Brochure - Canstar Instruments Inc.

Transcription

Information Book Ed.1.5.2 ‐ RotaChock Information Book 1 Table of Contents RotaChock Introduction ................................................................................................................................ 3 RotaChock® Configurations: ......................................................................................................................... 5 Contact Information: ..................................................................................................................................... 6 RotaChock® Brochure ................................................................................................................................... 7 Applications................................................................................................................................................... 9 Press Release June 2010 ............................................................................................................................. 10 RotaChock® ACE .......................................................................................................................................... 10 Selection Methods for RotaChocks ............................................................................................................. 11 RotaChock® Dimensions ............................................................................................................................. 12 RotaChock® Selection Guide for Gas Engines ............................................................................................. 14 RotaChock® Selection Guide for Separable Reciprocating Compressors ................................................... 15 RotaChock® Installation .............................................................................................................................. 16 Quick Installation Guide .......................................................................................................................... 16 Detailed Installation Instructions ............................................................................................................ 17 Foundation Bolts ......................................................................................................................................... 24 Spherical Spacers ........................................................................................................................................ 25 RotaChock® Adjustment Tools .................................................................................................................... 27 RotaChock Foundation – Design Notes ....................................................................................................... 28 Appendix A – Application Photo Album ...................................................................................................... 31 Appendix B– Data Sheets ............................................................................................................................ 37 Basic Data Sheet ...................................................................................................................................... 38 Ed.1.5.2 ‐ RotaChock Information Book 2 RotaChock Introduction The RotaChock is an adjustable, self leveling and reusable equipment mounting chock. The RotaChock is a blend of engineering and years of field experience to produce a strong, stiff and elegant device to end machinery softfoot. Machinery Mounting Solutions’ Philosophy Strive to design and manufacture the best chocking solution for our customers. Using the parameters provided by our customers we create technical and economical resolutions to a fundamental and core element of machinery installation ‐ chocking. Chocking solutions can take a variety of configurations and materials and we exploit our comprehensive experience with machine installations for the equipment stakeholders. Primarily, we consider mechanical chocks as the best life cycle decision for rigidly mounted machines because of the adjustability characteristics and reusability features. Our approach is to partition chocking into two needs either new construction or retrofit. For new designs, we have a standard brochure that illustrates our ease of installation and economics to suit the end users environment. For the retrofit and fixed design markets, we use our core elements and create solutions for the application. Chocks Chocks, liners and shims are placed between equipment and its foundation. Chocks by any other name or of the many configurations and materials which are used throughout industry have two simple goals: create a flat mounting surface for the equipment and transfer of energy from the machine to the foundation. The history of chocking began with milled foundations and fitted chocks which gave way to shims and poured epoxy chocks. All these techniques are good practices but at Machinery Mounting Solutions with experience in all these techniques we have developed the RotaChock with attributes that achieved the basic goals stated above plus we add reusability attributes that are unmatched in the field. RotaChock Details The RotaChock is a mechanical chock. The core technologies are from diverse backgrounds of applications that are time‐tested and standardized under a variety of technical organizations and societies. We package these successful techniques differently and we made the RotaChock the easiest chock to install and reuse. Ed.1.5.2 ‐ RotaChock Information Book 3 The following illustration exhibits some of the innovations of the RotaChock: Lenticular Top Part – at 4 degrees, the largest angular difference in the market Adjustment Slots to accommodate a variety of tools ANSI Compression Buttress Threads for maximum strength, stiffness and adjustment range for the material selected. Plus, ease of installation in all rugged environments. Surface: load rating ratio that is the best in the market We have blended technologies to evolve mechanical chocking and we proudly present a technically superior product. The RotaChock can be provided in a variety of configurations to suit the application. We manufacture the RotaChock in a variety of materials to suit lifecycle environments. The technical approach for development of the RotaChock was to create the highest load rating viable while using the lowest yield strength material required by industry (316 Stainless Steel per API Guidance). Our approach means the normal carbon steel and alloy steel chocks have an even greater margin of safety over and above the stated chock ratings. The RotaChock is easy to install and can be adjusted with a variety of hand tools usually available in the field. Also, the RotaChock needs to be reusable. The ability to readjust the mounting plane to accommodate modularity of machinery, settling of the foundations and machine wear is an essential element to lowering life cycle costs of machines. Another RotaChock innovation is the experimentation and implementation of a process to inhibit rust of normal steel chocks. Stainless Steel 316L is an excellent and required material for highly corrosive applications but it comes at a price. At Machinery Mounting Solutions with a consistent objective to improve our products, we incorporated a molecular diffusion process for carbon steel and alloy steel chocks. We call the process Anti‐Corrosion Enhanced – ACE! The process developed many years ago primarily for the automotive industry has been adopted by oil and gas for downhole applications, OEM’s for engine internals and many other industries use this process to enhance wear, scuff resistance and fatigue life. Well, it turns out the process has another attribute ‐ corrosion resistance. A by‐product of diffusing the iron and oxygen atoms with nitrogen and carbon at a low temperature results in surface that has negligible dimensional distortion and is rust resistant. Comparisons via salt spray testing show that stainless 316L marks at 420 hours, 1045 carbon steel‐ACE marks at 320 hours whereas untreated 1045 carbon steel marks within 90 minutes. A real advantage in the machinery mounting industry! Ed.1.5.2 ‐ RotaChock Information Book 4 RotaChock® Configurations: 




Basic Line Slim Line Tall Line RotaChock® Block Hi‐Shock Materials: 








CS=> Carbon Steel (SAE 1045) CS‐ACE => Carbon Steel (SAE 1045) –ACE SS=> Stainless Steel 316L AS => Alloy Steel (SAE 4140) AS‐ACE = > Alloy Steel (SAE 4140) – ACE G8 => Alloy Steel (SAE 4340) G8‐ACE=>Alloy Steel (SAE4340) K5 => K‐Monel 500 PL=> Plate Steel (ASTM A36) Piece Part Configuration Options 
Tall Line o Bottom Parts o Top Parts Ed.1.5.2 ‐ RotaChock Information Book 5 Contact Information: Locations:
USA
Virginia
Louisiana
Machinery Mounting Solutions, Inc.
