Shaft Alignment

and

Powertrain Vibration
Chris Leontopoulos

C1

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.
C2

Influence Parameters on Shaft Alignment

1.

Bearing offsets

2.

Thermal Effects

3.

Loads (propeller, gear)

4.

Crankshaft model

5.

Hull Flexibility

C3

Case Studies

C4

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

C5

Alignment Related Failure Statistics

45
40
35
30
25
20

15
10
5
0

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

C6

Stern Tube Bearing

Stern tube
bearing
damage

White Metal Bearing Damage

C7

Stern Tube Bearing

Teflon Bearing Damage

C8

Alignment Related Failures

C9

Shaft Alignment
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.

C10

Shaft Alignment Fundamental Principles



The simply supported beam

C11

Shaft Alignment Fundamental Principles



The simply supported beam

C12

Introduction


Demonstrate AVI

C13

Dry Dock

In Service -Waterborne

C14

Positioning the Bearings to Actual Design Values

C15

Alignment Procedure


Optical/Laser/Telescope

C16

Alignment Procedure

C17

Critical Areas

C18

Stern Tube Bearing Alignment

Desired: Even load distribution
throughout the bearing
length.

Ideal contact
between the
shaft and the
bearing

Edge contact.
C19

C20

Shaft Alignment Analysis



Modelling of the bearing

reaction

C21

Propeller Loads

Propeller operation in wake

field behind the ship

C22

Alignment Acceptance Criteria

1.

2.

3.

Bearing loads (force, pressure)

a)

8 bar white metal

b)

6 bar synthetic material

c)

5.5 for water lubricated

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

Engine Flange bending moments in accordance with

manufacturers limits

C23

Alignment Analysis ABS Capabilities

ABS Capabilities
Shaft Alignment Analysis

Shipyard Capabilities
Shaft Alignment Analysis

Hull Deflection Shaft Alignment

Interaction

Expertise in Installation and Build

Process

Optimization for Shaft Alignment

Shaft Alignment Procedure

Alignment Investigation

C24

Alignment Procedure


Sterntube Frame Boring

Vertical / Horizontal boring of
Stern tube frame

C25

Alignment Procedure


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.

C26

Alignment Procedure


Jack up method

Lowering curve

Hysterisis: difference in
jack load between lifting
and lowering

Lifting curve

Resultant line - average

between lifting and
lowering curve.
Bearing reaction is then:
mm

C27

Shaft Alignment Correlation

Correlation between measurements and

design calculation is top priority

C28

Alignment Procedure


Strain Gauges

C29

Alignment Procedure


Strain Gauge Installation Procedure

C30

Alignment Procedure


Strain Gauge Installation Procedure

C31

Alignment Procedure


Strain Gauge Installation Procedure

C32

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

C33

Indirect Indications of Misalignment



Crankshaft deflection measurements

C34

Indirect Indications of Misalignment



Shaft
Eccentricity
diagnosed
through
vibration
monitoring

Axial

Radial

Tangential

C35

Dynamic Measurements

C36

Dynamic Measurements

C37

Dynamic Measurements

C38

Dynamic Measurements

C39

Dynamic Measurements

C40

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.

C41

Hull Deflection

C42

Shaft Alignment Analysis

Refined FE model of the stern structures

C43

Shaft Alignment Analysis



Alignment optimisation

Optimised shaft line

C44

Shaft Alignment Analysis



Alignment optimisation

C45

Shaft Alignment Analysis



Alignment optimisation

C46

Powertrain Vibration

ABS possesses extensive practical

and design experience on vibration
of marine powertrains.

C47

Vibration Acceptance Criteria

1.

Torsional Stress limits (IACS)

2.

Lateral and Axial Vibration

3.

Torsio-axial Vibration (direct drives)

C48

Introduction


Demonstrate AVI

C49

Torsional Vibration

C50

Torsional Vibration Barred Speed Range

C51

Torsional Vibration

Powertrain components
affected by torsional
vibration

C52

Torsional Vibration


VIBRATION FAILURE

C53

Lateral Vibration


VIBRATION FAILURE

C54

Lateral Vibration

C55

Coupling bolts

C56

Vibration Training using the Rotor-kit

C57

Practical Vibration Problems

Within the Classification Rules and beyond we have
tackled a variety of powertrain vibration problems
and issues, such as:

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

C58

Shaft Alignment and Powertrain Vibration

&

ANSWERS
C59

Thank you for your attention

C60