轴系的顶升试验及计算.pdf

ROL 国ROYCE JRolls-RoyceREPORT PA0679 rev dBusiness Area Propulsion Propeller ApplicationAddress Rolls-Royce ABP.O.Box 1010S-681 29 Kristinehamn SWEDENTitleShaft Installation and Alignment CalculationTelephone+46 550 840 00Telefax+46 550 840 74Yard and Yard No.Damen Okean NB 7403Date2006-12-19ClassificationLRS,Ice 1A+F/SAuthor(s)of reportPer HjerdtRRAB order No.500 877RRAB file No.11962Approved byAndreas MalmkvistAbstractThe alignment calculation is made to determine the following:Bearing loads,shaft stresses,optimal bearing offsets,slope boring evaluation and installation data(gap/sag values and jack loads).Bearing offsets:A line through centre of bearing no.1 and no.2 defines the reference line.The gearbox bearing no 3 is positioned 1.15 mm below reference line and bearing no.4 is positioned 1.56 mm below reference line in cold condition.Alignment procedure:Gap and sag is measured inboard between every shaft connection after launching.Jack load measurement is performed to verify the alignment.The input data comprises:Shafts geometry,propeller weight in water,thrust eccentricity and transverse forces from propeller and tooth forces on main gear wheel in running conditions.The thermal expansion of the gearbox and the buoyancy effect of the water and oil in stern tube have also been considered.RevisiondRevision modificationAppendix 1 with alternative alignment and jack loadsDate071002Author(s)kk162Approved byMtaRevisioncRevision modificationDynamic movement changed from-0,02 mm to 0,12 mmDate070831Author(s)kk162Approved byWgoRevisionbRevision modificationPosition of fwd sterntube bearing,added jack,procedure updateDate070712Author(s)MtaApproved byWgoRevisionaRevision modificationAdded jack loads for warm static conditionDate070620Author(s)Kk162Approved byMtaKeywordsGroup 1:Group 2:Group 3:Rolls-RoyceROLLS f ROYCEPage 2 of 57 2007-07-12 Alignment report PA0679 rev d Damen Okean,NB 7403/11962/C12List of contents1 Introduction.1.1 Shaft alignment calculation.1.2 Description of the alignment program.1.3 Description of the calculation model.1.4 Plant particulars.1.5 Hull deflection influence.1.6 Gearbox alignment.1.7 Computed alignment conditions.2 Definitions and assumptions.3 Alignment calculation.3.1 Choice of alignment curve.3.2 Summary of bearing loads.3.2.1 MCR Warm condition.3.2.2 Cold static condition.3.2.3 Warm static condition.3.3 Slope boring evaluation.3.3.1 Conclusion.3.4 Slope bore proposal.3.5 Bearing load range.4 Instruction for installation and alignment of shaft and gear4.1 Before the final alignment starts.4.2 Proposal of alignment procedure.4.2.1 In dry dock before launching:.4.2.2 Afloat after launching:.4.2.3 The SKF flange coupling.4.3 Gap and Sag information.4.3.1 Gap&Sag tolerances.4.3.2 GAP&SAG protocol.4.4 Jack load measurement.4.4.1 Verification of alignment of shaft line.4.4.2 Jack load acceptance criteria.4.4.3 Jack load procedure.4.4.4 Jack load positions.4.4.5 Jack up protocol.5 Calculation results.5.1 Shaft deflection plot.5.2 Shaft stress plot.5.3 Shaft bending moment plot.5.4 Shaft slope,moment,stress and shear force.5.4.1 Vertical state,warm MCR condition.5.4.2 Vertical state,cold static condition.5.4.3 Horizontal state,warm MCR condition.5.5 Bearing loads.5.5.1 Vertical state.5.5.2 Horizontal state.Aft bearing.5.6 Bearing influence numbers.5.6.1 Warm MCR condition.5.6.2 Cold static condition.5.7 Open shaft.5.7.1 Open shaft plot,propeller immersed.5.7.2 Open shaft slope,moment,stress and shear force.5.7.3 Gap and sag values.5.8 Jack load values cold condition.5.9 Jack load values warm static condition.e44445556 70 12UI 1 di789901231111222224222222333333333333448 8 9 9 9 9 0133 4 4 4 6 7UI UI.1.1 4 di圖Rolls-RoycePage 3 of 57 2007-07-12 Alignment report PA0679 rev d Damen Okean,NB 7403/11962/C126 Input data.41Appendix 1.466.1 Shaft deflection plot.476.2 Open shaft plot.486.3 Gap&Sag values.496.4 Jack loads positions.506.5 Jack load values.516.5.1 Cold static.516.5.2 Warm static.516.6 Input data.52Page 4 of 572007-07-12Alignment report PA0679 rev dDamen Okean,NB 