4216 Hermitage Road
Virginia Beach, VA 23455
Toll Free: 877-460-0050
Phone: 757-460-0050
Fax: 757-460-0054
1750 MLK Blvd. Ste 109-295
Houma, LA 70360
Phone: 985-293-7723
Fax: 985-635-4585
POC: Mark Morner
POC: Bill Varmecky
bill.varmecky@machinerymountingsolutions.com
mark.morner@machinerymountingsolutions.com Texas
8000 Research Forest Dr, Ste 115-244
The Woodlands, TX 77382
Phone: 281-298-9911
Fax: 281-220-8368
CANADA
Canstar Instruments Inc. 7251‐67 Str. NW, #16 Edmonton, AB T6B 3N3 Phone: 780-440-1362
Fax: 780‐440‐0373 Email: info@canstarinstruments.com POC: Clive Parsons
clive.parsons@machinerymountingsolutions.com www.machinerymountingsolutions.com
info@machinerymountingsolutions.com
Ed.1.5.2 ‐ RotaChock Information Book 6 Adjustable
Self Leveling
Reusable
Economical
Marine
Gas / Oil Transmission
Anti-Corrosion Enhanced
Machinery Mounting Chocks
www.MachineryMountingSolutions.com
Pump Systems
CENTER
NUMBER
BOLT SIZE
RC2
RC3
RC4
RC4.5
RC5
RC6
RC7
RC8
RC9
RC10
Materials:
Carbon Steel
Alloy Steel
316L Stainless
TALL
LINE
BASIC LINE
OD
MIN HT
MAX
DESIGN
MAX HT DESIGN
HT
HT
SLIM
LINE
RATED
LOAD
STANDARD
OPTIONAL*
INCHES
INCHES
INCHES
INCHES
INCHES
INCHES
MAX INCHES
INCHES
KIP
3/8 - 5/8
5/8 - 3/4
3/4 - 1
1
1-1/8
2
3
4
1.18
1.38
1.57
1.34
1.63
1.83
1.50
1.89
2.09
1.84
2.74
3.74
0.75
0.75
0.75
23
35
45
7/8 - 1-1/8
1 - 1-3/8
1-1/8 - 1-1/2
1-3/8 - 1-3/4
1-3/4 - 2
2 - 2-1/4
2-1/2 - 2-3/4
1-1/4
1-1/2
1-3/4
2
-
4.5
5
6
7
8
9
10
1.77
1.97
2.17
2.36
2.76
2.95
3.15
2.07
2.34
2.54
2.68
3.11
3.31
3.50
2.36
2.72
2.90
2.99
3.58
3.66
3.85
4.21
4.62
5.64
6.69
7.53
8.65
9.65
0.75
0.75
1.0
1.0
*
*
*
68
90
135
200
270
360
450
* Contact Machinery Mounting Solutions
Anti-Corrosion Enhanced
ACE is our solution for corrosion resistant machinery
mounting chocks made of carbon and alloy steel
MIN HT
Configuration Options:
ACE processed
Slim Lines
Tall Top Parts
Block Type
Custom Chocks
Virginia
Texas
Louisiana
757-460-0050 (T) 757-460-0054 (F)
281-298-9911(T) 281-220-8368 (F)
985-293-7723 (T) 985-635-4585 (F)
Toll Free: 877-460-0050
www.machinerymountingsolutions.com
Ed. 4
Applications  Electric Motors  Engines  Compressors  Pumps  Gearboxes  Generators  Blowers  Critically Mounted Equipment See Appendix A for recent photo album Ed.1.5.2 ‐ RotaChock Information Book 9 Press Release June 2010 RotaChock® ACE Anti‐Corrosion Enhanced RotaChock® Machinery Mounting Solutions is leading heavy industry into more trouble‐free installations. The RotaChock® ACE assists machinery mounting stakeholders with a rugged solution for rust problems. Driven by our innovation and solutions provider philosophy we are implementing a new material process to our RotaChock® products for owners, operators and fabricators of complex machine installations. The RotaChock® is a reusable machinery mounting chock for rigidly mounted machines. The RotaChock® eliminates soft foot and is a proven success. The RotaChock® has a large adjustment range which is coupled with a significant self leveling capacity for an easy to use chock that results in a high quality installation. The company’s charter as a solutions provider understands and responds to the needs of our customers to address costs, technical needs and life cycle issues. ACE is one of our latest innovations!! While our stainless steel products address the technical and life cycle concerns, the cost of the core material is not appealing for all applications. For most of the land based applications, the chocking system is exposed to the weather which means plain ferrous based materials require maintenance. After thorough investigation and laboratory testing, Machinery Mounting SolutionsTM has selected a process that diffuses the ferrite regional layer of carbon steel and alloy steel with carbon and nitrogen. The result is an enhanced rust resistance surface and