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The Aromatic Hydrocarbon Unit ELLIOTT Machinery Installation INTRODUCTION Proper installation of the machinery will contribute to long trouble-free operating life with minimum maintenance. To aid in making a proper installation, this chapter describes a detailed procedure that has proven successful for installing hundreds of turbines and associated equipment. Therefore, it is the method recommended by Elliott Company. Other procedures do exist which can provide a satisfactory installation; however, prior to using any of these alternate procedures, it is recommended that the purchaser carefully investigate both the procedure and the ability of workers to produce a permanent and satisfactory installation. Elliott Service Representatives are experienced in installation procedures and can assist in providing a good installation. The installation procedure contained in this chapter is as specific as possible but cannot possibly cover all variations in field conditions. Therefore, the Elliott Service Representative may sometimes deviate slightly from the published procedures. This is done to give a better installation by using procedures to fit specific field and service conditions. Regardless of the procedure used, first class materials and quality workmanship should be employed. The procedure recommended by Elliott involves the following items: 1. Foundation 2. Chock blocks 3. Grouting 4. Setting the equipment on foundation 5. Shaft alignment 6. Coupling Installation 7. Piping Recommendations Included in this chapter is a detailed procedure for making “cold alignment” as well as methods for making machine “hot alignment” checks. While many aspects of an installation are the responsibility of the purchaser or his engineer, some suggestions are offered which may contribute to suitable installation. One such example is whether to install the machine outdoors under only a roof, or in a completely enclosed building. While this class of equipment can generally be installed outdoors, local conditions may suggest alternate arrangements. Freezing or low ambient temperatures around machinery can create difficulties during start-ups and shutdowns; for example, lubricating oil must be warm before starting equipment. Water and steam equipment must be drained completely or heated during shutdown. Alternately, in tropical areas, direct sun on one side of the foundation might cause expansions which, when coupled with other factors in the system, could create unacceptable alignment. In addition to operating considerations, maintenance and equipment inspections will be required-sometimes scheduled and occasionally unscheduled. Regardless of which, weather conditions may not always cooperate. Rain , snow, wind and low or high temperatures generally extend maintenance and inspection when workers are exposed directly to these elements. In addition, quality of workmanship may be lowered to a point where work accomplished is futile. For inspection and maintenance, a permanent overhead crane or hoist is recommended. Casing top halves and rotors have close clearances which must be protected, therefore, moves must be slow and positive. This is seldom achievable with crawler or wheel mounted cranes cranes. Installation of the machinery may be on either steel soleplates, a non-self-supporting fabricated