7403/11962/C12Rolls-Royce1 Introduction1.1 Shaft alignment calculationThe calculations are based on following information:CompanyRR drawing no.TitleRolls-Royce AB Reintjes Rolls-Royce AB167300 rev a.0-429-72506 167338 rev a.Shafting arrangement Gearbox,SVA 1050B K41 Aft stern tube bearingRolls-Royce AB167341-SKF OKFA coupling 380The alignment calculation of the shaft system has been carried out by using the alignment program from Shaft Analysis AB rev.98-10.1-2 Description of the alignment programThe Alignment program uses the transfer matrix method for solving the equations.All state quantities are related to the x-axis that coincides with the shaft centre line and points forward.The shaft line is modeled as elements with different characteristics.The distribution of mass is continuous in shafts and flanges,and concentrated(discrete)in the other element types.The system is considered to have fixed positions at the bearings.1.3 Description of the calculation modelThe propeller hub has been modeled as a mass element in the centre line of the blades and geometry with a density close to zero to show the hub outline in the graphic plot.The mass of the entrained water is added as a separate post in the model and the program adds it to the propeller mass.At the flanged shaft connection,the flanges are assumed to have contact outside the pitch circle of coupling bolts.In the gearbox,the output shaft has been calculated with the actual dimensions and weights.Due to complex geometry,parts of gear wheel have been modeled as point mass acting on gear wheel centre.Page 5 of 572007-07-12Alignment report PA0679 rev dDamen Okean,NB 7403/11962/C12Rolls-Royce1.4 Plant particularsGeneral informations:Propeller4 blades C.P.propeller 2 x 121XF5/4E-BGearReintjes SVA 1050B K41Main-engineMAK6M43CPropellerDiameter4.95 mWeight in air(including oil)i 13 577 kgWeight fully submerged in water MaterialPropeller speedI 11 462 kg:Ni-AI-bronze120.9 rpmEngineMCR condition6 000 kWEngine speed500 rpmAlignment Data:Vertical bending moment due to thrust eccentricity at propeller:86 kNm(upwards)*Horizontal bending moment due to thrust eccentricity at propeller:117 kNm(towards port)*Vertical hydrodynamic force acting in propeller centre:i 33 kN(upwards)*Horizontal hydrodynamic force acting in propeller centre:20 kN(towards starboard)*estimations based on wake field from similar vessels.1-5 Hull deflection influenceDuring normal usage of a vessel,the vessel varies between a light ship condition and heavy ship condition.The light ship condition occurs when the vessel has little deadweight onboard.The heavy ship condition occurs when the vessel is in full loaded,with full deadweight,condition.The different loading conditions influences the hull deflection of the vessel.The hull deflection of the vessel is an important factor influencing static bearing loads.If these hull deflections are known,the changes in offset at the bearing positions can be calculated and the resultant effect on bearing loads can be assessed.This is to be considered by the yard.1.6 Gearbox alignmentThe calculation is based on information Rolls-Royce AB received from the gearbox manufacturer.Rolls-Royce takes no responsibility for the correctness of the in data delivered by the gearbox manufacturer.The alignment recommendation in this report takes the requirements for the gearbox made by the gearbox manufacturer into account.Page 6 of 572007-07-12Alignment report PA0679 rev dDamen Okean,NB 7403/11962/C12Rolls-Royce1.7 Computed alignment conditions Static cold Warm MCR condition Open(cold)conditionAll conditions are after launching(propeller submerged).