A client was confronted with elevated vibration levels in a screw compressor installation, which had a direct impact on operational capacity. EMHA investigated the cause and fully restored the foundation. The result: stable operating conditions and restoration of the original rotational speed and production output.
Situation
During vibration measurements, it emerged that the foundation block and anchor bolts of the screw compressor and electric motor were in poor condition. As a result, vibrations that are normally dissipated through the foundation were insufficiently dampened. This led to elevated vibration levels and forced the client to reduce the rotational speed of the installation from 1500 rpm to 1200 rpm, with direct production losses as a consequence. The client’s objective was to structurally restore the foundation, reduce vibration levels and return the installation to full capacity.
Solution
EMHA took on the complete foundation design and developed an integral solution. Based on analysis, new sole plates and anchor bolts were designed and produced, tailored to the specific loads of the installation. On site, the existing configuration was completely dismantled, after which old sole plates, anchor bolts and deteriorated grouting and concrete were removed. The foundation was restored using high-quality Chockfast Red and fitted with new anchor pockets.
EMHA then bonded the newly designed anchor bolts, repositioned and precisely aligned the compressor and electric motor relative to the existing pipework. After grouting the installation and curing, the anchor bolts were torqued to specification and the final alignment was carried out. This fully restored the basis for stable and reliable operation.
Result and added value
The intervention resulted in a drastic reduction in vibration levels: from 3–4 mm/s with peaks above 7 mm/s to values below 1 mm/s. This represented an improvement of approximately 75%, bringing vibrations back to a stable and acceptable level. The installation can once again run at the original speed of 1500 rpm, fully restoring production capacity.
Thanks to EMHA’s thorough approach, the client now has a durable and future-proof foundation, with demonstrably better operational reliability and a reduced risk of future failures.
