Idea Transcript
Presented By: Jason Lewis Concrete and Composites Regional Manager
Deterioration Grout Packing Injection Repair
Foundation Repair 3
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Foundational Failure Is One Of The Most Common Factors Leading To Vibration In Pump and Motor Basins
If Foundational Failures Are Not Addressed You May Experience Significant Particle And Coupling Wear Which May Result In Premature Replacement And Unscheduled Shut Downs
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Foundational failures can occur from- Inferior Material Composition at time of pour
- Cracked or Deteriorating Grout Packing and Concrete
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Foundational failures can occur from-Corroding Reinforcing Steel in the Basin
- Chemical Attack To The Basin
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Deteriorating Grout Packing Is a Major Contributor Of Motor And Pump Foundational Vibrations -As Grout Packing deteriorates
it cracks and refines itself to granules or dust due to Vibration Transfer from the Pump and Motor to the sole plate
-This deterioration
Causes voids under the sole plate creating foundational Instability and Vibration
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-Combined with centrifugal force the Sole Plate
will lift from the Grout Packing allowing voids to move linear
This will allow Vibration to travel throughout the Sole Plate-
Including the Footpads & Anchor Points transferring to the Motor , Pump and possibly the Pipe
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Equipment Tiedowns Substantial amounts of Force Are Placed On The Footpads And Equipment Anchor Points
These areas are usually the most affected by Grout Packing Deterioration Creating Voids and an Unstable Foundation
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Previous Vibratory Solution Methods Included Shimming the Anchor Areas Although this method has been widely accepted for aligning the Pump and Motor and Specked by some Manufactures, It may have adverse affects when related to Vibration The Machine Level- Where the Pump and Motor meet- Should be Laser aligned If the Machine Level is out of alignment It is recommended to Mill to near perfect conditions This Method is only recommended if you have taken steps to ensure the Foundation and Soul Plate are Sound
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Epoxy Injection Repair Method Epoxies are a Composite that consist of 2 or more components to make a material specifically designed for certain Applications and Chemical Exposures Epoxies used for Grout Pack Solidification and Basin Injection have a compressive strength ranging from 8,500 PSI (when applied at 73°F and 1 day cure) To 12,000 PSI (at 73°F and 28 day full cure) The Injection Method Is Minimally Invasive Only Requiring Holes to be drilled in Hollowed Locations and can be Pumped under High or Low Pressure 11
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Epoxy Injection Repair Method Where Can Epoxy Injection Can Be Performed? Pump Basins Sole Plates Exciter Basins Concrete Foundations Structural Reinforcement Applications Reinforcing Steel Mitigation
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Steps For Epoxy Injection Repair Method (Please Note That it is Best That The Pump And Motor Are Removed Prior to Injection for access to the Interior Sides of the Footpads)
1-Perform Acoustic Testing Of Entire Sole Plate to Determine the Hollowed Areas 2-Mark Hollowed Areas To Be Drilled 3- Drill areas marked with 1/8 Bit 4- Place Injectors in Drilled Holes and Apply High Modulus Epoxy Gel around Injectors to secure in place and coat any potential leak sources and allow to cure for 1 hour
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Steps For Epoxy Injection Repair Method (Please Note That it is Best That The Pump And Motor Are Removed Prior to Injection for access to the Interior Sides of the Footpads)
5- Begin Injecting Epoxies under desired pressure ( not to exceed 25 PSI) 6- Transfer of Materials Under Pressure will Travel the path of least resistance do to Viscosity ( around 200 cps) 7-When Product is Visibly flowing out of a port, the port that is being injected will be capped and the Injector valve will be moved to the flowing port to ensure product movement linearly
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Steps For Epoxy Injection Repair Method (Please Note That is Best That The Pump And Motor Are Removed Prior to Injection for access to the Interior Sides of the Footpads)
8- Once product has Visibly been seen flowing out of all installed Ports and then capped, the operator will flow product to the maximum 25 PSI to test resistance, if none is found, the final port will be capped and Materials will be allowed to Cure
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Foundational Repair
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Foundational Repair Foundational repairs are required when the stability of the structure has been compromised by Chemical Exposure, Rebar Expansion, Concrete Spawling or other Environmental or Mechanical factors
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Foundational Repair Concrete breathes or expands and contracts do to the Environmental or Chemical elements it is subjected to This allows water, moisture vapors and gases to permeate through the structure attacking the reinforcing steel within it Even the smallest of cracks in the structure will allow absorption of moisture providing a direct path to the reinforcing steel 18
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Foundational Repair Once the reinforcing steel had has be compromised it is paramount that steps be taken to mitigate any future corrosion
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Foundational Repair If steps are not taken to mitigate corrosion the reinforcing steel will absorb the moisture, expand and create a spawl weakening the structure This will also allow the corrosion to move linear through the steel creating significant damage which may result in total failure of the basin 20
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Foundational Repair Repairs can include: 1- Cement Repair 2-Pressure Grouting 3- Epoxy Mortar Repair 4- Epoxy Injection Method
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AGENDA Our Mission and History Safety Discipline Where We Operate Today Our Concrete & Composite Repair Solutions Why Choose Furmanite?
