CCAMTG-2500 A04 — Structural Skid & Foundation Interface

Volume 08 defines the structural skid and foundation interface for the CCAMTG-2500 A04, providing the structural load path from the skid-mounted machine assemblies into the installation foundation while preserving rotor alignment, maintainability, transportability and safe lifting. The subsystem integrates the primary structural frame, cross-members, machinery mounting interfaces, soleplates and chocks, equipment support zones, lifting and transport provisions, grout and anchor interfaces, grounding and bonding attachment provisions, structural load transfer and the site foundation interface.

Structural Skid System Overview

Welded primary structural skid assembly
Continuous longitudinal structural load paths
Structural cross-members at concentrated machinery reactions
Local diaphragms, doublers and gussets
Machinery mounting pads
Machined soleplates and chock system
Equipment support brackets and structural interfaces
Lifting and transport attachment interfaces
Anchor and base interface system
Non-shrink machinery grout interface
Grounding and bonding attachment provisions
Site foundation structural interface

Primary Structural Frame

Primary frame based on continuous or fabricated longitudinal load paths
Cross-members positioned beneath major machinery and structural reaction locations
Structural reinforcement provided at concentrated load-transfer regions
Vertical, lateral, longitudinal and torsional loads transferred into the primary frame
Local reinforcement used where required to control yielding, buckling and distortion
Primary structural openings subject to engineering analysis before release
Secondary brackets separated from critical alignment and primary load paths where applicable
Primary structure designed as an integrated machine-alignment structure rather than a simple support frame

Structural Material Architecture

Primary skid structure based on ASTM A572 Grade 50 or approved equivalent
Secondary non-critical brackets may use ASTM A36 where specifically approved
Machined soleplates and chocks use qualified machinery-grade steel
Structural fasteners use high-strength controlled fastening systems
Weld consumables matched to the qualified base-metal and welding system
Industrial corrosion-protection system selected for the installation environment
Machined, grout and electrical bonding surfaces protected according to their functional requirements

Machinery Mounting System

Machined machinery mounting-pad architecture
Machined chock and soleplate system
Alignment-controlled equipment support surfaces
High-strength machinery hold-down system
Non-shrink high-strength machinery grout
Controlled leveling and alignment provisions
Mounting interfaces coordinated with actual equipment support reactions
Surface-protection requirements coordinated with grout and bonding zones

Machine Alignment Architecture

Common rotor centreline maintained as the principal rotating-machine alignment datum
Longitudinal, transverse and vertical structural reference datums
Mounting surfaces controlled for machinery alignment
Structural stiffness coordinated with rotating-machine requirements
Skid deformation assessed under operating and abnormal load conditions
Alignment preserved through installation, grouting and anchoring
Alignment reverified following piping and thermal-system connection
As-installed alignment recorded as part of the lifecycle baseline

Machine Support Zones

Air-intake, filter and inlet-guide-vane support region
Three-stage compressor support region
Compressor intercooler interface supports
PMSM/PMG high-stiffness support region
Central active magnetic bearing support region
Three-stage turbine support region
Interstage reheater support interfaces
Exhaust and control connection region
HP buffer vessel support interface
Cooling-package support interfaces
Electrical and control enclosure support interfaces

Compressor Structural Interface

Rigid aligned support for the compressor module
Structural load paths for compressor casing reactions
Rotor-support reactions transferred into the primary skid structure
Compressor torque reactions incorporated into structural analysis
Intercooler and associated piping reactions coordinated with the skid
Anti-surge and process piping loads incorporated into interface engineering
Service and maintenance access preserved around the compressor assembly

PMSM/PMG Structural Interface

High-stiffness aligned structural support
Common rotor datum maintained through the electrical-machine assembly
Cooling-system clearances preserved
Electrical cable routing and service access preserved
Machine loads transferred directly into the primary skid structure
Structural stiffness coordinated with rotor and magnetic-bearing requirements

Turbine Structural Interface

Aligned structural support for the three-stage turbine assembly
Turbine casing reactions transferred into the primary skid
Turbine torque reactions included in structural load cases
Support architecture accommodates approved thermal growth
Reheater and process-piping reactions coordinated with turbine supports
Structural arrangement maintains rotor alignment during thermal operation
Maintenance access preserved around turbine support regions

Active Magnetic Bearing & Touchdown Bearing Interfaces

Structural support for radial active magnetic bearing stations
Structural support for the axial active magnetic bearing system
Touchdown-bearing fault-reaction paths incorporated into the skid
Support stiffness coordinated with magnetic-bearing stability analysis
AMB instability and fault reactions included in dynamic structural analysis
Structural modes coordinated with rotor and bearing-control requirements
Support architecture designed to avoid compromising rotor critical-speed separation

