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ShaftLateralAnalysisoverview

Name:MohamedZeid
Livein:Sweden
Age:32
Role:SeniorRotordynamicsEngineer.

Education:
B S I N l A hi
B.Sc.InNavalArchitecture&Marineengineeringfromfacultyofengineering,SuezCanalUniversity2003.
&M i
i
i f
f l
f
i
i
S
C lU i
i 2003
AMRINA,AssociateMemberatRoyalInstitutionofNavalArchitects.

PracticalExperience:
[JuntoSep,2000],SuezOdenseMarineService(Training).
[JuntoSep,2001:2003],ConsultingEngineeringBureau(Training).
[Nov2003May2004],OceanClassicInternational,(Structuralanalysis).
[May2004Jul2005],TIMSAHShipyard,(Hydrodynamics,Structuralanalysis,...)
[Jan2006 ......],BERGPROPULSION,(Bladedesign,Shaftingdesignandanalysis/calculations,.....)

DNVSoftwareUserConference
Rio,Sep2012

Propellershaft alignmentBackground,
Analysis and Control
AnalysisandControl.
Alignment background.
Alignmentbackground

Straightinstallationforallthebearingsandthegearboxforinstallation
purposes only
purposesonly.

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Alignmentbackground.

Straightinstallationforallthebearingsand
positionthegearboxflangetofacetheflange
of the propeller shaft
ofthepropellershaft.

GB
SHAFT

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Alignmentbackground.

Alignmentcalculations?
g

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Alignmentbackground.

ShaftAnalysisinLateral

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Alignmentbackground.

Completeshaftanalysisandpositioningtheshaftlinebearingsincludingthe
gearbox/mainenginetofulfilltheallowableloadingcriteriaforallshaft
component.
component

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Alignmentbackground.

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Determineoptimumdomain.

OperatingCondition

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Straightaheadanalysis

Vesselloadingcondition

Propellershaft AnalysisandControl.

Modeling theshaft system

Reposition andadjusting
thebearing

Analysis
NOTOk
NOTOk

Shaft line deflection and


bendingstresses.
g
Ok

Bearingloads
Ok

NOT Ok
NOTOk

Other shaft component


p
(Seals,breaks,couplings,..)
Ok

Describe how thebearing


positioned (GAP/SAG).
Verifying thealignment.
(Jackload)
R
Reporting.
i
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Modeling theshaft system.

The tool used for build the model is NAUTICUS MACHINERY, SHAFT
ThetoolusedforbuildthemodelisNAUTICUSMACHINERY,SHAFT

ALIGNMENTwhichdevelopedbyDNV.

Theshaftsystemmodeledbythegeometricoftheshaftcomponents.

Themodelalsoisincludingthepropellerload,geartooth
forces,stuffinessandthermalexpansioneffect.

Alltheaboveismodeledfordifferentoperating
p
g

Vertical :

Horizontal :

conditionsas:
Propellerstatic&Gearboxcold.
Propellerstatic&Gearboxwarm.

Fa
Ft

Propellerrunningatfullpitch&Gearboxcold.
Fr

Propellerrunningatfullpitch&Gearboxwarm.
running at full pitch & Gearbox warm
Propeller

Fbt

Propellerrunningat0pitch&Gearboxwarm.
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Shaft line deflection andbendingstresses.

Checkingtheshaftdeflectionthroughallconditionsandlookifthereisany
excessivedeflectionspeciallynearbythebearinglocation.

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Shaft line deflection andbendingstresses.

Checkingthebendingstressesthroughallconditionsandlookintothebending
stressesspeciallyinthewayofthepropellerandinbetweenthebearings.

M
z-max

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Highslopeoftheshaft inside theaft stern


tube bearing.
bearing

Checking the shaft deflection inside the aft stern tube bearing and ensure
Checkingtheshaftdeflectioninsidetheaftsterntubebearingandensure
thatthereisenoughlubricatingfilmbetweentheshaftandthebearing.

Lubricant

White metal

Bearing pressure

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Highslopeoftheshaft inside theaft stern


tube bearing.
bearing

Whatsshappeninginthiscase?!
What
happening in this case?!