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Maximizing Asset Uptime Everything we do centers around keeping your assets operational Furmanite s definition of an Asset anything and everything that can impact a customer s bottom line Furmanite s definition of Uptime keeping the Asset productive and profitable at all times 23
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Hot-Tapping and Line Stopping OEM for World Class Tapping and Stopping Machines Engineering Services Online Leak Sealing On-Site Machining and Bolting Valve Repair
Shop or On-site
Trevitest On-line Valve Testing Tank Roof Repair Concrete and Composite Repairs Heat Treatment Services
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FURMANITE S HISTORY & EXPERTISE Since 1929, Furmanite has maintained its leadership role in the research and development of on-site repair and maintenance 2006, Furmanite purchases the Global Services Group (GSG) of Flowserve Furmanite is the single most authoritative source for all of your global industrial services needs
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DOMESTIC SERVICE CENTERS
For a complete listing of regional and global Furmanite locations, visit us online at www.furmanite.com 26
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SAFETY Central to Everything We Do Furmanite has a full-time safety director and a comprehensive safety program In 2005, we completed one-million man hours (over two years) without a lost-time injury Every technician must be certified in safety training
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FURMANITE TECHNICIANS Safety Backed by Training New hire (8 hours) HAZWOPER (40 hour) OSHA (10 hours) Annual refresher (8 hours) Area safety councils Supervisor s training (four days)
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SAFETY DOCUMENTATION Tracking Safety Success On-site job reference manual Daily job safety analysis Weekly safety meetings Equipment safety logs Corporate safety audits Site specific SOPs
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ENGINEERING SERVICES Turnkey problem solving expertise Design to ASME, API or ANSI standards 40 years of industrial service design experience Worldwide network of in-house designers and engineers Support to the entire range of Furmanite services disciplines
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Servicing All Types Of Industry
Pharmaceutical 32
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EXPERIENCE 20+ Man-Years of Concrete & Composite Management Experience 10 Year Average Technician Experience Level Best of the Best D.O.T Trained For Servicing Regulated Pipelines
Servicing : Maintenance Outages Turnarounds Capital Projects Call-Outs 24 Hour Service, 365 Days per Year 33
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SERVICES AND SOLUTIONS FOR EVERY BUSINESS SECTOR MUNICIPAL
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Sanitary Sewer Systems
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Water Treatment and Distribution Plants
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Airports
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Schools
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Hospitals
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Bridges , Ports, Roadways and Tunnel Systems
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Stadiums and Arenas
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SERVICES AND SOLUTIONS FOR EVERY BUSINESS SECTOR Industrial
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Utility Companies
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Hydroelectric Dams
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Petrochemical and Chemical Plants
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Refineries
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Fossil and Nuclear Power Plants
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Steel Mills
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Paper Mills
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Tank Farms and Storage Facilities
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SERVICES AND SOLUTIONS FOR EVERY BUSINESS SECTOR Commercial -
Building Management and Investment Groups
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Hospitals
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Private Owners
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General Contractors
Geotechnical - Mining Operations - Earthen Dams - Secondary Containment 36
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Epoxy Injection Urethane Injection Water Stops Surface repair and Coatings Restorations and Secondary Containment Structural repairs Pipe and Structural Composite Wraps Pipe Penetrations 37
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Structural Repair and Expansion Joints Water Control (Leak Stoppage) Surface Repair (coatings and linings) Epoxy Injection Pump and Motor Base Repair Soil Stabilization Pipe Penetrations Secondary containment Restoration projects
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EPOXY INJECTION: Low Viscosity Moisture Insensitive Easy Application Can be done under low or high pressure Extreme High Strength Chemical Resistance 100% Solids
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Applications Heavy machinery base repairs Pump and motor base repair Structural support base repair
Epoxy/Urethane pressure injection method Holes drilled into concrete at strategic locations Two part epoxy resin is injected 24 to 72 hours for final cure
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GROUTS, EPOXIES & COATINGS Epoxies: High and low modulus gels Viscous ( to +/- 0 cps) 100% solids