steel baseplate, or a self-supporting fabricated baseplate. The functional purpose of all these intermediate supports is to provide a permanent mounting plate for the machine feet which can be shimmed. The difference between steel soleplates and non-self-supporting fabricated steel baseplate is related only to ease of installation. When the foundation support cannot be continuous or mounting directly on columns is desired, a self-supporting fabricated steel baseplate must be designed that will minimize deflections between contact supports. Soleplates usually provide support for only one machine support foot while a baseplate usually supports all machine feet. In most cases, a baseplate is made to support both the driver and driven equipment. Some baseplates are also designed to contain or support lubrication and seal system piping and instrumentation in addition to the machinery. Baseplates with the lubrication system built in may require less space and have lower installation cost, but are generally more difficult to maintain. Baseplates usually reduce the installation time because less time is spent leveling the many pads and locating equipment and accessories. Thus, while initial cost may be higher, the installed cost usually will be less. Baseplates are generally fabricated from box-shaped structural steel; therefore, providing additional surfaces for noise generation or reverberation. Installations of a self-supporting baseplate on a reinforced concrete foundation should follow the guidelines presented with only the sections indicated on the outline drawing left unsupported. When the installation of a self-supporting baseplate is on structural steel or columns, care must be exercised to insure that the mating pads are machined level and flat. Full contacts between the pads are desired without the use of step shimming. With this installation arrangement, grouting is not used to fill in gaps, but other procedures presented in this chapter should be followed. FOUNDATION The principle function of the foundation is to provide a permanently rigid, non-warping support for the machinery. Proper fulfillment will, (1) hold machines in proper alignment under all operating conditions, (2) support the machine’s weight and load, and distribute it uniformly and evenly to the soil or main support structure, (3) maintain established equipment locations, and (4) , minimize transmission of vibration to or from the machines. While the responsibility for a successful foundation rests with the purchaser,the following suggestions are offered for assistance and consideration: 1. The outline drawing provides equipment mounting surface areas, anchor bolt locations, equipment weight distribution, main piping connections, and other information necessary in designing a foundation. 2. A foundation of reinforced concrete should be of ample size and proportion for adequate support of the machinery, as well as piping forces such as inlet and discharge piping. 3. Provision should be made in the foundation design for accessibility to all parts of the machine or its auxiliaries during operation, inspection and maintenance. 4. The foundation should rest entirely on natural rock or entirely on solid earth. A foundation resting partly on one or partly on another may warp due to settling of part of the foundation support. Distortion may also occur due to unequal pressures created by differences in ground water level. 