improved wear attributes. Inherently, the RotaChock® is strong, stiff and the economical solution for the installation of machinery that requires coplanar mounting surfaces. Adding to our portfolio the RotaChock® ACE addresses the cost concerns of the marketplace for a long life cycle and low maintenance. Contact Machinery Mounting SolutionsTM for details. Ed.1.5.2 ‐ RotaChock Information Book 10 Selection Methods for RotaChocks Selecting a RotaChock can take three methods: 1) Bolt Size Method: Select a RotaChock based upon the mounting bolt size. For example: 1”Bolt = RC4 (please refer to the brochure). Designers Notes: a) The RotaChock diameter versus the foundation mounting surface. The bottom should be fully supported b) The gap (distance from foundation to the component mounting surface) c) The material (carbon steel and carbon steel with our ACE process will be the best for most applications) stainless steel is also a stocked solution and other materials are available. 2) Chock Calculation Method: a) Provide weight, operating characteristics, foot print, gap and bolt size. A sizing calculation will be provided. Also, see the Designers Notes above. 3) Comprehensive Chocking Plan Method: a) Complete and submit the data sheets provided on the subsequent pages or download the files from our website. Designers Notes: This Chocking Plan Method is typically recommended for Class applications. Further, please note in your data sheets submittals any special environmental applications i.e. High‐Shock, Arctic Circle, Nuclear etc… This method recommends the chock, positioning of chocks, bolting design and bolt torques. Machinery Mounting Solutions typically provides mounting kits. Please contact us for this comprehensive supply option. See Appendix B for DataSheets Ed.1.5.2 ‐ RotaChock Information Book 11 ROTACHOCK®
RC2
RC3
RC4
RC4.5
RC5
RC6
RC7
RC8
RC9
RC10
BOLT SIZE BASIC LINE
OD
STANDARD
OPTIONAL*
INCHES
INCHES
3/8 ‐ 5/8
5/8 ‐ 3/4
3/4 ‐ 1
7/8 ‐ 1 ‐1/8
1 ‐ 1‐3/8
1‐3/8 ‐ 1‐1/2
1‐3/8 ‐ 1‐3/4
1‐3/4 ‐ 2
2 ‐ 2‐1/4
2‐1/2 ‐ 2‐3/4
‐
1
1‐1/8
1-1/4
1-1/2
1-3/4
2
‐
‐
‐
TALL LINE
SLIM LINE
RATED LOAD**
ID
BASIC CUT HT
MIN HT
DESIGN HT
MAX HT
MAX HT
MIN HT
INCHES
INCHES
INCHES
INCHES
INCHES
INCHES
KIP
INCHES
INCHES
2
3
4
4.5
5
6
7
8
9
10
1.18
1.38
1.57
1.77
1.97
2.17
2.36
2.76
2.95
3.15
1.34
1.63
1.83
2.07
2.34
2.54
2.68
3.11
3.31
3.5
1.5
1.89
2.09
2.36
2.72
2.9
2.99
3.58
3.66
3.85
2
3
4
4.5
5
6
7
8
9
10
0.75
0.75
0.75
0.75
0.75
1
1
1.5
1.5
1.5
23
35
45
68
90
135
200
270
360
450
0.67
0.79
1.10
1.22
1.42
1.57
1.81
2.13
2.31
2.87
0.91
1.02
1.22
1.34
1.54
1.73
1.93
2.20
2.40
2.60
* Contact Machinery Mounting Solutions for bolt
torque restrictions
SLOT SIZE
SLOT SIZE
Angular Offset
PITCH
PITCH
BUTTRESS THREAD DIA
TPI
INCHES
INCHES
16
0.0625
12
0 0833
0.0833
8
0.125
6
0.166
INCHES
5/32 X 1/4
5/32 X 5/16
4 degreees
CORE P
PART NUMB
BER
GENERAL DIMENSIONS
1.18
1.77
2.56
2.87
3.15
3.74
4.72
5.31
6.30
7.08
** Rated load = Machine Mass + Machine Dynamics + Safety Factor +
Clamp Force
Contact Machinery Mounting Solutions for your application
SLIM LINE
MIN HT
CUT HT
MAX HT
DESIGN HT
MIN HT
DIAMETER
BUTTRESS THD
DIAMETER
SLOT SIZE
TALL LINE
MAX HT
BOLT TORQUE STATEMENT
Bolt torque generates clamping force which is the signicant factor in the total force excerted on the RotaChock
our calculations are generated from customer supplied data. Please contact Machinery Mounting Solutions for a
calculation. There are many variables in the detailed equations and there are many websites that offer "standard
torque requirements." The standard sized bolts in the above RotaChock chart will accommodate 70% yield
for generally used materials. Contact Machinery Mounting Solutions if your application requires bolting that is
SAE Grade 10 or Metric 12.9 and 70% of yield
MACHINERY MOUNTING SOLUTIONS, INC.
