© Paul Smith — Alpha & Omega Limited — PlatformClouds.com —
Conceptual Engineering Preview — Not Approved for Manufacturing
HERPS-VOL-17-STRUCTURAL-SKID-EQUIPMENT-SUPPORTS-GUARDS-AND-LIFTING-REV-D-R2.0.webp
H.E.R.P.S — HYBRID ENERGY RECOVERY PUMP SYSTEM
Structural Skid, Equipment Supports, Guards & Lifting
HERPS-VOL-17 — Revision D R2.0
The H.E.R.P.S Revision D structural package is built around one continuous 10,400 mm S355 structural skid supporting the complete hydraulic, rotating, thermal, electrical, energy-storage and control package.
Volume 17 controls the primary structural rails and crossmembers, pump and motor mounting interfaces, recovery turbine and PMG rails, large-bore piping and valve supports, thermal rack, electrical deck, vibration isolation, guarding, lifting and tie-down provisions, anchor pads, bonding interfaces and structural load paths.
Engineering Status:
Master Design-Development — CAD / FEA / Procurement Input Subject
to Revision D Validation Gates — Not Released for Construction
Revision D Structural Identity
Complete Package Envelope
10,400 L × 2,600 W × 2,400 H maximum.
Structural Base
10,400 L × 2,400 W × 300 deep.
Pump / Motor Axis
Y=0, Z=+800.
Recovery Turbine / PMG Axis
Nominal Y=+950, Z=+850.
Lift Design Mass
13,500 kg minimum until actual approved lift-state mass is frozen.
Structural Equivalent Mass
18,000 kg including dynamic and handling allowance.
Primary Structural Frame
| Structural Item | Quantity | Revision D R2.0 Baseline |
|---|---|---|
| Main longitudinal rails | 2 | S355 RHS 250×150×10; length 10,400 mm |
| End cross rails | 2 | S355 RHS 250×150×10; width 2,400 mm |
| Primary crossmembers | 15 | S355 RHS 200×100×8; approximately 2,100 mm clear; ≤750 mm nominal spacing |
| Pump mounting plates | 4 | S355 plate 300×220×25; machined top |
| Motor mounting rails | 2 | S355 1,200×180×30; machined top |
| Recovery turbine / PMG rails | 2 | S355 1,800×120×20 baseline |
| Valve / manifold supports | As required | S355 RHS 100×100×6 minimum before final support calculation |
Structural Load Distribution
The two 10,400 mm longitudinal rails act as the principal package beams. The two end rails and fifteen primary crossmembers form one continuous full-package structural base.
Rotating equipment, DN350/DN300 piping and valves, the recovery train, thermal hardware and electrical/BESS cabinets transfer dead, operating, transient, service and handling loads through dedicated supports into the primary skid.
Pump and turbine nozzles and instrument connections are not used as structural supports. Large valves, vertical piping runs and other concentrated masses require independent support.
Pump & Motor Support System
Pump Plates
Four 300×220×25 mm S355 machined mounting plates.
Motor Rails
Two 1,200×180×30 mm S355 machined rails for the Revision D 160 kW liquid-cooled SynRM baseline.
Mounting Datums
Finish-machined after skid welding and structural stabilization.
Pump/Motor Coplanarity
≤0.25 mm before shimming.
Foot-Set Flatness
≤0.10 mm.
Final Alignment
Parallel ≤0.05 mm and angular ≤0.05° with hot-growth correction.
Motor removal requires at least 1,500 mm unobstructed clearance, and permanent DN300 piping must not pass above or through the motor removal axis.
Recovery Turbine & PMG Support System
Revision D supersedes the earlier DN250 support concept with a DN300 recovery branch and DN300 axial/Kaplan-inspired recovery cartridge.
Recovery Rails
2 × S355, 1,800×120×20 mm baseline.
Recovery Axis
Nominal Y=+950, Z=+850.
GA-D06 Zone
X=2,500–5,300; Y=+700..+1,250; Z=450..1,450.
Recovery Cartridge Removal
≥1,200 mm toward +Y.