Heat Exchanger & Cooling Package Supports

Compressor intercooler support interfaces
Aftercooler and heat-recovery exchanger support interfaces
Turbine preheater support interfaces
Interstage reheater support interfaces
Cooling-pump package support
Machine-loop heat exchanger support
Expansion and cooling-system equipment supports
Thermal expansion accommodated within the structural support architecture
Cooling and process-piping reactions coordinated with structural design

HP Buffer Vessel Structural Interface

Dedicated buffer-vessel structural support interface
Vessel saddle and skid load-transfer architecture
Pressure-vessel reactions coordinated with primary structural members
Process-nozzle loads incorporated into structural analysis
Placement coordinated with maintainability and process-line routing
Final support configuration controlled by structural and interface engineering

Foundation Interface

Preliminary machinery-foundation interface architecture
Structural load transfer from skid into the installation foundation
High-strength non-shrink machinery grout interface
Engineered anchor interface
Foundation reinforcement determined by site-specific structural engineering
Soil-bearing or pile requirements determined by geotechnical and site engineering
Dynamic foundation response coordinated with machine vibration requirements
Foundation design required to preserve rotating-machine alignment
Site seismic requirements incorporated through project-specific structural design

Anchoring & Grout Interface

Anchor locations coordinated with primary structural load paths
Anchors positioned to avoid unsupported or unsuitable base regions
Anchor preload controlled by engineered joint requirements
Anchor capacity coordinated with concrete and foundation design
Grout-bearing surfaces prepared for controlled machinery installation
Grout placement arranged to prevent voids beneath load-bearing interfaces
Leveling provisions incorporated before final grouting
Alignment verified before and after anchor tightening

Lifting System

Certified lifting points located on primary structural load paths
Machine lifting prohibited from guards, process piping or equipment nozzles
Lift-point reactions based on verified machine mass and centre of gravity
Rigging coordinated with approved lifting points
Certified slings, shackles and spreader arrangements used as applicable
Lift analysis incorporates applicable dynamic and amplification effects
Structural lifting interfaces verified before approved handling operations

Transport System

Dedicated transport-restraint attachment points
Transport restraints connected through engineered structural load paths
Road, sea and site-handling conditions considered in transport engineering
Shipping configuration coordinated with machine mass and centre of gravity
Transport restraints removable without damaging precision alignment surfaces
Shipping splits, where used, preserve datum transfer and field realignment capability
Post-transport dimensional and alignment inspection required before commissioning

Structural Load Cases

Machine and skid dead loads
Normal compressor charge-operation reactions
Normal turbine generation-operation reactions
Start, stop and operating-transition reactions
Overspeed structural consequences
Active magnetic bearing fault and touchdown-bearing reactions
Pressure-vessel and process-piping nozzle loads
Thermal expansion and differential thermal loads
Machine lifting conditions
Transport and handling conditions
Site-specific seismic loading
Applicable wind, flood and environmental site loading
Maintenance and partially assembled machine conditions

Dynamic & Vibration Engineering

Skid structural modes coordinated with rotor-dynamic behaviour
Support stiffness coordinated with active magnetic bearing analysis
Foundation modes considered in the integrated dynamic assessment
Forcing frequencies assessed against structural resonances
Critical-speed separation protected through coupled structural and rotor review
Dynamic support reactions transferred into foundation engineering
Machine alignment maintained under approved dynamic load conditions

Thermal Expansion Interface

Common rotor alignment maintained across compressor, PMSM/PMG and turbine modules
Fixed, guided and expansion-accommodating supports applied where required
Machine casing thermal growth accommodated without excessive structural restraint
Process piping thermal growth coordinated with machinery support design
Excessive nozzle and bearing loads avoided through controlled support architecture
Temperature-sensitive alignment regions separated from hot equipment where practical

Electrical, Cooling & Process Integration

Power-cable support and routing coordinated with structural members
Control and instrumentation cable trays supported independently where required
Electrical segregation and EMI requirements preserved
Cooling-line support reactions incorporated into structural coordination
Process-air piping loads coordinated with compressor, buffer, turbine and thermal systems
Drain routing arranged without compromising grout or foundation integrity
Dedicated accessible skid bonding points provided
Safety devices, emergency-stop access and service routes remain unobstructed

Grounding & Bonding

Dedicated structural grounding and bonding attachment provisions
Accessible bonding points integrated into the skid structure
Electrical continuity coordinated with the wider power-system architecture
Bonding surfaces protected from incompatible coating systems
Final grounding scheme coordinated with electrical-system engineering