5. Foundations supported on pilings should have a rigid continuous cap over the pilings on which the foundation rests. 6. Temperature surrounding the foundation should be uniform. Temperature differences between the top slab and mat, for instance, can create substantial bending stresses in columns. Care must be taken to reduce thermal distortion from radiation or uneven heating and cooling. Direct sunlight on outdoor tropical installations is to be avoided. Steam lines passing close to the foundation should also be avoided; but when unavoidable, they should be insulated and the foundation shielded. 7. Foundation should be isolated from all other structures and arranged so that outside vibrations are not transmitted to it. Where foundations must be supported by floor beams, a vibration dampening material should be interposed between the beams and the foundation. 8. Design of foundation structure should avoid resonant frequencies of operating speed, 40 to 50% of operating speed, rotor critical speeds, and two times operating speeds. 9. It is recommended that concrete foundations be allowed to cure for approximately 28 days before loading. This will allow for development of strength and reduction in shrinkage rate. Curing procedure should be in accordance with American Concrete Institute recommendations. 10. Use of a pipe sleeve around anchor bolt allows for some shifting of the anchor bolt if found necessary during installation of equipment. It allows for increased stretch length of anchor bolts. 11. When establishing the top elevation for the foundation, allow approximately 0.5 inch (12㎜) for removal of top crust of concrete by chipping. Reinforcing rods, ties, or steel members should be sufficiently below the surface to permit chipping away of approximately 1.00 inch (25 ㎜) of concrete without making contact. A minimum space of 1.00 inch (25 ㎜) should be provided between foundation and chock block to provide adequate room for insertion of grout. The maximum distance between the foundation and soleplate or baseplate should not exceed 4.00 inches (100㎜). Foundation preparation When the foundation is constructed of reinforced concrete, it is not practical to pour the concrete block with the necessary precision to permit setting the machinery directly onto the block. Therefore, the soleplate or baseplate is set with a void between it and the foundation. After the soleplate or baseplate is positioned, machinery placed and cold alignment check made, the soleplate or baseplate is cemented or grouted to the foundation. This procedure essentially creates one continuous support for the machinery. In order to obtain good bonding surfaces for the grout, all defective concrete, laitance, dirt, oil, wax, grease and loose material must be removed from the mating surfaces. This can best be accomplished by chipping, bush hammering or by other means until sound, clean surfaces are obtained. Removal of approximately 0.5 inch (12㎜) of the top concrete surface should provide a strong, laitance-free surface for bonding and anchoring of the grout. CHOCK BLOCKS In this manual, the term “chock block” is used to describe steel or grout blocks which serve to level and support the soleplate or baseplate prior to full grouting. The size of a steel chock block may vary. To provide for