WWW.MACHINERYMOUNTINGSOLUTIONS.COM
INFO@MACHINERYMOUNTINGSOLUTIONS.COM
VA
877‐460‐0050 (TOLL FREE)
757‐460‐0050 (P)
757‐460‐0054 (F)
TX
281‐298‐9911 (P)
281‐220‐8368 (F)
LA
985‐293‐7723 (P)
985‐635‐4585 (F)
Rev3
ROTACHOCK®
RC2
RC3
RC4
RC4.5
RC5
RC6
RC7
RC8
RC9
RC10
BOLT SIZE BASIC LINE
TALL LINE
OD
SLIM LINE
RATED LOAD**
ID
BASIC CUT HT
SLOT SIZE
STANDARD
OPTIONAL*
MIN
MIN HT
HT
DESIGN HT
DESIGN
HT
MAX
MAX HT
HT
MAX
MAX HT
HT
MIN HT
MIN HT
M
M
mm
mm
mm
mm
MAX mm
MIN mm
kN
mm
mm
mm
10‐16
16‐18
20‐24
24‐27
28‐35
33 39
33‐39
39‐45
48‐52
56‐60
64‐68
‐
24
30
33
39
45
48
‐
‐
‐
51
76
102
114
127
152
178
203
229
254
30
35
40
45
50
55
60
70
75
80
34
42
46
53
59
65
68
79
84
89
38
48
53
60
69
74
76
91
93
98
51
76
102
114
127
152
178
203
229
254
19
19
19
19
19
25
25
38
38
38
100
150
200
300
400
600
900
1200
1600
2000
17
20
28
31
36
40
46
54
59
73
23
26
31
34
39
44
49
56
61
66
4 x 6
* Contact Machinery Mounting Solutions for bolt
torque restrictions
SLIM LINE
MIN HT
4x8
4 x 8
Angular Offset
4 deegrees
CO
ORE PART NU
UMBER
GENERAL DIMENSIONS
PITCH
PITCH
BUTTRESS THREAD DIA
TPI
mm
mm
16
1.5875
12
2.11582
8
3.175
6
4.2164
30
45
65
73
80
95
120
135
160
180
** Rated load = Machine Mass + Machine Dynamics + Safety Factor +
Clamp Force
Contact Machinery Mounting Solutions for your application
CUT HT
MAX HT
DESIGN HT
MIN HT
DIAMETER
BUTTRESS THD
DIAMETER
SLOT SIZE
TALL LINE
MAX HT
BOLT TORQUE STATEMENT
Bolt torque generates clamping force which is the signicant factor in the total force excerted on the RotaChock
our calculations are generated from customer supplied data. Please contact Machinery Mounting Solutions for a
calculation. There are many variables in the detailed equations and there are many websites that offer "standard
torque requirements
requirements."" The standard sized bolts in the above RotaChock chart will accommodate 70% yield
for generally used materials. Contact Machinery Mounting Solutions if your application requires bolting that is
SAE Grade 10 or Metric 12.9 and 70% of yield
VA
877‐460‐0050 (TOLL FREE)
757‐460‐0050 (P)
757‐460‐0054 (F)
TX
281‐298‐9911 (P)
281‐220‐8368 (F)
LA
985‐293‐7723 (P)
985‐635‐4585 (F)
REV3
RotaChock® Reference Guide
Gas Engines
CAT Engines Waukesha
RotaChock® Size
QTY
3300
RC2
See Remarks
3400
RC2
See Remarks
C 18
C‐18
RC4
See Remarks
See Remarks
3500
RC4
8
3600
RC4.5 / RC5
2 per foot
CM34
RC7
12 Cylinder ‐ 14
CM34
RC7
16 Cylinder ‐ 18
Cummins
RotaChock® Size
QTY
16V275GL
RC5 /RC6
10
12V275GL
RC5 /RC6
RC5 /RC6
8
275GL
ATGL
12V‐AT27GL
RC6
8
P9390GSI/GL
RC4
10
VHP
L7044GSI
RC4
10
L7042GSI/GL/G
RC4
10
L5794GSI/LT
RC4
10
L5774LT
RC4
10
L5790G
RC4
10
F3524GSI
RC3
10
F3521GL/G
RC3
10
F3514GSI
RC3
10
H24G/GL/GLD/GSI/GSID
RC4
4
Remarks:
The Caterpillar foot is available in a variety of mounting point configurations contact Machinery Mounting Solutions with the best configuration for your application.
RotaChock® Size
QTY
G5.9C
RC3
4
G8.3C
RC3
4
G855
RC3
4
KTA190
RC3
4
Remarks:
The Cummins foot is available in a variety of mounting point configurations contact Machinery Mounting Solutions with the VGF
Remarks: The Waukesha engines require a preload on the center mounting position to permit adequate thermal growth of the crankshaft. The center mounts may require two or four mounts at the center point to achieve NOTE: THIS IS A GUIDANCE LIST ONLY Each application class should be investigated as engine configurations can change without notice.
We invite your questions and request an opportunity to accomplish sizing calculations for your applications.
Machineryy Mounting
g Solutions,, Inc.
4216 Hermitage Road
Machineryy Mounting
g Solutions,, Inc.
8000 Research Drive, Ste 115-244
Houston, TX 77382
Machineryy Mounting
