Method of transporting rotating equipment modularization

A module for an engineering, procurement, and construction (EPC) project is described. The module comprises machinery disposed on a baseplate. The baseplate is coupled with a support structure via adjustable, self-leveling chocks. The chocks maintain a level baseplate surface regardless of whether or not the underside of the baseplate and the support structure are parallel. The chocks reduce and/or eliminate the transfer of the deflection forces from the support structure to the baseplate.

FIELD OF THE INVENTION

The field of the invention is engineering, procurement, and construction (EPC) projects, more specifically, systems and methods for modularization of EPC projects.

BACKGROUND

In the construction industry, an Engineering, Procurement, and Construction (EPC) project refers to the task of (i) designing a structure or facility, (ii) procuring the materials necessary to build the facility, and (iii) building the facility, either directly or indirectly using subcontractors. For large EPC projects, such as the construction of a large oil refining complex or an upstream process facility, it is becoming more and more common to modularize the assembly and construction process in order to reduce on-site work. For example, in the case of a refining complex, the facility can be constructed by building “modules” (e.g., sub-structures or smaller structural units) off-site at a “module yard.” The modules are then transported to the construction site and assembled with other modules to complete the construction project. Modularizing an EPC project can reduce field labor costs and improve process efficiency by allowing different module yards to specialize in specific construction/assembly techniques.

Modularization of EPC projects is discussed in further detail in co-owned U.S. patent application Ser. No. 12/971365, filed on Dec. 17, 2010. This and all other referenced extrinsic materials are incorporated herein by reference in their entirety. Where a definition or use of a term in a reference that is incorporated by reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein is deemed to be controlling.

For some EPC projects, a “module” can comprise a piece of equipment or machinery (e.g., centrifugal pump, driver motor, etc.) mounted on a baseplate, the baseplate being supported by a support structure (e.g., steel I-beams, frame structure, etc.), as shown inFIG. 1. In conventional modular EPC methods, the baseplate is rigidly coupled with the steel beam, such as by welding or using anchor bolts.

One problem that can arise during a modular EPC project is the deflection and warping of the baseplate (e.g., bending, torsional twisting, etc.) caused during transportation of the module from the module yard to the project site by rail or by land.FIG. 1illustrates the deflection of a baseplate during transportation. The deflection of the baseplate is caused by several factors including the sag of the support structure (due to the support structure's own weight and the impact loads or shock loads due to uneven road surface, or potholes in the road that are encountered during transportation). If the baseplate deflects past a certain limit, called its elastic limit, the baseplate will likely warp, causing the machinery mounting pedestals to distort. A warped baseplate will then need to be repaired, replaced, and/or machined at the project site, which can be very costly and time consuming.

Another related problem is the possible deflection of, and permanent damage to, expensive equipment and machinery (e.g., deflection of coupled shaft ends). Again, this may require repair at the project site, which will increase costs and delay deadlines.

Thus, there is still a need for devices and processes that improve the modularization of EPC projects by reducing and/or eliminating the risk of baseplate warping.

SUMMARY OF THE INVENTION

The inventive subject matter provides apparatus, systems and methods in which a module for an EPC project comprises a machinery baseplate coupled with a support structure via adjustable, self-leveling chocks. The chocks maintain a level baseplate surface regardless of whether or not the underside of the baseplate and the support structure are parallel. The chocks reduce and/or eliminate the transfer of the deflection forces from the support structure to the baseplate.

DETAILED DESCRIPTION

FIG. 1shows a conventional module100for an engineering, procurement, and construction (EPC) project. Module100comprises two or more support steel structure130rigidly coupled with a baseplate120. Structure130can be rigidly coupled with baseplate120via welding or a mechanical fastener (e.g., anchor bolts). A piece of machinery or equipment110is disposed on top of the baseplate120. Support structure130is disposed on, and may be rigidly coupled with, a module surface140.

During transportation of module100from a module yard to an EPC project site, support steel structure130may sag. This sagging can cause baseplate120to warp (e.g., the deflection forces in support structure130are transferred to baseplate120). If baseplate120warps beyond acceptable limits, baseplate120will need to be repaired after it arrives at the EPC project site. Moreover, deflection of baseplate120may cause bending in machinery110, resulting in permanent damage to machinery110.