ease of installation and leveling, four jack screws are furnished in the chock block. A screw anchor in the center of the block is used to anchor the chock block securely until grouting in of the blocks. Chock Block 1. Material carbon steel plate 2. Machine both top and bottom flat 3. Break all corners and chamfer all holes Epoxy grout chock blocks can also be used in place of steel chock blocks. When using epoxy grout chock blocks, small forms should be positioned at each anchor bolt just as suggested for steel chock blocks. The top surface of each from should be level and at essentially the same elevation as all other chock block forms. Forms should be anchored, coated with wax and sealed around the bottom. When pouring grout, forms should be completely filled. This will minimize need for shimming between chock and baseplate or soleplate. Use of chock blocks allows the installation workmen to easily make a change in elevation at a soleplate or baseplate support pad. The chock blocks also distribute the machinery weight and hold down nut force so that deflections of the soleplate or baseplate due to these forces are minimized. With chock blocks, the soleplate or baseplate can be easily shifted horizontally without disturbing established elevations. For machines mounted on soleplates, the number of foundation anchor bolts increases while available surface area decreases, therefore making effective placement of chock blocks more difficult. If the chock blocks have been coated with a catalyzed epoxy primer, the surface coating should not be removed but surfaces should be cleaned with solvent with solvent to remove any oil or dirt prior to setting. If the chock clock surfaces are coated with rust or some other surface coating, they should be sandblasted. Sandblasting is best, but a disk grinder or other mechanical method can be used. If chock blocks will be immediately grouted after setting, no further surface treatment is required. A clean, sandblasted surface will provide a good bonding surface. If grouting in of the chock blocks will be delayed after cleaning, the cleaned surfaces should be coated with an epoxy primer or surface coating recommended by grout supplier. To set a chock block, determine the chock block anchor screw locations on the foundation and drill 0.5 inch (12㎜) diameter by 1.00 inch (25㎜) deep holes (if screw anchor shield is other than that shown, appropriate drilling should be used) in the concrete. Level the individual blocks using the four set screws provided. All blocks must be level and approximately at the same elevation. It is desirable to maintain all chock block elevations within a few thousandths of an inch or a few hundredths of a millimeter. This makes final installation and shimming of the equipment much easier. On installations where overall length of the equipment is short, elevation of the chock blocks can best be set by use of a straight edge and precision level. On installations where the overall length of the equipment is large, use of a precision tilting level may be advantageous. Regardless of the method used, shimming should be used between the chock blocks and soleplate or baseplate to correct any elevation variations required. GROUTING The procedure to be followed for grouting in of chock blocks, soleplates or baseplates is the same except for quantity of grout placed. Elliott