PMG Pull Clearance
≥800 mm local clearance.
Load Isolation
Piping loads are isolated from the turbine cartridge and PMG train.
DN350 / DN300 Piping & Valve Support System
| Service | Revision D Line | Structural Rule |
|---|---|---|
| Intake | DN350 Duplex 2205 | Independent support; preserve Y0/Z800; no pump-nozzle weight |
| Common discharge | DN300 Duplex 2205 | Independent riser/header/valve supports |
| Direct path | DN300 Duplex 2205 | Support valves/check devices without nozzle loading |
| Recovery branch | DN300 Duplex 2205 | Independent branch support to turbine throat and rejoin |
| Cooling | DN40 316L | Preserve service access and drainability |
| Drain / seal flush | DN50 / DN15 | Support without instrument or root-valve interference |
Thermal Rack Structure
The Revision D thermal rack occupies GA-D07, approximately X=6,000–7,500, Y=+250..+1,200 and Z=300..1,900.
The baseline rack uses S355 RHS 80×80×6 with an approximate 1,600×1,000×1,600 mm envelope.
It supports the 40 kW radiator, two EC fans, 40 kW plate heat exchanger, duty/standby VSD coolant pumps, 50 L expansion tank, 80 L reservoir, filter and DN40 thermal interfaces.
Electrical Deck & Cabinet Supports
The Revision D electrical deck extends approximately from X=6,000 to X=10,400 across the 2,400 mm structural width.
GA-D08
AFE/VFD — X=6,000–7,200.
GA-D09
Switchgear / control — X=7,200–8,100.
GA-D10
DC / supercapacitor — X=8,100–8,900.
GA-D11
BESS A — X=8,900–9,500.
GA-D12
BESS B — X=9,500–10,100.
Cabinet fronts require at least 1,200 mm external clear space, or greater where required by applicable codes.
Vibration Isolation
| Parameter | Revision D R2.0 Basis |
|---|---|
| Quantity | 12 |
| Type | Spring / elastomer |
| Static Capacity | ≥25 kN each |
| Target Static Deflection | 8–12 mm |
| Final Selection | Vendor + D-G17 structural validation |
The isolators are package-support elements and are not substitutes for internal skid stiffness.
Guarding System
Pump / Motor Coupling Guard
304 stainless steel, 2 mm perforated baseline, tool-removable.
Turbine / PMG Coupling Guard
304 stainless steel, 1.5–2.0 mm baseline.
Fan / Auxiliary Guards
304 stainless steel or OEM-compliant guarding.
Guard Support
Skid/rack-mounted and arranged so rotating housings are not distorted.
Lifting, Tie-Down & Handling
Primary Lifting Lugs
4.
Auxiliary Lift / Tie-Down Lugs
2.
Minimum Lift Design Mass
13,500 kg.
Planning CG Target
X=4,800–5,600; |Y|<200; Z<950.
Lift Arrangement
Four-point primary lift baseline.
Final Release
D-G17 lifting calculation and controlled lift drawing / plan required.
Primary lifting reactions must enter the principal rail/crossmember load paths. Deck plate alone is not permitted to carry a primary lift reaction.
Anchor Pads & Foundation Interface
| Feature | Revision D R2.0 Basis |
|---|---|
| Anchor Pads | 16 × S355 plate 180×140×25 |
| Slots | 34×60 mm for M30 concept anchors |
| Anchor Rows | Y=±950 |
| Anchor X Coordinates | 400, 1,800, 3,200, 4,600, 6,000, 7,400, 8,800, 10,000 |
| Foundation Planning Envelope | 11,200 L × 3,400 W × 400 thick minimum |
| Concrete Planning Baseline | ≥35 MPa |
| Grout | 25–50 mm non-shrink machinery grout |
Volume 17 controls the skid-side anchor pads, slots and reaction handoff. Final anchor product, grade, embedment, reinforcement, concrete breakout, seismic verification and site foundation design remain controlled by Volume 18 and site engineering.
