WEB DEFLECTION ANALYSIS

AND
THE USE OF WEBMAP
SOFTWARE
 OUTLINE
A WEB DEFLECTION SURVEY IS..
WHY RUN WEB DEFLECTIONS
TOOLS AND TECHNIQUES
WEBMAP DEVELOPMENT
CASE HISTORIES
DEMONSTRATIONS: SOFTWARE
and HARDWARE
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 A WEB DEFLECTION
SURVEY IS:
MEASURING CRANKSHAFT WEB
FLEXURE AS A FUNCTION OF
CRANK ROTATION

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 WHY CONDUCT A SURVEY

REALIGNMENT / MAJOR REPAIR

ROUTINE MECHANICAL
INSPECTION

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 Repairing Block Separation

Courtesy: Adhesive Services

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 CRANKSHAFT BEHAVIOR

Large crankshafts are flexible

Can sag 60+ mils from gravity
Crankshaft assumes frame shape

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 FACTORY ASSEMBLY: TCV-16

Courtesy: Clark Bros Co.

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 FINAL GRIND

Courtesy: Fusion, Inc.

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 CRANKSHAFT BEHAVIOR
Location of max stress
Bending takes
place primarily
in the webs!
Web acts like a
hinge
Max stresses
Apparent hinge points
occur at the
fillets
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 WEB DEFLECTION MECHANICS
If the bearings in a machine are not precisely
aligned, the crankshaft webs will move farther
apart or closer together as the crankshaft is
rotated.

Bearings aligned Bearings misaligned Bearings misaligned

web deflection zero webs closer together webs farther apart
with pin up with pin down

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 GAS PLANT COMPRESSOR

DONT
I
WISH!

Courtesy: Philadelphia Resins

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 KING RANCH GAS PLANT TLA-8

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 Clark Cross-section
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 DISTORTION GAGE BETWEEN WEBS

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 THE WEB DEFLECTION IS
OVER THE LIMIT !!
The
Superintendent
is going to kill
me!
Easy, Now,
Dont Panic.

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 GET AN ACTION PLAN !
Check tools/ Rerun survey.
Suspect bad bearings before
suspecting distorted frame.
Check bearing clearances.
Replace bearings as necessary.
A bent crankshaft is rarely the
cause of excessive deflections.
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 The Web Deflection Survey
Tools
Techniques
Recording the data (Forms to use)
Units (Inches, Mils, MM, Whatever)
Maximum Limits

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 TOOLS FOR THE SURVEY
INSIDE MICROMETER
STARRETT DISTORTION GAUGE
INDIKON ELECTRONIC GAUGE
LASER ALIGNMENT KIT

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 INSIDE MICROMETER
USED BY DRESSER-RAND
CAN REACH BETWEEN VEE RODS
SLOWER AND MORE DIFFICULT
THAN USING A DISTORTION
GAUGE

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 STARRETT DISTORTION
GAUGE
TRADITIONALLY RECOMMENDED
SUBJECT TO SOME UNCERTAINTY
FULLY ADEQUATE

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 DISTORTION GAGE AND EXTENSIONS IN BOX

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 STARRETT TECHNIQUES
USE FACTORY POINTS
AVOID BENT EXTENSIONS
REVIEW ACCURACY
PERIODICALLY
USE CARE REGARDING PUNCH
MARK INDENTIONS

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 INDIKON ELECTRONIC
VERY HIGH RESOLUTION
SOMEWHAT COMPLICATED
PROVIDES ANGULAR DATA
RECOMMENDED, BUT IS NOT
NECESSARY WHEN USING
WEBMAP

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 LASER ALIGNMENT KIT
THEORETICALLY EXCELLENT
NOT YET DEVELOPED AS AN
APPLICATION
DETECTS OFFSET AS WELL AS
ANGULAR MISALIGNMENT

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 FACTORS AFFECTING DATA
Condition of the Tools
Positioning of the Tool
Temperature of the Engine
Temperature of the Instrument
Condition of the Punch Marks
Extensions: Bolts or
Counterweights

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 EXTENSIONS
RECORD EXTENSION LENGTHS
DO NOT RECORD CORRECTED
READINGS AS DATA
CORRECT FOR EXTENSION LATER
WEBMAP CORRECTS READINGS

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 Maximum Deflection Limits
Three mils is about the number
you will hear for most large
engines (10 to 20 inches of stroke)
It is best considered a function of
the stroke length
Traditional formula 0.18 mils /
inch of stroke (Courtesy: Cooper
Energy Services)

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 Recording the Data
Do not use inches
Make written marks in Mils
Use a form for recording data
Employ circles for the data, not a
table
Show approximate angle for data
points

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 This Many Inches Deflection?
This Many WHAT?
0.00025 Inches, You say?
0.0025 Or was it this many?
Uh...Well. It was about a quarter
of a mil. I was looking at it!

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 INCIDENTAL DATA
DATE AND TIME
ENGINE SUMP TEMPERATURE
MECHANICAL CONSIDERATIONS
COMPLETE IDENTIFICATION

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 Typical Deflection Readings

As Viewed From Oil Pump End

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 FILE The DATA
Keep a good file on location or at
the nearest field office.
Send a copy to the area engineer.

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 WEBMAP DEVELOPMENT
EXXONS KING RANCH GAS
PLANT
ALIGNMENT PROBLEMS
GROUT CREEP
ASSISTED BY RAY JAMES
CONVERTED TO PC BY GMRC

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 THE QUESTION WEBMAP ANSWERS

Courtesy: Cooper Bessemer

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 MATHEMATICAL BASIS
ASSUME A HARMONIC FUNCTION
DEVELOP A SIMPLE ANALOGY
INCLUDE ENGINE GEOMETRY
THE RESULTS APPLY DIRECTLY
TO THE SHAFT, BUT
INDIRECTLY TO THE FRAME

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 APPLYING THE THEORY
CHOOSE A ZERO REFERENCE
FIT WEB DEFLECTION DATA TO A
SINE FUNCTION
FORMULA FOR CORRECTIONS FOR
EXTENSIONS
RELATES ENTIRE SURVEY FOR
VERTICAL AND HORZ. PROFILES
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 WEBMAP ANALYSIS
SCREENS FIELD DATA
CORRECTS FOR EXTENSIONS
EXTRAPOLATES FOR 360 DEGREES
GENERATES A LONGITUDINAL
PROFILE OF THE INFERRED
FRAME POSTURE

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 EXAMPLES OF WEBMAP
KVR CASE CONFIRMS CRUCIAL
DATA
HRA CASE ILLUSTRATES HEAT
EFFECTS
OFFSHORE GMVA DATA
CONFIRMS FRAME DISTORTION
MEASUREMENTS

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INGERSOLL-RAND 3400 HP KVR

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 CRANKSHAFT ALIGNMENT
AND WEB DEFLECTIONS
WHY RUN A WEB SURVEY
DOING SURVEYS RIGHT
WHAT WEB SURVEYS REVEAL
THEY WILL ALWAYS BE
NECESSARY
BUT...

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 BUT...THE WEB SURVEY
IS ONLY AN INDIRECT
INDICATOR OF FRAME ALIGNMENT
BEST PRACTICES CALL FOR
DIRECT MEASUREMENTS OF
FRAME SETTING POSTURE AND
POSITION?

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NEW SPLIT STEEL CHOCKS

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