recommends that the grout used be a good quality epoxy grout system from a reliable manufacturer of heavy machinery grouts. Epoxy grouts consist of an epoxy resin, hardner and graded silica aggregate. The resin and hardner serve as the adhesive while the aggregate serves as a filler to reduce cost, improve thermal expansion compatability absorb heat released by curing. With proper application, an epoxy grout should provide a permanent, reliable installation. Use of sand-cement grout or sand-cement grout with various additives may also provide an adequate installation, however they are generally lower in strength, have more tendency to shrink unevenly and are generally more susceptible to chemical attack and deterioration by oils. The prime purpose of grouting is to, (1) fill all voids between the foundation and the soleplate or baseplate, (2) provide a permanent bone between the foundation and the soleplate or baseplate, (3) to assist the foundation anchor bolts in preventing lateral movement, (4) provide a solid, level base to which the machine can be anchored by the foundation anchor bolts to prevent vertical movement, (5) make the soleplate or baseplate more or less an integral part of the concrete foundation. As anchor bolts are designed for hold down purposes, it is desirable to provide for some stretching of the anchor bolt between the bottoms of the sleeve and the bottom of the nut. Therefore, it is recommended that the sleeve be filled with a pliable material such as silicone rubber, prior to final grouting. Use of epoxy grouts requires some installation procedures which differ from those used for sand-cement grouts. The procedure which follows provides a general guide for use with epoxy grout; but for more specific details, consults the grout supplier’s bulletins or labels. This is particularly important in regard to safety precautions. Keywords: Foundation; Chock Blocks; Grouting; Coupling; Piping Recommendation 10 芳烴裝置 Elliott機械設(shè)備的安裝 引言： 正確安裝機械設(shè)備能延長設(shè)備無故障運行的壽命和極大的減小維修次數(shù)。為了幫助進行適當?shù)陌惭b，此章詳細敘述了安裝程序，此安裝程序已完成過數(shù)百次安裝透平機及其輔助設(shè)備。因此Elliott公司推薦這種安裝程序及方法。也缺有能使安裝得到滿意效果的其他安裝程序。因此在使用別的程序之前，建議買方要對程序和工人的技術(shù)水平進行調(diào)查研究以得到經(jīng)久耐用和滿意的安裝結(jié)果。 Elliott安裝服務(wù)代表在安裝程序方面是有經(jīng)驗的能幫助提供良好的安裝程序。此章盡可能的規(guī)定了安裝程序但不可能包括各種現(xiàn)場條件的變化，因此Elliott服務(wù)有時可以對此安裝程序稍加改變。這樣做是為了在特定的安裝現(xiàn)場和工作條件下更好的安裝。無論程序怎樣但必須首先保證一流的材料和工作質(zhì)量。 Elliott公司推薦的安裝程序包括下列項目： 1. 地基 2. 止動塊 3. 灌漿 4. 把設(shè)備安裝在地基上 5. 軸的校準 6. 安裝聯(lián)軸器 7. 管路 包括在這章是進行“冷校準”和進行“熱校準”檢查方法的詳細程序。許多安裝方面的問題是買方或者買方工程師的責任，他們可以提供適合安裝的建議。一個這樣的例子是機器是否可以安裝在僅有頂蓋的戶外或者安裝在封閉的建筑內(nèi)。當設(shè)備的種類適合一般的戶外安裝條件，那么根據(jù)現(xiàn)場的情況可以提出更改的方案。例如，在冰凍和低溫環(huán)境下會引起機器啟動和關(guān)閉的困難，可以把潤滑油加溫。對于水和蒸汽設(shè)備在關(guān)閉時要把水和蒸汽放出或者在停機期間加熱。 另一方面，在炎熱的區(qū)域，太陽光對地基一個側(cè)面的直接照射會引起膨脹，再加上系統(tǒng)中的其他因素就會引起不可接受的偏差。 除操作注意事項外，不要求進行維護保養(yǎng)和設(shè)備的檢查—有時是按計劃的偶爾是不按計劃的。不管那種情況，天氣條件總是不合作的。雨、雪、風和低溫或高溫總是延長維修和檢查時間，因為工人直接暴露在這類天氣條件下。另外，工作質(zhì)量也可能降低到完全無效的地步。 對于檢查和維修，應(yīng)備有永久性的吊車或卷揚機。箱頂半部和轉(zhuǎn)動體之間有嚴格的間隙，必須加以保護，因而在拆卸時必須輕而穩(wěn)，這是用輪式吊車和履帶牽引裝置很難達到的。 機器安裝在地腳板上，一個非自（己）支撐的鋼底板上或者自（己）支撐的組合鋼底板上。這些中間支撐的目的是提供一個機器腳可以加墊片的永久性安裝板。鋼底板和非自（己）支撐組合鋼底板的區(qū)別僅在于安裝的難易程度。當?shù)鼗闹问遣贿B續(xù)的或者要求直接安裝在主柱上，必須設(shè)計自支撐組合鋼底板基座可以最低的減少接觸支撐偏差。 地腳板通常僅支撐一個機器支撐而底板一般支撐機器的所有腳。多數(shù)情況下，底板用于支撐驅(qū)動者和驅(qū)動裝置。一些底板也設(shè)計成包含或支持潤滑和密封系統(tǒng)管路和儀器及其機構(gòu)。帶有內(nèi)裝潤滑系統(tǒng)的底板要求較少的空間和較低的安裝費用，但是維修起來一般比較困難。 