1. Re-grout of CLARK-BROS 4 cylinder Hyper Compressor Assigned by Dresser Rand, the Netherlands Sope Total re-grouting of Hyper compressor foundation and soleplates End user Petrochemical Industry1

2. Schematic Lay-out of Clark-Bros compressor (2 cylinders only) Mainframe Frame extension Tie Rod Cylinder 2 3. History Previous revision 1990 Top of foundation was covered with Chockfast Red epoxygrout Chocks were grouted with Chockfast Orange epoxygrout New anchors 1 x 8UN were installed 3 4. Scope 2010I.Investigate present status of foundationII. Register exact position of mainframe with 3D laser equipmentIII.Repair cracks in foundation by epoxy injectionIV. Remove 100 mm from top of foundation in order to create clearance for soleplatesV.Drill all required pockets for new anchorsVI. Make existing 16 anchors suitable for re-use (compress the injected cold-joints)VII.Design, supply & install soleplates for E-motor and frame extensionsVIII. Align mainframe and soleplates for extensions and E-motorIX. Grout anchors, mainframe and soleplates (extensions & E-motor)X.Install BoltSafe sensors on all anchorsXI. Install / grout new pipe support-anchorsXII.Products used 4 5. I. Investigate present status of foundation Measurements were taken during a 1 day stop 7 months before TA: Vibrations on anchors/feet URS on concrete/CFRed cracks Core samples were drilled for: Compressive strength tests Oil penetration De-lamination (non adhesion) CO2 penetration (carbonization) Thorough visual investigation 5 6. I. Results from investigationMain conclusions: Some small areas of delaminated CFRed/concrete Penetration of oil was not confirmed No serious cracks could be identified Vibration levels in general proved to be to be too high One (extension) anchorbolt was broken6 7. II. Register exact position of mainframe with 3D laser before removal In order to re-connect all piping without tension, it is important to position the mainframe back into its exact original position, even without having the extensions and cylinders attached The SOKKIA Total station 0.5 3D Laser equipment is used to measure the original position of the mainframe & E-motor Reproducible fixed points were taken from the top cover threaded holes Targets were fixed on various stable structures as reference points for later orientation 7 8. III. Repair of cracks in the concrete foundation Hand injection of delaminated layers with low viscosity epoxy 8 9. III. Repair of cracks in the concrete foundationSome cracks were sample-drilled in order toidentify the depthThis crack did not continue into the concrete9 10. III. Repair of cracks in the concrete foundationHowever when drilling out the old anchors,another big horizontal (cold joint) crack wasidentified in the concreteAdditional injections were made10 11. IV. Remove 100mm from top of foundation for clearance of soleplatesA grout-clearance of 50mm is required under the soleplates for thenew Chockfast Red grouting Including the soleplates thickness 100mm was removed by firstcutting the existing Chockfast Red into small bricks followed byhydraulic jacking11 12. V. Drilling (diamond-) of all pockets for the new anchors12 13. VI. Make existing 16 anchors suitable for re-use Considerations for re-use of the existing anchors The anchors installed in 1990 are ca 4000 long; drilled and grouted into the mat of the concrete foundation Taking them out would require a time consuming drilling-action with very likely a break through into the ground water Initial vibration tests had been performed with the 16 anchors in function Not re-using them could give a significant difference The (later confirmed) suspicion of the existence of horizontal cracks in the concrete block make vertical compression necessary as much as possible Adding vertical compression after installation of the compressor would leave not enough space to introduce additional anchors afterall 13 14. VI. Making existing 16 anchors suitable for re-use A guiding piece was designed to make sure the 1 -8UN thread was aligned properly to the B7 quality anchor New thread was cut after the anchors were cut down to sizeVIDEO 14 15. VI. Making existing 16 anchors suitable for re-use New thread was cut after the anchors were cut down to size 15 16. VI. Making existing 16 anchorssuitable for re-use16 large flanges were grouted in with Chockfast GrayAfter cure the nuts were set to 1000 Nm 16 17. VII. Design, supply & install soleplates for E-motor After removal of the stator (sliding backwards) The old soleplates were removed The steel shims became visible (frequently corrosion of the shims create misalignment of the stator) And the top-layer was jacked off17 18. VII. Design, supply & install soleplates for E-motor After removal of the old soleplates 150mm was jacked off The anchors drilled out Jackplates positioned Shuttering installed 18 19. VI. Design, supply & install soleplates for E-motor Soleplates aligned with 3Dlaser And grouted with ChockfastRed epoxygrout 19 20. VI. Design, supply & install soleplates for E-motorFinished soleplates with E-motor installed 20 21. VII. Design, supply & install soleplates for the Frame-extensions The soleplates for the Frame extensions required a new approach. After detailed discussions it was approved to install a soleplate under each extension mounted into the concrete with 2 grouted anchors and 2 gibkeys to resist horizontal forces The extensions are mounted with 4 studbolts 21 22. VII. Installation of soleplates in steps Layout of a soleplate with 2 anchors and gibkeys Per anchor 2 holes were drilled in an -8- shape One 125 1500 deep One eccentric 60 750 deep This smaller hole allows the anchor glue Chockfast Red to flow smoothly into the pocket 22 23. VII. Installation of soleplates in steps Layout of a frame-extension soleplates Soleplate Grout-anchor Pocket23 24. VII. Installation of soleplates in steps A gibkey is mounted into the soleplate with a H7 fitting an spotwelded Grout-anchor Gibkey24 25. VII. Installation of soleplates in steps The gap between anchor and gibkey is closed with kit in order to avoid epoxy to enter in-between anchor and gibkey, which otherwise would influence stretching of the anchor Stretch length of anchor Gibkey Kit Passage along the gibkey allows the Chockfart Red to pass the gibkey 25 26. VII. Installation of soleplates in steps First the anchor is grouted with Chockfast Red The anchor needs to be fixed in order to align the extensions also along z axis Grout blocks air-passage through the tube as soon as the correct level is reached The tubing functions as level- control26 27. VII. Installation of soleplates in steps Next the Gibkey is grouted with Chockfast Gray Chockfast Gray has a lower viscosity, applicable for the smaller clearance between gibkey and pocketdiameter Cured Chockfast Red Horizontal displacement is blocked27 28. VII. Installation of soleplates in steps Last step is to grout the soleplate with Chockfast Red new Chockfast Red layer Existing (old) Chockfast Red layer28 29. VII. Installation of soleplates in practiceAssembly of the soleplates withgibkey, anchors and stud-boltsThe Bolt-Safe sensors areinstalledThe level-tube is checkedThe soleplates are installed withthe prepared anchors hangingloose in the pockets29 30. VIII. Align mainframe and Soleplates Thanks to precise 3D Laser alignment of the frame-extension- soleplates, the frame was re- installed at an accuracy of 0,5 mm30 31. IX. Grout anchors, mainframe and Soleplates Inflated tubing protects grout from running under frame-carter31 32. X. Installation of Bolt Safe sensors Bolt Safe sensors were installed under each nut of both soleplate-anchors and the stud-bolts of the frame extensions With the hand-held read out attached, the sensor gives the real compressive force exerted by the nut in kN This clamping-force is checked on a regular basis 32 33. XI. Install & grout new pipe support-anchors Following vibration measurements it was indicated that some re-designed pipe supports had to be installed33 34. XII. Products used Chockfast Red 3 component epoxy groutChockfast Gray 2 component epoxy grout Chockfast Orange 2 component epoxy groutBoltSafe anchor tension sensor type CMS 34 35. Final result 35