g Solutions,, Inc.
1750 MLK Blvd. Ste 109-295
Houma, LA 70360
877/757-460-0050 (T)
757-460-0054 (F)
281-298-9911 (T)
218-220-8368 (F)
Phone: 985-293-7723
Fax: 985-635-4585
ED. 1
RotaChock® Selection Guide For
Separable Reciprocating Compressors
Ariel
GE
Frame
Crosshead
Crosshead
Support
JG/A 2
JG/A 4
JGA/6
JGB/4
JGB/6
JGC/D 2
JGC/D 4
JGC/D 6
JGE/H 2
JGE/H 4
JGE/6
RC4
RC4
RC4
RC7
RC8
RC6
RC6
RC6
RC5
RC5
RC5
RC2-ID.78
RC2-ID.78
RC2-ID.78
RC4.5-ID1.56
RC4.5-ID1.56
RC4-ID1.2
RC4-ID1.2
RC4-ID1.2
RC3-ID1.06
RC3-ID1.06
RC3
ID1.06
RC3-ID1.06
RC5-ID1.9
RC5-ID1.9
RC4.5-ID1.56
RC4.5-ID1.56
RC4.5-ID1.56
RC4-ID1.2
RC4-ID1.2
RC4
ID1.2
RC4-ID1.2
JGJ/R 2
JGJ/R 4
JGJ/6
JGK/T 2
JGK/T/4
JGK/T 6
JGM/P 1
RC4.5
RC4.5
RC4.5
RC5
RC5
RC5
RC4
RC2-ID.78
RC2-ID.78
RC2-ID.78
RC3-ID1.06
RC3-ID1.06
RC3-ID1.06
RC2-ID.78
JGM/P 2
JGN/Q 1
JGN/Q 2
KBU/Z 2
KBU/Z 4
RC4
RC4
RC4
RC7
RC7
KBU/Z 6
KBB/V 4
KBB/V 6
RC7
RC7
RC7
Cameron
Frame
Crosshead
M301
M302
H301
H302
H304
A352
A354
D422
D424
D502
D504
RC3
RC3
RC3
RC3
RC3
RC4
RC4
RC5
RC5
RC5
RC5
RC2
RC2
RC2-ID.78
RC2-ID.78
RC2-ID.78
RC2
ID.78
RC2-ID.78
RC3-ID1.06
RC3-ID1.06
RC3-ID1.06
RC4-ID1.2
RC4-ID1.2
RC4-ID1.2
-
D602
D604
ES502
ES504
ES506
ES602
ES604
RC5
RC5
RC5
RC6
RC6
RC6
RC6
RC2-ID.78
RC2-ID.78
RC2-ID.78
RC2-ID.78
RC2-ID.78
RC2-ID.78
RC2-ID.78
RC2-ID.78
RC2
ID 78
RC2-ID.78
RC2-ID.78
RC4.5-ID1.56
RC4.5-ID1.56
RC5-ID1.9
RC5-ID1.9
ES606
ES702
ES704
ES706
FS502
RC6
RC6
RC6
RC6
RC6
RC2 ID 78
RC2-ID.78
RC2-ID.78
RC2-ID.78
RC2-ID.78
RC2-ID.78
RC4.5-ID1.56
RC4.5-ID1.56
RC4.5-ID1.56
RC5-ID1.9
RC5-ID1.9
RC5-ID1.9
C-FORCE 32
C-FORCE 34
RAM 52
RAM 54
CFH5- 2/4/5
CFH6- 2/4/6
MH2- 2/4/6
WH6- 2/4/6
WH7- 2/4/6
WG6- 2/4/6
WG6
WG7- 2/4/6
Dresser-Rand
Frame
Crosshead
RC4
RC4
RC4
RC4
call
call
RC5
RC5
RC5
RC6
RC6
RC2-ID.78
RC2-ID.78
call
call
RC2-ID.78
RC2-ID.78
RC2-ID.78
RC2-ID.78
RC2
ID.78
RC2-ID.78
Crosshead
Support
Frame
-
RC4.5
RC4.5
RC4.5
RC4.5
RC4.5
3.5/4.5A-VIP2
3.5/4.5A-VIP4
6/5B-VIP2
6/5B-VIP4
6/5/4C-VIP2
6/5/4C-VIP4
MOS2
MOS4
MOS6
7/6/5D-VIP2
7/6/5D
VIP2
7/6/5D-VIP4
RC4
RC4
RC4
RC4.5
RC5
RC5
RC5
RC5
RC5
RC8
RC8
7/6/5D-VIP6
6/7 HOS2
6/7 HOS4
6/7 HOS6
HOSS2
HOSS4
HOSS6
RC8
RC8
RC8
RC8
RC6
RC6
RC6
NOTE: THIS IS A GUIDANCE LIST ONLY
Each application class should be investigated as compressor configurations
can change without notice.
We invite your questions and request an opportunity to accomplish sizing calculations for your applications.
4216 Hermitage Road
8000 Research Drive, Ste 115-244
Houston, TX 77382
1750 MLK Blvd. Ste 109-295
Houma, LA 70360
877/757-460-0050 (T)
757-460-0054 (F)
281-298-9911 (T)
218-220-8368 (F)
Phone: 985-293-7723
Fax: 985-635-4585
ED. 2
RotaChock® Installation Instructions
Quick Field Guide
1
Clean the chocking areas - equipment foot and foundation surface (<2mils of primer is acceptable)
Carbon steel RotaChocks® are packaged with LPS3 on the surfaces‐ Clean off the top of the top part and bottom of the bottom ring with a degreaser solution.
2
Preliminary Checks:
RotaChock diameter;
• Jacking bolt clearances versus the RotaChock®
• Bottom part of the RotaChock® is fully supported on the foundation;
• Bottom part does not rock or wobble on the on the foundation.
If a problem exists contact us - there are many simple fix options.
3
Accomplish alignment with jacking devices
• Align the moveable unit 0.002" above cold alignment target
4
Install RotaChock®,
RotaChock , tighten by hand with chisels, dowels or screwdrivers
5
Release jack bolts.
6
Install foundation bolts.
The weight of the unit plus clamping force of the bolt
will extrude some of the lubricant between the surfaces
approximately 0.002"
7
Check alignment.
8
Repeat step 3 if needed.
9
Installation is complete with no soft foot!