M
Minimumoil
lfilmthickn
ness[mm]

Theoilfilmthicknessisdecreased
byincreasingtherelativeslope

0.4
03
0.3

0.2

0.1
0.2
03
0.3

Slope of shaft,
[mm/m]

0,1
0

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1.5

Bearinglength/shaftdiameter

2
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Highslopeoftheshaft inside theaft stern


tube bearing.
bearing

Solution!

Bearing pressure

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Highslopeoftheshaft inside theaft stern


tube bearing.
bearing

Examples!
p

Bearingdamagedduetohighslope
oftheshaftinsidethebearing.

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Bearingmaterialyieldedunderthe
highbearingpressureduetohigh
slope and the bearing still working
slopeandthebearingstillworking.
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Bearingloads criteria.

Slidesurfacebearingminimumload!
g
Thebearinghavetobeloadedwithaminimumloadwhich
avoidingthebearingwiping/burning.

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Bearingloads criteria.

Slidesurfacebearingmaxload!
g
Thebearinghavetobeloadedbelowthemaximumload
whichavoidtooverloadthebearing.
Projectedpressureinaftmost bearingshouldnotexceed
8bar(Oillub.).
Projectedpressureinotherjournalbearingsshouldnot
exceed12barinthelowerspeedrangeand18barinthe
upperspeedrange(Oillub.).

Ensurethedirectionoftheresultantforceisfar
from the lubricant feeding grooves !
fromthelubricantfeedinggrooves!

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Bearingloads criteria.

Rollerbearingminimumload!
g
Thebearinghavetobeloadedwitha
minimumloadwhichavoidingthebearing
slippingandhammeringeffect.

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Bearingloads criteria.

Rollerbearingmaximumload!
g
Thebearinghavenottobeloadedmorethanthemaximumloadwhich
allowedbythebearingmanufacturetoachievetherequiredlifetime.

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Other shaft component (Seals,breaks,


couplings )
couplings)

Seals

Incaseofonesterntubebearinginstallations,thedeflectionoftheshaftatthe
locationoffwdsealisofinterest.
g
p
y
g
Incaseoftheaftsterntubebearingwasslopeboredbytakingoffmaterialfromthe
aftendofthebearing,Theaftsealadjustmenttolerancehavetobechecked.

Breaks
Thebraketypeandcompatibilitywiththeshaftingsystemshouldbechecked.
yp
p
y
g y
AtRest

Startup

DuringOperation

Couplingsandothercomponents
Thecouplingsandallotherintegrateddevicescompatibilitywiththeshaftingsystem
shouldbecheckedandrelatedcriteriafromthedevicemanufacturehavetobefulfilled.

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Describe how thebearing positioned.


GAP/SAG

GAPSAGmethod
The GAP/SAG method have been found that the most reliable way to
TheGAP/SAGmethodhavebeenfoundthatthemostreliablewayto
describehowthebearingspositionedrelatedtoeachother.

SAG

y1

A
B

GAP

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A
y3

B
SAG

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Describe how thebearing positioned.


GAP/SAG

GAPSAGmethod
The GAP/SAG method have been found that the most reliable way to
TheGAP/SAGmethodhavebeenfoundthatthemostreliablewayto
describehowthebearingspositionedrelatedtoeachother.

SAG x

GAP

A
x

B
SAG

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GAP/SAG

Seen from aft

SAGinstallation!

t
top

x1

y1

sag

p.s.
p

B
x4

x2

s.b

sag
x3

bottom
Rotating forward shaft (B) with dial gauge
Vertical sag (A below B) = (x3-x1)/2

Horizontal sag (A to s.b. from B) = (x4-x2)/2

sag
y3

Rotating aft shaft (A) with dial gauge


Vertical sag (B below A) = (x3-x1)/2
Horizontal sag (B to s.b. from A) = (x4-x2)/2

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GAP/SAG

GAPinstallation!
top

Seen from aft:

y1

A
B

s.b

y2

y4

p.s.

