Pre-Cast Machine Bases

Transcription

1 Pre-Cast Machine Bases BY WG ENGINEERING Contents Page Product Introduction 1 Justification and Benefits 2 Detailed Illustration 3 Examples for Improvement 5 Our Offer 7 REVISION /09/2016 WG ENGINEERING PHONE: WEBSITE:

2 PRODUCT INTRODUCTION WG Engineering Pre-cast Machine Bases are designed for precise assembly and alignment of motors, pumps, gear boxes, compressors, blowers and other rotating equipment up to gross mass 20tons (practical transport limit). The pre-cast concrete base design has an internal steel reinforcing structure and also includes mounting and support components, electrical conduits and integral drains as required by machines operating in production. The following image demonstrates a general arrangement of WG Engineering Pre- Cast Machine Base with an Industrial Motor and Centrifugal Pump attached, ready for installation as a complete assembly. Pre-Case Machine Base Centrifugal Pump used as example Coupling Guard Motor as required Figure 1: Concrete and Reinforced Steel Machine Base with Motor and Pump assembly 28/09/2016 WG Engineering ABN Page 1/7

3 JUSTIFICATION AND BENEFITS The justification and key benefits for using WG Engineering Pre-Cast Machine Bases include the following: Optimal Machine Conditions Superior performance when compared to similar steel structures that resonate and deflect due to the reaction forces of rotating machines Concrete has very good vibration damping qualities which are capable of reducing torsional, axial and bending deflection Improved stiffness to reduce movement caused by external forces such as pipe loads or water hammer, lowering vibration and noise levels to improve overall health and safety Improved machine alignment with less vibration leads to longer in service life of bearings, gears and coupled components Corrosion is greatly reduced and concrete base can be placed directly in contact with soil or road base Workshop Constructability Motor to driven component coupling and alignment set up to precise dimensions prior to delivery or installation Dynamic balancing and performance testing can also be completed in workshop if requested Process down time reduced given much of the construction can be done prior to arrival on site Lower manufacturing, installation, maintenance and whole of life cost due to materials and controlled manufacture off site Integral drains and brackets provided for water, oil and other services as required Electrical conduits added to the base as required Concrete curing time, 7 to 28 days, is not required on site (pre-cast in workshop) Easy and Safe Installation on site Machines can be delivered and set up within as little as 1 to 2 days on site. Machine guarding will be provided in compliance with Australian standards. Concrete base mass protects motor and driven equipment bearings from impact, vibration and damage during transport Bases are designed to protect equipment from vehicle impact with no need for bollards or other civil work in most cases. Machine assembly can be isolated from major structures, to reduce noise and vibration, making them suitable for mounting of building services equipment. Bases can be placed with compacted road base or sand/gravel eliminating or greatly reducing the need for onsite civil work and cost. Pipe anchors, supports, and small slabs and footings can also be supplied pre-cast. Lifting points are an integral part of the concrete base design and ensure easy manipulation of the whole assembly on site. On site staff and vehicle movements kept to a minimum to improve safety. 28/09/2016 WG Engineering ABN Page 2/7

4 DETAILED ILLUSTRATIONS Figure 2: Side View showing lifting holes and transparent concrete Coupling and Cover Drain Pre-Cast Concrete Steel Reinforcing Lifting Points Support Bracket Footing Plates grouted in place Drain Dish Figure 3: Pre-Cast Base without rotating equipment 28/09/2016 WG Engineering ABN Page 3/7

5 Figure 4: Machine Feet base plates with jacking and levelling bolts provided Lateral Jacking bolts for alignment Height adjustment nuts for alignment Space under base plate grouted after alignment is completed in workshop Non-shrink grout has been omitted for clarity Figure 5: Top down view with Electrical cable entry shown through base Pre-cast concrete base protects equipment and cabling from vehicle impact Electrical conduit to suit motor cable 28/09/2016 WG Engineering ABN Page 4/7

6 EXAMPLES FOR IMPROVEMENT In our opinion, the following machine base examples are not stiff enough to resist deflection resulting in coupling misalignment when equipment is running. Pumps will not be able to withstand pipe forces without deflection of the steel base. High vibration will lead to short life and high noise levels with increased costs and risk to health and safety. WG Engineering can provide a complete designed solution to improve the following: 28/09/2016 WG Engineering ABN Page 5/7

7 28/09/2016 WG Engineering ABN Page 6/7

8 OUR OFFER WG Engineering provides the design of pre-cast machine bases for use in many applications. We currently work in collaboration with other professionals, manufacturers and tradespeople in a multi-discipline environment to reach a complete solution with benefit to all parties involved. As part of the process, we offer all or some of the following services for this product: 1. An initial survey and reporting service to document the current condition of machine assets with a risk based approach to prioritise work scope and determine design requirements as justified. 2. Quality engineered design of pre-cast machine bases provided for your asset management system for design review and approval prior to manufacture. 3. Planned manufacture of pre-cast bases with machine assembled, delivered and installed using appropriate equipment and procedures to assure safety and reliability for the required life. Designs will be verified by Mechanical, Civil and Electrical Engineers as appropriate to ensure safety, constructability, operability, reliability and maintainability to reduce total cost of ownership. Designs will be reviewed and agreed with the customer prior to manufacture. Goods and services will be provided in accordance with appropriate Australian Standards. If you are considering WG Engineering Pre-Cast machine bases, please contact us. Regards, Wayne Wiley MIEAust, CPEng, RPEQ (Mechanical) WG Engineering Ph: /09/2016 WG Engineering ABN Page 7/7