VA 877‐460‐0050 (TOLL FREE)
757‐460‐0050 (P)
757‐460‐0054 (F)
TX
281‐298‐9911 (P)
281‐220‐8368 (F)
LA 985‐293‐7723 (P)
985‐635‐4585 (F)
Detailed Installation Instructions Chocking Introduction Chocking is the interface between machinery and the foundation structure. The function of this interface is to create a coplanar surface for the installed machinery. The RotaChock® creates the machinery mounting plane effectively and efficiently. The following instructions were prepared for those that are new to mechanical chocks or those that need a refresher that mechanical chocks are not shims – they are gap fillers. They are intended to create a coplanar mounting surface for your machine quickly and easily. If you follow these instructions, the installation should be completed in less than one hour. If it is taking longer, contact us! Pre‐Requisites for Chocking System design ‐ Considering any chocking system includes ensuring the foundation is structurally stiff for the static and dynamics of the equipment plus the forces from the environment. Each industry has a different consideration for environmental forces i.e. military Grade A shock requirements are vastly different from petrochem pump systems and the chocking system must meet or exceed the requirements of the application. Defining and understanding these topics are the responsibility of the design activity but Machinery Mounting Solutions can assist. System design considerations specific to the RotaChock® include chocking thickness (gap) and bottom part support. Step 1) Using the mounting bolt size make a preliminary selection of the RotaChock®. From the RotaChock brochures select a configuration and nominal design height (gap). GAP
SATISFACTORY
UNSATISFACTORY
Step 2) Insure the foundation width will accommodate the RotaChock® diameter. The RotaChock® bottom part should be fully supported. Ed.1.5.2 ‐ RotaChock Information Book 17 Sizing Calculation – Contact Machinery Mounting Solutions, to insure the best sizing of the RotaChock®. This is free service. The rule of thumb solution is to select a RotaChock® based upon bolt size but for many applications technically sound and better economic solutions will be offered. Jacking Devices – Moving the machinery into plumb and/or alignment is most efficiently positioned by using jack bolts. There are other techniques such as our bolt and nut, hydraulic jacks or wedges but no matter the jacking device it needs to be clear of the RotaChock. The design of the package should take in consideration ease of installation, access and the lifecycle of the machinery. RotaChock® is a mounting chock and we recommend that it not be used as a lifting device – it’s just too much work – keep it simple. Machinery Checks Clean the underside of component mounting foot. Check the mounting area for damage or debris and take corrective action. Foundation Checks Clean the mounting surface and if primed that there is only a light coat (1 or 2 mils) of primer. Rocker Check ‐ Position RotaChock in approximate final location, apply hand load to top of RotaChock and try to rock the RotaChock® assembly side‐to‐side. If it rocks, investigate the reason and correct. In most instances the surface preparation is only some localized sanding. Ed.1.5.2 ‐ RotaChock Information Book 18 A more quantitative check procedure follows but typically the rocker check is adequate. 0.
00
2
(0
,0
5)
Feeler Gauge Check – Push down on the RotaChock® and examine the circumference of the bottom part at the foundation with a feeler gauge of 0.05mm (0.002”). The acceptable mounting surface check is achieved when the feeler does not pass completely through the interface area 0.002 (0,05)
0.002 (0,05)
.
ACCEPTABLE
UNACCEPTABLE
Alignment Accomplish alignment per machine/system target requirements for cold alignment, thermal growth and crankshaft deflections using jacking devices. Because the RotaChock® is a mechanical device align the unit 0.002” (0.05mm) above target. The 0.002” (0.05mm) is a nominal dimension to accommodate extrusion of the lubricant in the chock’s internal surfaces. There may be some slight variances due to machine load, chock size, foundation surface condition and bolt stretch and we recommend that installers take notes of their equipment alignments to make the next alignment event quicker. Ed.1.5.2 ‐ RotaChock Information Book 19 Chock Preparation Unpack the RotaChock Carbon steel RotaChocks® are packaged with LPS3 on the surfaces‐ Clean off the top of the top part and bottom of the bottom ring with a degreaser solution. Notes: The RotaChock® has slots for adjustment. Many tools can be used to tighten the chock. Tools that can be used for the RotaChock include: Flat head screw drivers (with tip slightly ground off to provide grip in the slot), chisels or dowel pins. We also have spanners for sale but they are not essential for a perfect installation. The RotaChock® is designed with a buttress thread. The force required to tighten the chock in place against the gap is minimal (20 – 30 lbs‐ft). Because of this thread configuration they will lock sooner (less force) than other mechanical chocks that do not use a buttress thread configuration. Slot sizes: RC2 & RC3
DEEP
0.20"
OPENING
0.16"
RC4 AND LARGER
DEEP
0.31"
OPENING 0.16"
0.25"
0.12"
0.20"
RECTANGLE
0.31"
0.12"
0.25"
RECTANGLE
ILLUSTRATION 1
Chock Installation Place the RotaChock® in position (generally concentric with the bolt hole). Fit the RotaChock by rotating (unscrewing) by hand. A single person using 2 tools should tighten each RotaChock®. Please do not have multiple technicians tightening the chocks. Once each RotaChock® is fitted, take the load off of the vertical jacking screws and install foundation bolts. Ed.1.5.2 ‐ RotaChock Information Book 20 After tightening foundation bolts to the required torque, check the final alignment. The alignment should be within cold alignment target tolerances and with no softfoot. SHOP HELPER: NOTE: The RotaChock is simply a gap filler device for the space between the skid/foundation and the piece of equipment. Zero softfoot installations are typically achieved within 15 ‐30 minutes depending on the number of mounting positions. If you do not achieve zero softfoot installations within 1 hour contact us, there is something amiss with the mounting procedure or the skid/foundation. Again, these are gap fillers not shims! Position the machine where you want it on jacking screws or similar devices. Below are some jacking device ideas for applications where the equipment provider placed their jacking bolts too close to the mounting hole – it is not a problem just something to be aware of before chock installation. Ed.1.5.2 ‐ RotaChock Information Book 21 An alternative jacking setup is to use a nut and bolt which is slightly shorter than the height of the system intended gap. A 1” bolt and nut(s) is enough but use whatever you are comfortable with. Remember the machine will only be on these for 15‐30 minutes. 