015G, where n is the number of foundation bolts tightened when aligning the equipment; F is the estimated cross-sectional area of the foundation bolts, m2; G is the mass of the equipment being verified, kg.
Temporary support elements are positioned so that it is convenient to align the equipment and eliminate the possibility of deformation of the body parts of the equipment under the influence of its own weight and pre-tightening forces of the bolt nuts.
Permanent (load-bearing) support elements are placed on one side or both sides of the bolt (as close to the bolts as possible).
Secure the equipment in the correct position by tightening the bolt nuts to the amount of pre-tightening force specified in the technical specifications for installation of the equipment.
The supporting surface of the equipment in the adjusted position must fit tightly to the support elements, the release adjusting screws - to the support plates, and the permanent support elements - to the surface of the foundation. The tightness of the fit is checked with a feeler gauge 0.1 mm thick.
The maximum torque when final tightening the bolts should not exceed the following values:
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Bolt thread diameter |
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Permissible maximum torque when tightening structural bolts, Nm |
The tool for tightening foundation bolts is indicated in the work plan. For example, design bolts with threads with a diameter greater than M64, as a rule, are tightened with special hydraulic wrenches with force control using a pressure gauge. The bolts are tightened evenly in a checkerboard pattern symmetrically relative to the axes of the equipment. Structural bolts are tightened in two rounds, design bolts - in at least three.
When installing equipment without a backing (for joints of type 2), preliminary and final tightening of the bolts is carried out in two stages. The bolts are finally tightened when the strength of the grout reaches at least 70% of the design value.
When operating equipment with significant dynamic loads, the bolt nuts are protected from self-unscrewing by locking (which should be indicated in the design), locknuts, spring or lock washers with tabs.
After completing the commissioning cycle and testing the equipment, the bolt nuts are tightened to the design tightening force. The tightening force is controlled by the magnitude of the torque, by the movement or lengthening of the bolt, the angle of rotation of the nut, or the pressure in the hydraulic system of special hydraulic tongs.
The torque applied to the nut of a structural bolt depends on the type and nature of the equipment.