底板一般能減少安裝時間，因為不需要花費較多的時間用來水平調(diào)整很多密封墊及安裝設(shè)備和輔件。這樣雖然開始花錢可能較多但安裝費用花的較少。底板普通用方形結(jié)構(gòu)鋼制造，因而增加了產(chǎn)生噪音的和回響的表面。 在堅固的水泥地基上安裝在結(jié)構(gòu)鋼或支柱上必須仔細進行保證裝配墊的水平和平整。密封墊之間要全接觸不使用梯形填隙片。用這種安裝方法不需要灌漿填隙，但應(yīng)遵守這章中規(guī)定的其他程序。 地基： 地基的基本作用是提供給機械裝置一個永久剛性的、非扭曲的支撐。合格的地基會（1）在任何操作條件下都保持機器合適的平直度，（2）支撐機器的重量和負載，使其均勻一致地分布到地面或主支撐結(jié)構(gòu)上，（3）保持安置的設(shè)備位置和（4）減小機器的振動傳出和傳入。 雖然良好的地基取決于買方，下面的建議可考慮： 1. 輪廓圖提供了設(shè)備的安置表面區(qū)域、緊固螺栓位置、設(shè)備重量分布、主要管道接頭和其他設(shè)計地基的必要資料。 2. 堅固的水泥地基應(yīng)具有足夠的尺寸和比例，足以支撐機構(gòu)裝置和管路負荷，如入口和出口管路。 3. 地基的設(shè)計使得機器極其輔件的各部分在操作、檢查和維修過程中易于接觸到 4. 地基因完全建造在巖石或堅固的地面上。如果地基部分建造在一處而另一部分建造在其他部分上，這樣會由于地基支撐部分的下沉引起地基的繞曲。由于地下水位的不同產(chǎn)生的壓力不等也會引起扭曲。 5. 由樁子支撐的地基，應(yīng)在樁子上有一個連續(xù)的剛性的蓋，以使地基建在這剛性蓋上面。 6. 地基周圍的溫度應(yīng)均勻一致。頂板和基墊上溫度的差別會引起主柱中產(chǎn)生顯著的彎曲應(yīng)力，因此必須注意減少由于輻射或者不均勻的加熱或冷卻導(dǎo)致的熱變形。在熱帶地區(qū)室外安裝時，應(yīng)避免太陽光的直接照射。不要蒸汽管路緊靠著地基，但若不能避免時，要采用隔熱和屏蔽的辦法以使地基與管路隔開。 7. 地基應(yīng)與所有其他結(jié)構(gòu)隔開，使外部的振動不能傳給地基。在地基必須被橫梁支撐的地方，在地基和橫梁之間要放入振動阻尼材料。 8. 地基結(jié)構(gòu)的設(shè)計要避免與操作速度頻率共振，避免操作速度的40－50％，轉(zhuǎn)子臨界速度和2倍的操作速度。 9. 地基允許校正，但必須經(jīng)過大約28天后才能加負載。這樣會使強度增大和減少縮孔率。校正程序應(yīng)按照美國水泥協(xié)會的建議進行。 10. 地基底腳螺栓和地基上突出物的尺寸表示在輪廓圖中。圍繞底腳螺栓可以加用一個管套以便在安裝設(shè)備期間有必要的話可使底腳螺栓作少量位移。這樣還允許延長螺栓的長度。 11. 在確定地基頂部高度時，允許大約0.5英寸（12㎜）的水泥頂部硬殼倍鏟除。用于加強的鋼筋，鋼棒或其他的鋼件要距允許鏟除的表面足夠低，使得可以鏟去大約1英寸（25㎜）的硬殼而不與鋼件接觸。在地基和塞塊之間要留有足夠的間隙供灌入水泥砂漿，至少要每有1英寸（25㎜）的間隙。地基和地腳板或底板的最大距離不應(yīng)超過4.00英寸（100㎜）。 地基的準備： 地基若是鋼筋混凝土結(jié)構(gòu)，都不會澆灌出具有必要精度讓極其直接安裝上去的水泥混凝土塊。因此，地腳板或基板之間要留有間隙。在地腳板或基板倍位置固定好后把機器防上并做調(diào)試檢驗，地腳板或基板再灌漿到地基上。這個程序基本上制造出了一個連續(xù)的支撐機器的支座。 為了得到好的灌漿粘結(jié)表面，所有混凝土缺陷、水泥翻沫、贓物、油污、臘脂、油脂和疏松材料都必須從結(jié)合表面上清除掉。這些缺陷最好被鏟除，用鑿石錘或者其他方法修整直到得到干凈完善的表面為止。混凝土表面的頂部約有0.5英寸（12㎜）厚應(yīng)予鏟除以得到堅固的、無水泥翻沫的表面以便粘結(jié)灌漿。 塞塊： 在此手冊中術(shù)語“塞塊”是指鋼的或水泥塊，它用于在完全灌漿前調(diào)整水平和支撐地腳板或基板。鋼塞塊的尺寸可以改變。為了便于安裝和水平調(diào)整，在塊四周有四個起重螺旋器。在塞塊的中心有一個連接螺釘以保證牢固的固定住塊直到塊灌漿。 塊： 1. 碳鋼板材料 2. 加工頂部和底部平面 3. 打掉所有的角和弄圓所有的孔 環(huán)氧樹脂灌漿塊也能用來代替鋼塞塊。當使用環(huán)氧樹脂灌漿塞塊時應(yīng)用小型模型定位在每個底腳螺栓處正如鋼塞塊一樣。每個模型的頂表面應(yīng)是水平的，基本上與其他塞塊模型的高度相同。模型應(yīng)固定好，涂臘底部封死。灌漿時，模殼應(yīng)完全充滿。這將減少塞塊和底板或底腳板之間填隙的必要性。 使用塞塊可是安裝工人便于改變底腳板或底板的支撐墊片的高度。塞塊也分散了機械的重量和夾緊螺母的力，以便減小由于這些力而使底腳板或基底板產(chǎn)生變位。使用塞塊，地腳板或底板易于水平移動而不容易改變已經(jīng)定好的高度。 對于安裝在地腳板上的機械，地基底腳螺栓的數(shù)量隨有效表面積減小而增多，因而有效地放置塞塊比較困難。 如果塞塊表面涂有一層催化的環(huán)氧樹脂底漆，在安裝之前表面的這層涂漆不必清除，但表面應(yīng)用溶劑清除油類或其他贓物。 如果塞塊表面有一層銹或其他涂層，塞塊應(yīng)噴砂，噴砂是最好的方法，也能用盤磨機或其他機械方法。如果塞塊在安裝后立即灌漿就不需要做進一步的表面處理。一個清潔的經(jīng)噴砂的表面具有優(yōu)良的粘結(jié)性。 如果塞塊在清潔處理后不立即灌漿，那么清潔的表面應(yīng)涂上環(huán)氧樹脂劑或涂上由灌漿供應(yīng)者建議的涂料。 為了安裝塞塊，要確定塞塊連接螺釘在地基上的位置和在混凝土上的直徑為0.5英寸（12㎜）深度為1英寸（25㎜）的孔（如果連接螺釘套所示的不同，要鉆合適的孔）。使用4個調(diào)節(jié)螺釘使各個塞塊水平。所有的塞塊必須水平或幾乎同樣高。所有塞塊的高差應(yīng)以保持在一英寸的千分之幾或一毫米的幾分之幾為最佳。這使得最后的安裝和設(shè)備的填隙容易得多。在安裝總長度短的設(shè)備時，則使用精密的傾水準儀為佳。 不論使用什么方法，在塞塊與地腳板或底板之間應(yīng)使用填隙片來矯正所要的高度變化。 灌漿： 對塞塊、地腳板或底板的灌漿程序是相同的，只是在灌漿多少上有區(qū)別。Elliott推薦使用高質(zhì)量的環(huán)氧樹脂漿裝置，要從可靠的重型灌漿機械廠購得。環(huán)氧樹脂漿由環(huán)氧樹脂，固化劑和分等級的硅土攪拌在一起。樹脂和固化劑起粘結(jié)作用，而硅土集合物作為添加物以降低成本、改進熱膨脹的一致性和吸收凝固所放出的熱量。如應(yīng)用適當，環(huán)氧樹脂漿應(yīng)能使安裝永久性可靠。使用砂子－水泥漿或砂子－水泥漿加入其他物質(zhì)也可以提供一個合適的安裝，然而這種灌漿一般強度較低，縮孔不均勻，并且一般對化學(xué)腐蝕敏感和易被油類浸蝕變質(zhì)。 灌漿的主要目的是（1）填充地基和地腳板或底板之間的所有空隙，（2）使地基和地腳板或底板形成永久性的粘結(jié)，（3）有助于防止地基連接螺栓以后移動，（4）提供一個水平堅固的基礎(chǔ)，機器可以用底板螺栓固定在基礎(chǔ)上防止機器垂直方向移動，（5）使得地腳板或底板在某種程度上成為混凝土地基整體的一部分。 連接螺栓用于固定的目的，最好是能是套底部和螺母底部之間的地腳螺栓有伸長的余地，因此建議在灌漿之前要充填柔軟的材料如硅橡膠。 使用環(huán)氧樹脂灌漿所要求的安裝程序不同于砂子－水泥的灌漿程序。本手冊只提供個一般所要遵守的程序，對于更詳細的關(guān)于環(huán)氧樹脂漿的規(guī)定要請教環(huán)氧樹脂供應(yīng)者編寫說明書。這對安全措施是很重要的。 關(guān)鍵詞：地基；止動塊；灌漿；聯(lián)軸器；管路