Structural Materials, Coating & Galvanic Isolation
| Component Family | Material / Finish |
|---|---|
| Primary skid / frame / supports | S355 structural steel |
| Structural coating | Zinc-rich epoxy + high-build epoxy + polyurethane |
| Coating thickness | 250–350 µm DFT baseline |
| Guards | 304 stainless steel, 1.5–2.0 mm family |
| Dry structural fasteners | Class 10.9 zinc-flake or engineered corrosion-resistant |
| Duplex-to-S355 interfaces | Nonconductive isolation where required |
Fabrication & Dimensional Control
Fabricated Skid Overall
±2.0 mm baseline unless released drawing is tighter.
Pump / Motor Coplanarity
≤0.25 mm before shims.
Foot-Set Flatness
≤0.10 mm.
Alignment-Zone Rail Deflection
L/1000 or 2 mm, whichever is more stringent.
Mounting Datums
Finish-machine after welding and stabilization.
Final Survey
As-built X/Y/Z supports, elevations, flatness, anchor pads, lift points and package mass/CG.
Service & Removal Clearances
| Service Requirement | Minimum Clearance |
|---|---|
| General side access | ≥1,000 mm outside package |
| Pump shaft / cartridge pull | ≥2,000 mm |
| Motor removal | ≥1,500 mm |
| Recovery cartridge | ≥1,200 mm toward +Y |
| PMG local pull | ≥800 mm |
| Cabinet front | ≥1,200 mm or code greater |
| Radiator face | ≥600 mm |
| Seal cartridge | ≥250 mm |
| Bearing housing | ≥400 mm |
| Valve actuator | ≥300 mm beyond envelope or OEM greater |
Real-World Structural Build Sequence
- Close the Revision D vendor/CAD interfaces and structural-design inputs.
- Fabricate the two 10,400 mm main rails, two 2,400 mm end rails and fifteen primary crossmembers in a controlled fixture.
- Install released local reinforcement, anchor-pad framing, support stools and lift-load-path members.
- Complete structural welding using the approved sequence.
- Perform post-weld dimensional survey and finish-machine pump plates and motor rails after structural stabilization.
- Fabricate and install the Revision D thermal rack and electrical deck framing.
- Blast-clean and coat the carbon-steel structural assembly.
- Install the twelve selected vibration isolators after reaction and stiffness approval.
- Mount the pump at Y0/Z800 and the selected 160 kW motor and establish preliminary alignment.
- Install the DN350 intake and DN300 common/direct/recovery support system with independent piping load paths.
- Install the DN300 recovery turbine/PMG support rails and verify cartridge and PMG withdrawal clearances.
- Install thermal equipment and electrical/DC/BESS cabinets while preserving service clearances.
- Install guards and structural brackets and verify non-contact clearance under vibration, misalignment and thermal growth.
- Install protective bonding straps and verify continuity.
- Complete final piping-connected pump/motor and turbine/PMG alignment and nozzle-strain checks.
- Freeze approved as-built masses and coordinates and complete the structural FEA, lift analysis, final CG, isolator reactions and lift plan.
- Issue final anchor-pad reactions to the foundation design.
- Complete FAT/SAT structural, guarding, bonding, alignment and documentation acceptance.
Structural FEA, Lifting & Validation
The Revision D structural validation includes dead load, rotating loads, DN350/DN300 piping and valve loads, electrical/BESS loads, handling and lifting, structural-equivalent mass, anchor/foundation reactions, maintenance loads, site seismic/wind and modal/stiffness load cases.
Final weld sizes, local gusset geometry, lift-lug reinforcement and WLL, isolator stiffness/damping, actual package mass and centre of gravity, final cabinet base patterns, local recovery-support geometry, anchor/foundation capacity and seismic/wind response remain validation-, OEM- or site-controlled and are not fabrication-final.
Master Design-Development — Not IFC — Not Shop Release — Not Approved for Manufacturing.
VOLUME 17 — STRUCTURAL SKID / EQUIPMENT SUPPORTS / GUARDS / LIFTING