Structural Detailing Rules

Abrupt stiffness changes avoided beneath rotor and bearing stations
Structural drainage provided where required
Corrosion traps avoided within fabricated structural assemblies
Precision-machined alignment surfaces protected from uncontrolled welding
Removable access maintained to anchors, chocks, drains and inspection locations
Equipment pads and brackets uniquely identified for interface control
Primary structural penetrations require engineering approval

Manufacturing & Fabrication

Material identification and traceability maintained for primary structural members
Controlled cutting, forming and welding sequence
Fabrication sequence arranged to limit structural distortion
Critical mounting regions subject to controlled machining sequence
Final machinery-pad machining performed after structural distortion control where required
Structural welding performed using qualified procedures and personnel
Fabricated skid geometry verified by dimensional survey
Datum transfer and anchor-interface coordinates recorded

Inspection, NDE & Quality Control

Incoming material certification and traceability verification
Structural fit-up inspection
Member location and squareness verification
Weld-preparation inspection
Qualified welding procedure verification
Visual and required non-destructive examination
Post-weld distortion survey
Machined mounting-surface inspection
Trial machine assembly and interface verification
Lifting-system inspection and certification where applicable
Pre-shipment dimensional and preservation inspection
Site foundation and anchor survey
Final as-built alignment verification

Factory Acceptance

Overall skid-envelope conformity verified
Machinery mounting surfaces inspected for alignment readiness
Machine-module trial fit verified where applicable
Structural weld and NDE records completed
Critical dimensions traceable to controlled drawings
Lifting and transport interfaces verified
No unacceptable permanent structural distortion following approved handling verification
Foundation and anchor interface coordinates transferred to the installation package

Site Installation & Foundation Acceptance

Foundation dimensions and elevation verified before skid placement
Foundation flatness and condition inspected
Concrete condition and installation readiness confirmed
Anchor locations surveyed against released interface documentation
Skid established on approved leveling and chock system
Structural and rotor datums established before final installation
Machinery grout installed under controlled procedure
Anchors tightened according to engineered requirements
Skid distortion and machine alignment rechecked following installation
Alignment reverified following process piping and thermal-system connection
As-built foundation, anchor and alignment records retained for lifecycle reference

Maintainability & Service Access

Structural arrangement preserves machinery service access
Anchor nuts and machinery chocks remain accessible
Drain and inspection locations remain serviceable
Electrical and control routes remain accessible for maintenance
Guards and secondary panels remain removable
Structural support arrangement accommodates approved module removal procedures
Maintenance conditions included in the structural load-case architecture

Structural Component Families

Primary structural skid assembly
Primary longitudinal beam set
Structural cross-member set
Local diaphragms, doublers and gussets
Machinery mounting pads
Machined soleplates and chocks
Secondary service brackets
Guard and panel support structures
Lifting-lug assemblies
Transport-restraint points
Anchor-interface and base-plate assemblies
Machinery hold-down fasteners
Structural fasteners
Qualified structural welded joints
Machinery grout system
Engineered foundation anchor system
Site foundation interface

Cross-Subsystem Interfaces

General arrangement, datums, service envelopes and lifting architecture
Air-intake, filter and inlet-guide-vane supports
Three-stage compressor feet, casing loads and torque reactions
HP buffer vessel saddle, support and nozzle loads
Three-stage turbine feet, casing loads, thermal growth and torque reactions
Active magnetic bearing and touchdown-bearing support requirements
Heat exchanger and cooling-package supports
Electrical enclosure supports, cable routes and bonding interfaces
Fastener, preload and joint-integrity engineering
Manufacturing, welding and machining engineering
System interface-control architecture
QA, inspection and NDE systems
Assembly, alignment, grouting and site installation
Controls and fault cases contributing to structural load conditions
Safety and hazard-control requirements
Rotor-dynamic and structural-analysis interfaces
Maintenance and lifecycle engineering
Factory and site acceptance verification

Structural Engineering Verification

Static structural analysis
Dynamic structural analysis
Member stress and deflection verification
Mounting-pad reaction analysis
Structural modal-frequency assessment
Local buckling assessment
Fatigue-sensitive detail assessment
Machine-alignment deformation assessment
Foundation and anchor reaction determination
Lifting and transport structural analysis
Mass and centre-of-gravity verification
Rotor-dynamic interface assessment
Active magnetic bearing support-stiffness assessment
Site foundation structural and dynamic assessment

Subsystem Documentation

Structural skid and foundation interface specification
Structural skid general arrangement
Machinery mounting-pad details
Alignment, chock and grout details
Lifting and transport-frame details
Foundation load-interface documentation
Preliminary foundation general arrangement
Structural skid bill of materials
Static and dynamic structural analysis
Lifting and transport analysis
Foundation and site structural design interface
Factory and site acceptance records