y3
bottom

gap

Rotating forward shaft (B) with dial gauge


Vertical gap (at bottom) = y3-y1
Horizontal gap (at s.b. side) = y4-y2
Rotating aft shaft (A) with dial gauge
Vertical gap (B below A) = y3-y1
Horizontal gap (B to s.b. from A) = y4-y2

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GAP/SAG

WhytheGAP/SAGisareliablemethod?
The reason of GAP/SAG reliability is that this method is a describe how the shaft line
ThereasonofGAP/SAGreliabilityisthatthismethodisadescribehowtheshaftline
partsrelatetoeachotherandthencompensatingthebearingpositiontokeeptheshaft
lineasitwantedtocomeoverthechangeonthehulldeflectionwhichchangedafter
g
launching.

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GAP/SAG

GAP/SAGTolerance
Any alignment calculation have to provide a minimum tolerance of +/ 0.05mmforboth
Anyalignmentcalculationhavetoprovideaminimumtoleranceof+/
0.05 mm for both
GAPandSAGfigures.
Why?!

Manufacturingquality.

Toolaccuracyinuse.

Practicalexperience.

Importantnote:TheGAPandSAG
tolerancetheyareinfluencingeachother!

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GAP/SAG

GAP/SAGmeasuringtools
Dialgauge.

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Laserequipment.

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Verify thatthealignment have been done


correctly.
correctly
AfteraligningtheshaftwiththeGAPSAGmethod,thealignment
havetobecheckedthatitisdonecorrectly.
Jackloadmethod.

X [mm]

F1

F [kN]

F2

F3

F4

Fj

F3 = F j Corr

Fj F3
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Jackload test.

actualjackingcurve
actual
jacking curve
includinghysteresis
fromfriction

X [mm]
theoretical
jacking curve
jackingcurve

2
3

3
1

F [kN]

Fj
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Alignment verfication

Loadcell

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Alignment verfication

Jackloadnotes!
Thejackloadresultscanveryalotdueto:
Jacking Bearing

Shaftmanufacturingquality.
60

Toolsaccuracy.
y
Jack load [kN]

Practicalexperience.

50
40
30
20
10
0
0

90

180

270

Degrees

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Jackload tips!

Checkingthatthedialgaugenotinfluencedbythejackstiffnessandfoundation:

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Jackload tips!

400

Fwdsternbearing

Int.bearing

Jackcorrectionfactor:Cj=1.0154
K kl
Knucklepointfactor:C
i f
Cj=0.9727
0 9727
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Jackload tips!

1300

Fwdsternbearing

Int.bearing

Jackcorrectionfactor:Cj=1.0370
Knucklepointfactor:Cj=0.8917

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Jackload tips!

Bearing with no load,


or jacking to short.
Check slope !

Too much friction loss

Stick-slip, oil suction,


pump pulses

Several bearings
unloaded

Jacking until
ntil contact
in top of bearing

0.001

Initial contact
in top of bearing
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Alignment verfication

Straingaugemethod
- More complicated measurements
- Require bending moment in the shaft
- Costly
- Often much time needed to analyse
- Few companies are able to carry out the analysis

Pick-Up

Commutat
or
transformer

+ Accurate
Antenna, Wire around shaft
+ Analytical solution possible for some shafting systems
+ Hot running condition can be verified
+ Data stored online
Strain gauge

PC etc.
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Reporting

Theclassificationsocietieshaveastandardrequirementsincaseofthealignmentreportis
required.
Alignmentreportstructure:
p
y
Completeshaftanalysis.
Alignmentmethod(GAPSAG).
Alignmentverification(Jackload).
Alignmentprocedures.
Ali
t
d

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Questions ?

Questionsanddiscussion!

BERG PROPULSION PRODUCTION AB


Mohamed Zeid
N
Naval
l Architect
A hit t - Rotordynamics
R t d
i S
Specialist
i li t
Direct: +46 31 30 10 736
Mobile: +46 761 175 022
E-mail: mohamed.zeid@bergpropulsion.com
Box 1005
475 22 cker
Sweden
Office: +46 31 976 500
www.bergpropulsion.com

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