Grouts: Hydrophilic and Hydrophobic Particulate Can be used for Void fills and Water Stops Creates new seals around Pipe Penetrations Can be used as Flexible Gaskets
Coatings: Elastomeric, Mastic, Non Skid Epoxy Can withstand a variety of Chemicals including up to 98% Sulfuric Acid 41
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Polymer cementitious products and chemical resistant coatings repair surface damage as a result of: Corrosion Chemical Attack Freeze/Thaw Wear & Abrasion Physical damage
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URETHANE GROUT INJECTION: Cost Effective Non-Toxic Single component Void Fill Capability - Vertical and Horizontal Can be used as a flexible joint or gasket No Down Time - Work can be completed while components are online Stops water intrusion in cracks, joints and pipe penetrations Can be used in potable water applications
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Solution for problems such as: Freeze / thaw damage Corrosion of reinforcing steel Erosion of the structure Mineral deposits Loss of dry environment
Repair sealant capabilities: Thin enough to penetrate hairline cracks Work in flowing water Bond to wet surfaces Remain flexible and inert after quick curing
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COATINGS AND LININGS COATINGS: Rapid Cure, Fast Turnaround, Minimal Downtime Available Equipment to Heat Treat for Specialty Coatings Resistant to Acids and other Chemicals Odorless Tough Elastomeric Membrane Liners Excellent Wear & Adhesion Traffic Resistant Wide Variety of Colors
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Surface Overlayments & Toppings
Expansion Joint Design & Repair
Spall Repair With Epoxy Adhesive & Polymer Concrete
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PIPE & COMPOSITE WRAPS PIPE WRAP & COMPOSITE WRAP: Low Cost Pipe Wrap gives back to 100% integrity with up to 80% wall loss due to corrosion or blunt defects Utilizes High Strength Carbon Fiber or Urethane Impregnated Fiberglass Cloth No Downtime
work can be done on-line
Engineered Solution Conforming -Can Easily turn Elbows and Tee s unlike most Materials Is Water Insensitive - Resistant To Bad Rain Weather, Can be Applied Underwater in Splash Zones and Transition zone 48
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How Composite Wraps Work
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Permanent pipe repair Stronger than the existing material Pipe rehabilitation Small-bore pipe repairs Nozzle repair Tank repairs Structural repairs Applied on site No Workshop Simple Preparation 50
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Specialized Product:
FurmaWrap-FW1 Resin-impregnated fiberglass tape adheres to PVC, fiberglass, concrete and all forms of metal pipes Immediately repairs non active leaks and reinforces pipes Protects against corrosion, abrasion and impact Effectively stops leaks on pipes of all sizes Resistant to a wide range of dangerous chemicals 51
Used for underwater repairs Furmanite Confidential - 1/9/04
Specialized Product:
FurmaWrap-FW2 Durable and cost-effective solution for permanent reinforcement and repairs Resin-impregnated fiberglass composite wrap Stronger than steel, high tensileand high flexural-strength product Increases axial load strength and load bearing capabilities in steel (pipe) and concrete
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Specialized Product:
FurmaWrap-FW2 (continued) Remediates pipes, elbows, tees and concrete structures Inhibits corrosion and restores pipeline integrity Resistant to a wide range of dangerous chemicals Works in wet or dry conditions, including underwater repairs Classified according to ANSI/NSF 61 standards for drinking water safety
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Design and Construction Guidelines United States ACI 440.2R-02
Canada CSA S 806
Europe FIB TG 9-3
Asia JCI / JSCE / AIJ
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Used for: Increasing load bearing capacity Correcting design/construction errors Restoring strength lost from damage/deterioration Improving seismic performance of existing structures Blast hardening structures
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Traditional Strengthening Techniques Section Enlargement Beam flexural strengthening Adding flexural reinforcement New Reinforcing Steel
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Traditional Strengthening Techniques Steel Plate Bonding -Slab flexural strengthening -Steel plates bonded with epoxy adhesive -Supplemental anchor bolts
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Carbon fiber reinforced polymer (CFRP) laminate applied to surface of the substrate
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Materials Carbon fiber composites Advanced composites Fiberglass composites Structural plastics
Material Characteristics Very High Strength Light weight Non-corrosive Non-magnetic
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Fiber Reinforced Polymers (FRP)
Polymer (Resin)
Fiber Reinforcement
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Types of Fiber ReinforcementsCarbon Fiber Aramid Fiber Glass Fiber
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Types of Polymers -Epoxy -Vinyl Ester -Silicone -Phenolic -Polyimide -Ceramic -Geopolymer 62
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CF 130
CF 530
EG 900
AK 60
0.0065
0.0065
0.0139
0.0110
Guaranteed 550 ksi Strength
510 ksi
220 ksi
290 ksi
Elastic Modulus
33 Msi
54 Msi
10.5 Msi 17.4 Msi
1.7%
0.9%
Design Thickness
Elongation at Rupture
