shaft alignment powertrain vibration - · pdf filec2 shaft alignment definition “most...
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Chris LeontopoulosChris Leontopoulos
Shaft AlignmentShaft Alignment
andand
Powertrain VibrationPowertrain Vibration
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Shaft Alignment
Definition
� “Most shipboard configurations of shafts and bearings are likely to be aligned when some or all of the centrelines of the bearings are offset from the theoretical straight line condition, so as to achieve an acceptable bearing load distribution and shaft slope.”
Design Process
� “The classic alignment technique would involve the calculation of the bearing reactions following a quasi-static analysis and varying of the bearing offsets until an acceptable set of bearing reaction loads and shaft slope is achieved.”
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Influence Parameters on Shaft Alignment
1. Bearing offsets
2. Thermal Effects
3. Loads (propeller, gear)
4. Crankshaft model
5. Hull Flexibility
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Case Studies
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Design Trends
1. Increased engine power and reduced rpm
2. Increased propeller weight and efficiency
3. Shorter shafts (except container vessels)
� Hence, increased bending moments and stiffness and sensitivity on bearing influence coefficients
1. Changes in propeller design
2. Changes in hull design
3. Increased propeller weights
� Hence, increased propeller loads, which affect shaft slope and hence slope boring
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0
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Bulk Carrier Chemical
Carrier
Container
Carrier
General
Cargo
Carrier
High Speed
Craf t
Of f shore
Supply
Vessel
Oil Carrier Passenger
Vessel
Special
Purpose
Vessel
Tug Yacht
z
Alignment Related Failure Statistics
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Stern Tube Bearing
Stern tube bearing damage
White Metal Bearing Damage
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Stern Tube Bearing
Teflon Bearing Damage
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Alignment Related Failures
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“The alignment process is critical as it involves high risk consequences, which usually immobilise the vessel.”
“ABS possesses extensive practical and design experience on shaft alignment.”
Shaft Alignment
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� The “simply supported beam”
g
Shaft Alignment – Fundamental Principles
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� The “simply supported beam”
g
Shaft Alignment – Fundamental Principles
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IntroductionIntroduction
� Demonstrate AVI
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C14
Dry Dock
In Service -Waterborne
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Positioning the Bearings to Actual Design Values
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� Optical/Laser/Telescope
Alignment Procedure
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Alignment Procedure
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Critical Areas
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Stern Tube Bearing Alignment
Ideal contact between the shaft and the bearing
Edge contact.
Desired: Even load distribution throughout the bearing length.
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Shaft Alignment Analysis
� Modelling of the bearing reaction
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Propeller operation in wake
field behind the ship
Propeller Loads
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Alignment Acceptance Criteria
1. Bearing loads (force, pressure)
a) 8 bar white metal
b) 6 bar synthetic material
c) 5.5 for water lubricated
2. Relative shaft slope inside stb bearing:
a) <0.3 mrad then slope boring is not required
b) >0.3 mrad then slope boring is required
3. Engine Flange bending moments in accordance with manufacturers’ limits
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Alignment Analysis – ABS Capabilities
Shaft Alignment Analysis
Optimization for Shaft Alignment
Alignment Investigation
Hull Deflection – Shaft Alignment
Interaction
Shaft Alignment Analysis
Shaft Alignment Procedure
Expertise in Installation and Build
Process
ABS Capabilities Shipyard Capabilities
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� Sterntube Frame Boring
• Vertical / Horizontal boring of
Stern tube frame
Alignment Procedure
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� Reactions Measurements
• Bearing reactions are measured directly or indirectly or both. The most commonly applied methods that measure the alignment condition are:
– Gap and Sag
– Jack-up
– Strain gauge method
• The Sag and Gap
and the strain
gauge procedures
are indirect methods
to measure the
deflections and
correlate shaft
strain to the
bearing reactions,
in a “reverse
engineering” way.
Alignment Procedure
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� Jack up method
Lifting curve
Lowering curve
Hysterisis: difference in
jack load between lifting
and lowering
Resultant line - average
between lifting and
lowering curve.
Bearing reaction is then:
mm
Alignment Procedure
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“Correlation between measurements and design calculation is top priority”
Shaft Alignment – Correlation
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� Strain Gauges
Alignment Procedure
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� Strain Gauge Installation Procedure
Alignment Procedure
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� Strain Gauge Installation Procedure
Alignment Procedure
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� Strain Gauge Installation Procedure
Alignment Procedure
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Shafting Alignment Measurements
Problems with alignment verification are often related to our ability to have control over the following:
� accuracy and reliability of the applied alignment procedure
� reliability of the alignment calculation (modeling, loads,..)
� ability to control factors which may affect/change the preset alignment parameters (stern tube bearing slope angle, bearing offset, etc.)
� accuracy of the applied alignment verification method alignment condition monitoring
� skills of the engineers conducting alignment procedure and measurement
� ability to validate measurement method and obtained results
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� Crankshaft deflection measurements
Indirect Indications of Misalignment
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� Shaft Eccentricity diagnosed through vibration monitoring
Axial
Radial
Tangential
Indirect Indications of Misalignment
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Dynamic Measurements
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Dynamic Measurements
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Dynamic Measurements
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Dynamic Measurements
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Dynamic Measurements
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Hull Deflection
� ABS have established correlation among hull deflections and use the same data to predict the hull deflections of the newly designed vessel of the same type.
� Collected data is to be applied in the ABS Shaft Alignment Optimization software to provide a basis for more robust shaft alignment design, which will be less susceptible to the alignment condition change during the operation of the vessel.
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Hull Deflection
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Shaft Alignment Analysis
Refined FE model of the stern structures
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Shaft Alignment Analysis
� Alignment optimisation
� Optimised shaft line
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Shaft Alignment Analysis
� Alignment optimisation
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Shaft Alignment Analysis
� Alignment optimisation
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“ABS possesses extensive practical and design experience on vibration of marine powertrains.”
Powertrain Vibration
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Vibration Acceptance Criteria
1. Torsional Stress limits (IACS)
2. Lateral and Axial Vibration
3. Torsio-axial Vibration (direct drives)
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IntroductionIntroduction
� Demonstrate AVI
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�
Torsional VibrationTorsional Vibration
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Torsional Vibration – Barred Speed Range
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C52
Powertrain components affected by torsional
vibration
Torsional Vibration
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� VIBRATION FAILURE
Torsional Vibration
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� VIBRATION FAILURE
Lateral Vibration
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Lateral Vibration
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C56
Coupling bolts
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C57
Vibration Training using the Rotor-kit
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Practical Vibration Problems
� propeller induced vibration,
� engine misfire,
� barred speed range,
� gear hammer,
� coupling bolts failure,
� crankshaft failure,
� bearing failure,
� tailshaft torsional fracture
� vibration due to misalignment
� propeller cavitation
� shaft whirling
…………and many more
Within the Classification Rules and beyond we have tackled a variety of powertrain vibration problems
and issues, such as:
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C59
ANSWERSANSWERS
&&
Shaft Alignment and Powertrain Vibration
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C60
Thank you for your attention