12 MW Diesel Engine Anchor Bolt Replacement and Realignment

Alphatec Engineering was selected to address the ongoing anchor bolt failures and vibration issues of the Mitsubishi–MAN diesel engine (model 18V40/54, installed in 1979).

This engine powers a brushless alternator rated at 10 MW. Alphatec Engineering undertook the replacement of 40 critical anchor bolts. After a 65-day intensive operation, Alphatec Engineering successfully mitigated vibrations, restoring the diesel engine to optimal operating conditions and full power capabilities.

Features

Client

Commonwealth Utilities Corp.

Final user

Saipan Main Power Plant

Project

Foundation Repair, Anchor Bolts Replacement, Regrout, Re-alignment and Re-choking

Equipment

Mitsubishi-Man Diesel Engine 18V40/54

Work period

Summer 2024

Location

Saipan CNMI

01 The Challenges and Procedure

Executing this anchor bolt replacement and epoxy grout project in a remote location required meticulous planning. Alphatec Engineering carefully coordinated logistics, shipping specialised materials, tools, and epoxy grout products to Saipan.

The process involved removing old anchor bolts, installing new 3.2-meter-long anchor bolts, rebuilding the concrete foundation, and precisely realigning the crankshaft. Rigorous quality control was maintained throughout to ensure project accuracy, safety, and effectiveness.

02 Solution

Alphatec Engineering applied specialized epoxy grout solutions:

Alphatec® 800 epoxy grout for anchor bolt stability.
Alphatec® 342 epoxy resin injection to consolidate the foundation.
Alphatec® 440 adhesive to bond concrete sections.
Alphatec® 170 epoxy chock grout to replace traditional liners and wedges.

Leveraging advanced epoxy grout technology and extensive experience, Alphatec Engineering provided a tailored solution addressing the plant’s unique structural issues.

03 Results

The successful anchor bolt replacement and epoxy grout application significantly reduced engine vibrations and corrected misalignment, enabling stable, full-power engine operation. The intervention improved plant safety, reduced maintenance needs, and enhanced operational efficiency and reliability for years ahead.