FIGS. 2aand 2bshow various views of an improved EPC module200. Module200comprises machinery210(pump210aand driver motor210b) disposed on top of a baseplate220. Baseplate220is coupled (e.g., secured to, fastened to, etc.) with two or more support structures230via a plurality of chocks225. The chocks help to isolate the deflection of support structure230from baseplate220. More specifically, chocks225have self-leveling (e.g., self-adjusting) capabilities that compensate for a slight angular variation between baseplate220and the support structure230. This allows support structure230to deflect and bend under static and/or dynamic loads, without warping or twisting baseplate220.

FIG. 3ashows a close-up, partial cross-sectional view of one of the chocks225coupled with baseplate220and one of the support structure230. Chock225is coupled with baseplate220and support structure230via an anchor bolt340. When the through-holes350(as shown inFIGS. 3band 3c) of chock225, baseplate220, and structure230are aligned, anchor bolt340can be inserted through the through-holes350and secured by tightening a nut on the end of bolt340. Before the nut is completely tightened, the vertical height of chock225, and thus the distance between baseplate220and the structure230, can be adjusted. (The manner of adjusting the height of chock225will be described in more detail later on). Once baseplate220is leveled by adjusting the height of all chocks225, bolts340can be tightened to the required torque.

FIGS. 3band 3cshow various views of chock225apart from baseplate220, structure230, and bolt340. Chock225comprises a top annular member320threadably coupled with a bottom annular member330. The threaded coupling allows top member320and bottom annular member330to rotate relative to one another, which provides for adjustment of the vertical height of chock225. Top member320and bottom member330each have a plurality of divets322and332(e.g., holes), respectively, on their cylindrical sides. Divets322and332can be engaged by a tool (e.g., wrench) to rotate members320and330relative to one another to thereby adjust the height of chock225.

Chock225also includes a washer310coupled with top annular member320. The top surface312of washer310is substantially flat whereas the bottom surface of washer310is curved (e.g., spherical, convex, etc.). The top surface of top annular member320is concave and has a curvature that complements (e.g., is substantially concentric with) the spherical bottom surface of washer310. In some embodiments, top surface312has a flatness of 0.002 inches or better and/or a surface finish of Ra 250 micro-inches or better. In addition, the portion of the bottom surface of baseplate220may also have a flatness of 0.002 inches or better and/or a surface finish of Ra 250 micro-inches or better.

The spherical bottom surface of washer310is in sliding contact with the top concave surface of top annular member320such that angle360(e.g., the angle between the plane defined by the top surface312of washer310and a hypothetical horizontal plane) is adjustable. In some embodiments, the coefficient of friction between the bottom surface of washer310and the top concave surface of top annular member320is less than 1, more preferably less than 0.5, and most preferably less than or equal to 0.2. In some embodiments, a lubricant can be used to decrease the coefficient of friction between washer310and top annular member320. Lubricant may also be used to decrease the coefficient of friction between the threads of top annular member320and bottom annular member330. Angle360can range from 0-5 degrees, more preferably 0-15 degrees, most preferably 0-35 degrees.

FIG. 4shows module200being transported from a module yard to an EPC project site on a module surface240. During transportation, support structure230and/or module surface240may experience sag and impact loads along its length and/or width, and thus deflect as a result of these loads. In conventional modules, these bending forces and moments are transferred to the baseplate, which can cause permanent deformation of the baseplate and machinery.

Chocks225prevent deflection of baseplate220due to their self-leveling capability. More specifically, when support structure230bends and deflects, washer310slides with respect to top annular member320, thus allowing angle360to fluctuate. There is enough clearance between both (i) the outer diameter of the anchor bolt340and the through hole of washer310, and (ii) the anchor bolt340's nut and baseplate220such that baseplate220can maintain a horizontal configuration (e.g., a level orientation) while the support structure230may have deflected. In this manner, chocks225prevent the transfer of twisting and bending moments from support structure230to baseplate220.