3 per side should do it for long machines. Position the component for its final vertical location/alignment, on the jacking devices. The horizontal moves can be accomplished on the jacking devices or the RotaChocks. Install the RotaChocks – adjust to fit by hand. Then, one person using RotaChock tools, flat head screw drivers, allen wrenches or anything else (flat bar) that fits the slots tighten the RotaChocks. Remember the RotaChocks have buttress threads so it does not take much force to make these chocks tighten (friction lock with about 20 ‐30 ft‐lbs) in the gap between the component and its foundation. Loosen the jacking bolts. The RotaChocks are now taking the weight of the machine. Install and tighten foundation hardware. Please note: Directly out to the packaging RotaChocks have lubricant in the thread and spherical surface. As the bolts are tightened, this lubricant will be extruded out. We recommend that you allow approximately 0.002” above your position target for this extruded lubricant. Just a note: this is not crush‐ if the chock crushed it would never rotate again. These chocks only crush when we tell them to! And it usually will require very large servo‐hydraulic presses or high explosives. Also, there is a long (wrong) approach to machinery mounting with RotaChocks. We call it the Lottery Approach! Make skid/foundation plumb on shop floor (cool), measure RotaChocks to some height to achieve the center line target of your machine and install the chocks . Install the machine and tighten mounting bolts. If you have no softfoot with this procedure YOU ARE LUCKY! Most of the time, you will not be that lucky. Ed.1.5.2 ‐ RotaChock Information Book 22 Here’s what’s happening! The machine is really still sitting on three points – yes, in the case of really big machine it maybe four or five – but it still has softfoot! The machine’s feet are not coplanar and the skid is twisted! So you and your helpers get out hydraulic jacks and start lifting the machine at a point and ask ”… how much does a RotaChock adjust per adjusting hole?” Forget it! You will chase softfoot around the machine for hours – like a shim. Sure eventually you will get it. We recommend that you save your energy for the next rodeo and follow the instructions provided earlier in this section. For years before mechanical chocks and epoxy resins – we did it! That’s why we developed the RotaChock! Don’t chase soft foot around! Do not wait for epoxy resins to setup. Do not make machinery mounting difficult – use RotaChocks! AGAIN, set the machine on target using jacking screws. Fill the gap with the RotaChock. Release the jacking screws. Tighten the mounting hardware. You are finished! Sure for your QA documents confirm alignment and zero softfoot, get the sign‐off and pick‐up your tools! Just to drive it in: The RotaChock is not a shim! It is a gap filler – a chock! The alignment process for the RotaChock is the same as for poured chocks. Align as required for the thermal conditions and fill the gap. Be done in minutes – use the RotaChock! Guess what? In the field it is the same way – because that foundation will rack in transportation. During commissioning, alignment and softfoot are checked and 85% of the time the chock will need to be adjusted. The RotaChocks will be there and ready to be adjusted to accommodate the new machinery plane. Protecting the RotaChock® The RotaChock® uses a relatively fine thread interface, debris in the thread will make the device hard to adjust. Protect the thread from debris while the unit is being stored, transported or in the field. Also, the carbon steel chock will rust and must be preserved. All methods for steel preservation are acceptable but please note the thread should be protected during the lifecycle. What Lubricant is used on the RotaChocks? All RotaChocks have the threads and spherical top part lubricated with Loctite® Nickel Anti‐
Seize. Carbon Steel RotaChocks have, the outer surfaces are coated with LPS 3® Premier Rust Inhibitor. The LPS‐3 should be cleaned off of the top and base surface of the chock. Ed.1.5.2 ‐ RotaChock Information Book 23 Foundation Bolts Each industry has specifications for foundation bolting and each manufacturer and customer has their own bolting preferences, follow their requirements. It does matter for the RotaChock. We use the size, grade and style of bolting information supplied by the customer for our bolt torque calculations. For the chocking plan method, we recommend bolting arrangement best for the application. We have time proven solutions which have been used across multiple industry sectors. Bolt Torque The founders of Machinery Mounting Solutions have over 100 years experience in machinery mounting and foundation bolts. The final torque and resulting stretch of the bolt is critical to the life cycle performance of the machine. The bolt stretch has to take into account the bolts / nuts, washers, foundation interfaces, chock height, we have taken these into account in the minimum stretch required to maintain frictional forces in the nut. Contact Machinery Mounting Solutions for detailed design solutions. We offer design, and supply foundation studs and fitted studs to suit your application. Ed.1.5.2 ‐ RotaChock Information Book 24 Spherical Spacers The purpose of chocking is to create a perfect coplanar mounting surface for the machine(s). The RotaChock product is a mechanical chock that corrects for the inherent mounting surface inconsistencies between a machine and its’ foundation – coplanar mounting surfaces are assured! Now that the unit is mounted properly using RotaChock, pour chocking systems or blocks and shims what about the mounting hardware? Illustration 1 depicts two configurations currently in the field.` EQUIPMENT
EQUIPMENT
ANGULAR
MISALIGNMENT
ANGULAR
MISALIGNMENT
TAPPED BLOCK
SKID
HARDWARE
MISALIGNMENT
SKID
HARDWARE
MISALIGNMENT
