Upload
dangxuyen
View
227
Download
1
Embed Size (px)
Citation preview
C1
Chris LeontopoulosChris Leontopoulos
Shaft AlignmentShaft Alignment
andand
Powertrain VibrationPowertrain Vibration
C2
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.”
C3
Influence Parameters on Shaft Alignment
1. Bearing offsets
2. Thermal Effects
3. Loads (propeller, gear)
4. Crankshaft model
5. Hull Flexibility
C4
Case Studies
C5
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
C6
0
5
10
15
20
25
30
35
40
45
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
C7
Stern Tube Bearing
Stern tube bearing damage
White Metal Bearing Damage
C8
Stern Tube Bearing
Teflon Bearing Damage
C9
Alignment Related Failures
C10
“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
C11
� The “simply supported beam”
g
Shaft Alignment – Fundamental Principles
C12
� The “simply supported beam”
g
Shaft Alignment – Fundamental Principles
C13
IntroductionIntroduction
� Demonstrate AVI
C14
Dry Dock
In Service -Waterborne
C15
Positioning the Bearings to Actual Design Values
C16
� Optical/Laser/Telescope
Alignment Procedure
C17
Alignment Procedure
C18
Critical Areas
C19
Stern Tube Bearing Alignment
Ideal contact between the shaft and the bearing
Edge contact.
Desired: Even load distribution throughout the bearing length.
C20
C21
Shaft Alignment Analysis
� Modelling of the bearing reaction
C22
Propeller operation in wake
field behind the ship
Propeller Loads
C23
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
C24
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
C25
� Sterntube Frame Boring
• Vertical / Horizontal boring of
Stern tube frame
Alignment Procedure
C26
� 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
C27
� 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
C28
“Correlation between measurements and design calculation is top priority”
Shaft Alignment – Correlation
C29
� Strain Gauges
Alignment Procedure
C30
� Strain Gauge Installation Procedure
Alignment Procedure
C31
� Strain Gauge Installation Procedure
Alignment Procedure
C32
� Strain Gauge Installation Procedure
Alignment Procedure
C33
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
C34
� Crankshaft deflection measurements
Indirect Indications of Misalignment
C35
� Shaft Eccentricity diagnosed through vibration monitoring
Axial
Radial
Tangential
Indirect Indications of Misalignment
C36
Dynamic Measurements
C37
Dynamic Measurements
C38
Dynamic Measurements
C39
Dynamic Measurements
C40
Dynamic Measurements
C41
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.
C42
Hull Deflection
C43
Shaft Alignment Analysis
Refined FE model of the stern structures
C44
Shaft Alignment Analysis
� Alignment optimisation
� Optimised shaft line
C45
Shaft Alignment Analysis
� Alignment optimisation
C46
Shaft Alignment Analysis
� Alignment optimisation
C47
“ABS possesses extensive practical and design experience on vibration of marine powertrains.”
Powertrain Vibration
C48
Vibration Acceptance Criteria
1. Torsional Stress limits (IACS)
2. Lateral and Axial Vibration
3. Torsio-axial Vibration (direct drives)
C49
IntroductionIntroduction
� Demonstrate AVI
C50
�
Torsional VibrationTorsional Vibration
C51
Torsional Vibration – Barred Speed Range
C52
Powertrain components affected by torsional
vibration
Torsional Vibration
C53
� VIBRATION FAILURE
Torsional Vibration
C54
� VIBRATION FAILURE
Lateral Vibration
C55
Lateral Vibration
C56
Coupling bolts
C57
Vibration Training using the Rotor-kit
C58
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:
C59
ANSWERSANSWERS
&&
Shaft Alignment and Powertrain Vibration
C60
Thank you for your attention