Module200thus provides a means for isolating (or reducing the transfer of) deflection forces between the baseplate and support structure. In this manner, warping of the baseplate is eliminated or at least partially reduced. While some kinds of chocks have been used conventionally to address the issues of soft foot (e.g., unequal distribution of weight and lack of full contact between the feet and the mounting pads/pedestals), those of ordinary skill in the art have failed to appreciate that adjustable, self-leveling chocks can be used to isolate deflection that occurs during transportation of a module for an EPC project.

Machinery210can be any piece of machinery, equipment, or structure that is needed for an EPC project, including but not limited to, pumps, drivers, compressors, motors, fans, blowers, and the like. Additional examples of equipment and installation requirements are disclosed in further detail in U.S. Provisional Application Ser. No. 61/831,052 and U.S. Provisional Application Ser. No. 62/007,363, which are incorporated herein by reference. In some instances, machinery210may produce oscillations (e.g., centrifugal compressors, rotary motors, etc.) that may further produce sag, fatigue, and deflection in the module components (e.g., baseplate, chocks, support structure, module surface, etc.).

Chocks225(including washer310, top member320, bottom member330, and anchor bolt340) can be made of any material and manufactured by any process that provides suitable strength for the application in which it is used. Factors such as weight, size, and type of machinery may affect the material, size/dimensions, and manufacturing process of chocks225. In addition, the properties of the baseplate and support structure may also affect the material and manufacturing process of chocks225. Moreover, the amount of deflection and the required range for angle360may also affect the material and configuration of chocks225. Even still, the temperature conditions may also affect the configuration of chocks225. In some embodiments, chocks225are suitable for winter use (in temperatures as low as negative 40 degrees Fahrenheit) and are designed for shock loading of 3.0 g's (gravitational acceleration) or better.

In some embodiments, chocks225are made of steel and are machined with high tolerances. In particular, the flat top surface312of washer310that contacts the underside of baseplate220, and the bottom surface of the bottom annular member330that contacts the top surface of support structure230, are machined to have a flatness of 0.002 inches or better and a surface finish of Ra 250 micro-inches or better.

Baseplate220and support structure230can be made of any material suitable for supporting the weight of machinery210. In some embodiments, baseplate220is made of steel or a composite epoxy polymer. In some embodiments, support structure230is a steel I-beam. Moreover, the portions of the underside of baseplate220that come in contact with the chocks are made to have a flatness of 0.002 inches or better and a surface finish of Ra 250 micro-inches or better. Similarly, the portions of the top surface of support structure230that come in contact with the chocks are made to have a flatness of 0.002 inches or better and a surface finish of Ra 250 micro-inches or better. In addition, all surfaces contacting chocks225can be level within 0.0005 inch/foot in two directions 90 degrees opposed. In some embodiments, the surfaces contacting chocks225are free from paint and grease. In addition, the taper between baseplate220and support structure230can be less than 4 degrees (less than 0.069″ over 1-inch distance).

Baseplate220can be a single piece or multiple pieces joined together. In some instances, baseplate220may be multiple pieces of steel welded together and are of the non-grout type. In some embodiments, support structure230has an ultimate sag under vertical load that does not exceed 0.1 mm/m of the structure's span or 0.04 inches (1 mm), whichever is lower. Moreover, for some applications, structure230may have a minimum torsional stiffness of 1×10^5 in-lb./rad (113×10^2 N-m/rad).

In yet other aspects of some embodiments, the contact area between the chocks and baseplate and support structure can be 80% or better.

Several examples of implementations of the inventive subject matter are disclosed in U.S. Provisional Application Ser. No. 61/831,052 and U.S. Provisional Application Ser. No. 62/007,363 in greater detail. More specifically, the appendices of these applications include guidelines, criteria, and considerations for installation of rotating equipment and reciprocating equipment, including their auxiliary systems. The appendices provide details about the minimum preservation and protection measures during storage of equipment, dynamic analysis of steel structure, vibration limits, piping, baseplates, alignment, piping and supports, nozzle loads, and verifications to be performed in the module yard and at job sites. Tolerances and application limits are also prescribed. In addition, the appendices outline various components and requirements for analytical methods that are required not only for installation of machinery on transportable modules but also for reliable operation of the equipment. The details disclosed in the appendices are provided merely as exemplary embodiments and are not intended to limit the inventive subject matter unless those details are explicitly referenced in the claims.