ILLUSTRATION 1 Hardware Bending No matter what type of chock is installed, the bolt is stressed into position during installation. Usually in production line settings it is not a problem, but all the time, over time, the hardware will loosen. The loosening hardware will affect the vibration, maintenance requirements and eventually the chock and/or equipment. All service teams have a story of at least a few packages out there that are having problems relative to mounting hardware loosening. It is not the equipment, not the chock and not the service guy not taking care when tightening the hardware. It is a bolt or stud that is stress relieving due to angular misalignment. Ed.1.5.2 ‐ RotaChock Information Book 25 Spherical Spacer Solution The Machinery Mounting Solutions Spherical Spacer accomplishes two functions: 1) it creates hardware planes and 2) bolt elongation. The RotaChock® by design is capable of taking the clamping force created by the hardware at any length. Whereas the rule of thumb for poured epoxy resins is about 12 bolt diameters minimum. We offer the spacer to suit your application while creating a fastener that is in pure tension and no longer a maintenance problem for the life cycle of the machine. Illustration 3 and Table 1 depicts our part number and diameters offered. The angular offset maximum angle is 4 degrees. The length of the spherical spacers can be manufactured to your requirements. EQUIPMENT
ANGULAR
MISALIGNMENT
SKID
HARDWARE PLANE
MISALIGNMENT USING
THE SPHERICAL SPACER
ILLUSTRATION 3 Spherical Spacer Solution (Illustration shows a non specific configuration, a particular application may require a different configuration) Contact Machinery Mounting Solutions for more information Ed.1.5.2 ‐ RotaChock Information Book 26 Machinery Mounting Solutions ’
RotaChock® Adjustment Tools
Adjusting the RotaChock® is a simple task that can be accomplished using a large variety of tools. From years in the
field, we have learned that having options is a significant RotaChock® advantage. The slots are shown in Illustration 1
below. Tools like: Flat head screw drivers ( with tip slightly ground off to provide grip in the slot ) , chisels, Allen
wrenches, dowel pins or similar hand tools accomplish the job. Further, we recognize some technicians like the feel
of a spanner. In support of customer inquiries we stock a range of adjusting tools:
RotaChock ®
Part #
RC2
RC3
RC4
RC4.5
RC5
RC6
RC7
RC8
RC9
RC10
TB‐RC2
TB‐RC3
TB‐RC4
USE ‐ TB‐RC5
TB‐RC5
TB‐RC6
TB‐RC7
TB‐RC8
TB‐RC9
TB‐RC10
Other tools:
RC2 & RC3
DEEP
0.20"
OPENING
0.16"
0.25"
0.12"
0.20"
RECTANGLE
RC4 AND LARGER
DEEP
0.31"
OPENING 0.16"
0.31"
0.12"
0.25"
RECTANGLE
ILLUSTRATION 1
Tel: 757‐ 460‐0050 VA 281‐298‐9911 TX 985‐293‐7723 LA www.MachineryMountingSolutions.com
RotaChock Foundation – Design Notes Q. How much coverage does the RotaChock need? A. Insure the foundation width will accommodate the RotaChock® base part diameter. The RotaChock® bottom part should be fully supported. Not having the base ring fully supported can distort the thread in the base. The distorted thread could lock the device prematurely. Prevent a problem and support the base. GAP
SATISFACTORY
UNSATISFACTORY
Coverage of the top part is usually governed by the bolt position of the machine. As long as that position is acceptable for equipment manufacture for shear forces (side pullout requirements) from the machine it will be acceptable for the RotaChock. Ed.1.5.2 ‐ RotaChock Information Book 28 Q. Can a spacer be added to mounting system? A. Yes, but we caution the installing activity to control the configuration of the spacers and condition of foundation surface. Below are some scenarios that we have seen in the past years. Double chock on a single shim: The scenario is: The foundation is off slightly (normal condition) The shim (usually thin) is sheared and not necessarily flat. A unit is aligned properly on the jack screws. Chock 1 is installed (at the four corners) the bolts are tightened. Technician A walks away and is happy with a good job. The Technician B comes in and installs chock #2 and tightens everything up. Next thing to check is softfoot. You got it! Softfoot! What’s happened? The shim is not flat but it is thin enough to deform (spring) into contour as clamping force to chock #1 is applied. The remaining shim under chock #2 is now a loaded spring (un‐calibrated). The RotaChock with its buttress thread tightens with a small amount force – as designed! It must be the chocks fault! We offer taller top parts to accommodate the shop and field. If spacers are required, we recommend milled flat spacers which are positioned between the component foot and the chock. Ed.1.5.2 ‐ RotaChock Information Book 29 Q. What other considerations need to be taken into account? A. Some installations require cutouts to be made in the I‐Beam webs to gain access to the foundation bolts. Below are some illustrations. Incorrect – fastener access is too large for the diameter of the chock and the removing the web material is too close to the mounting flange. The results are a greatly reduced beam strength and system that acts like it has softfoot. Improved fastener access maintains the strength of the mounting flange. Add a spacer to access the nut for ease of maintenance for the lifecycle. Ed.1.5.2 ‐ RotaChock Information Book 30 Appendix A – Application Photo Album RotaChock Photo Album of some recent installations 




Engines Motors Compressors Gearboxes Marine Ed.1.5.2 ‐ RotaChock Information Book 31 Engines:‐ Ed.1.5.2 ‐ RotaChock Information Book 32 Electric Motors:‐ Ed.1.5.2 ‐ RotaChock Information Book 33 Compressors: ‐ Reciprocating & Screw Ed.1.5.2 ‐ RotaChock Information Book 34 Gearboxes:‐ Ed.1.5.2 ‐ RotaChock Information Book 35 Shaft Brakes: ‐ Marine and Wind power Ed.1.5.2 ‐ RotaChock Information Book 36 Appendix B– Data Sheets 
Basic Data Sheet Contact Machinery Mounting Solutions or check our web site for the following data sheets 




Rail Mounted Engine Foot Mounted Engine Electric Motor / Generator Compressor Pump Ed.1.5.2 ‐ RotaChock Information Book 37 Basic RotaChock Sizing Data Sheet
Date:
CUSTOMER DATA
Company
Contact
Project
Phone
Machine
Email
Make
REQUIRED DATA
Power
Hp / kW
Width between Bolt Holes (across C.L)
in / mm
Gap Height (L)
in / mm
Speed (RPM)
Bolt Hole Dia
Machine Foot Thickness (F)
in / mm
# Foundation Bolts in / mm
Foundation Thickness (J) in / mm
BOLT DIA
Weight
lbs / kg
BOLT HOLE DIA
BOLT DESIGN
BOLT DESIGN
Bolt Dia
Notes
in / mm
F
L
Qty of Bolts
J
Grade of Bolt
VA 877‐460‐0050 (TOLL FREE)
757‐460‐0050 (P)
757‐460‐0054
757
460 0054 (F)
TX
281‐298‐9911 (P)
281‐220‐8368 (F)
LA 985‐293‐7723 (P)
985‐635‐4585 (F)
Rev 1
Rev 1

Brochure - Canstar Instruments Inc.

Transcription

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