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2.1%
1.7%
600
Carbon
Stress (ksi)
500 400
Aramid
300 200
E-Glass
100 0 0
0.005
0.01
0.015
S tr a in (in /in )
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0.02
0.025
Carbon Fiber - High Strength - High Stiffness - High Endurance - Excellent Durability - Conductive
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Aramid Fiber - High Toughness - Impact Resistance - Moderate Endurance - Non-conductive
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Glass Fiber -High Elongation - High Strength - Poor Durability - Low Endurance - Low Stiffness - Non-conductive
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Used for:
External reinforcement of existing structures Increasing load bearing capacity Restoring strength lost from damage/deterioration Improving seismic performance of existing structures Blast hardening structures
System Types:
Fabric Systems Laminate Systems 68
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Flexible, unidirectional fabrics woven of high strength fibers that are 10 times stronger than steel
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Fabric Systems Application Apply two-component epoxy resin directly onto substrate
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Fabric Systems Application -Apply two-component epoxy resin directly onto substrate
-Place dry fiber fabric into resin
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Fabric Systems Application -Apply two-component epoxy resin directly onto substrate -Place dry fiber fabric into resin -Apply a second layer of resin to encapsulate the fabric -Allow the epoxy to cure and form a rigid FRP plate bonded to the substrate
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Fabric Systems Advantages Flexible, contour to shape of structure
Can be installed with minimal access
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Laminate Systems Rigid FRP plates, precured with high strength fibers and resin
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Laminate Systems Application -Adhesive is placed onto one side of rigid FRP laminate
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Laminate Systems Application -Adhesive is placed onto one side of rigid FRP laminate -Laminate and adhesive pressed onto substrate
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Positive Moment
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Flexural Cracking
Shear Strengthening Shear Reinforcement -Fibers placed vertically or at an angle to shear cracks -Can be discrete strips or a continuous plate -Increased shear capacity of 2-kips per inch of (beam) depth are reasonable -Beams, shear walls, shear diaphragms
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Confinement Column Wrapping -Some increase in axial capacity is possible (very limited for prismatic members) -Large increase in ultimate deformation is possible -3X to 4X increase in ductility index is reasonable
-Large columns require significant number of layers
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Confinement
Lateral failures of columns in a seismic event
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Masonry Wall Retrofit
The MBrace® System Replaces steel reinforced shotcrete
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Slab Cut-out 8 Concrete Slab New 3 x4 opening cut 12 #6 reinforcing bars cut
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Slab Cut-out Traditional Technique Steel wide flanges Anchored into adjoining beams 1200-lbs dead load
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Slab Cut-out FRP Technique 4 Strips of MBrace® CF 130
Replaces cut reinforcement 5-lbs dead load
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Strengthening around Openings and Cutouts The MBrace® System Replaces steel reinforcement and prestressing that is cut Controls cracking
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THE INDUSTRIES BEST TWO STAGE EPOXY PUMP GROUT INJECTION PUMPS 45:1 SPRAY PUMP
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BENEFITS OF CONCRETE & COMPOSITE REPAIR RESOLVES VIBRATION PROBLEMS STOPS WATER LEAKAGE STOPS REBAR EXPANSION REPAIRS SPAWLED AREAS SOIL STABILIZATIONS (PERMIABLE SOILS) REPAIRS PIPING -ELIMINATES COSTLY SHUT DOWNS OR REPLACEMENTS MAINTENANCE -ADDS LIFE TO THE STRUCTURE OR PIPE LINE SAFETY 87
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FURMANITE QUALITY ASSURANCE Furmanite is a NUPIC Approved 10CFR 50 Appendix B Supplier and is a member of the Nuclear Industries Assessment Committee (NIAC). Furmanite s Quality Assurance Program consists of the following manuals: QA Manual to Nuclear & ISO 9000 format QA Procedures and Forms Standard Procedure Manual Training Program Measurement and Calibrations NIST Traceable NUPIC Approved Calibration Supplier Onsite Pre & Post Calibration
Procedures to applicable Industry Codes ASME BPVC Sections I, III, VIII and XI ASME B31.1 and B31.3 API, NBIC, AWS 88
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WHY CHOOSE FURMANITE? Backing of a company with a global presence and knowledge base Over 75 years of proven experience in solving unique problems and managing large projects Quick response with over 25 locations in USA Diverse and flexible solutions for proactive repair, maintenance and turnaround support Experienced, field-proven and motivated technicians State-of-the-art equipment and tools Patented technology
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Visit Furmanite online at
www.Furmanite.com Or for immediate assistance
Contact your Local Office:
Jason Lewis 704-488-1140 90
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