圖Rolls-RoycePage 7 of 57 2007-07-12 Alignment report PA0679 rev d Damen Okean,NB 7403/11962/C122 Definitions and assumptionsJack load measurementReference pointAft end of propeller(1020 mm aft of propeller centre)Reference lineA straight line between bearing 1 and bearing 2 states the reference line.Bearing support point0.3*0 from the aft end of aft stern tube bearing in cold condition and 1.4*0 from fwd end in warm MCR condition.For all other bearings and conditions the mid point.Bearing clearance aft stern tube0.8 mm(aft stern tube bearing)Bearing offsetsPositive when above the reference line.Bearing typeAll bearings are oil lubricated white metal type.Load reference directionGiven loads are positive downwards,while reaction forces are positive upwards.Given bending moments turn anti-clockwise if positive.Bearing load influence numbersShows the change in bearing reaction when one bearing is moved vertically relative to the others.Hull deflectionsDeflections due to different draught and load conditions are not considered.Vessel conditionMost frequent sailing condition(=design condition).Thermal expansion of gearboxThe gearbox is rising 0.24 mm between cold(20)and warm(50%)condition.Warm static,giving a thermal rise of 0.12 mm.Single tubeThe weight of the single tube has been included.Stern tubeFilled with oil during alignment of shafting.Buoyancy effectThe buoyancy effect for the shaft parts in water and in oil is considered.Warm conditionWarm(50)condition at MCR speed.Cold conditionStatic cold(20)condition.Gap and Sag measurementBefore the shaft line is connected the bearing offsets can be adjusted by this method.The vertical and horizontal angular and position of shaft ends is measured and compared with the calculated values.The final alignment checking is performed by this method.When the bearing is relieved the load of the jack should be equal to the calculated jack load if the alignment is satisfactory.The jack load test must be carried out with the whole shaft line coupled.Page 8 of 572007-07-12Alignment report PA0679 rev dDamen Okean,NB 7403/11962/C12Rolls-Royce3 Alignment calculation3-1 Choice of alignment curveThe curve is chosen in such way that the shaft line fulfil the following desired conditions:Allowable bearing loads and if possible downwards bearing reaction for all bearings.Acceptable stresses in all parts of the shaft line.Acceptable angular slope at the bearings.Acceptable load distribution on the two gearbox bearings.Bearings no 1 and no 2 are with zero offsets to reference line.Bearings no 3(gearbox bearing)are positioned 1.15 mm below reference line and bearing no 4(gearbox bearing)are positioned 1.56 mm below reference line in cold condition.圖Rolls-RoycePage 9 of 57 2007-07-12 Alignment report PA0679 rev d Damen Okean,NB 7403/11962/C123.2 Summary of bearing loads3.2.1 IBrg.MCR Warm conditionDist.Vertical JHorizontal-ResultantLoad Angle aLoad direction in MCR Warm conditionOffsetLoadOffsetLoad(no.)(m)(mm)(N)(m)(N)(N)(Deg.)1.。1.2,4480,001186080,00-5982118759182,9C2.7,0090,00401220,004700861802130,5c3.9,497-0,912935310,00-344668452721229,6C2.Vy4.10,449-1,32148130,00-236864237327266,4C3.2.2(Cold static condition3.QJ)Vertical JHorizontal Resultant夂OBrg.Dist.OffsetLoadOffsetLoadLoadAngle a(no.)(m)(mm)(N)(mm)(N)(N)(Deg.)1.2,2180,001759620,000175962180,02.7,0090,00216080,00021608180,03.9,497-1,15321690,00032169180,04.10,449-1,56410550,00041055180,03.2.3 Warm static conditionBrg.Dist.Vertical JHorizontal rResultantOffsetLoadOffsetLoadLoadAngle a(no.)(m)(mm)(N)(mm)(N)(N)(Deg.)1.2,2180,001773870,000177387180,0c2.7,0090,0093650,0009365180,0c3.9,497-1,03640860,00064086180,0c4.10,449-1,44199560,00019956180,0cPage 10 of 572007-07-12Alignment report PA0679 rev dDamen Okean,NB 7403/11962/C12Rolls-Royce3-3 Slope boring evaluationLength of aft stern tube bearing(no.1)Diametrical clearanceMCR warm condition:Vertical planeHorizontal planeStatic cold condition:1,063 m 0,8 mmCalculated slope at bearing no.10,196E-03 rad-0,302E-03 rad(0,196 mm/m)(-0,302 mm/m)0,553E-03 rad(0,553 mm/m)3-3,1 ConclusionFor warm MCR condition the slope in the aft bearing is within clearance for both horizontal and vertical direction.For cold condition the vertical slope is above the recommended limit of 0,3 mm/m.Although deflection is within bearing clearance,a slope bore will give a better margin for miss alignment and is therefore recommended.For slope bore proposal see below.圖Rolls-RoycePage 11 of 57 2007-07-12 Alignment report PA0679 rev d Damen Okean,NB 7403/11962/C123.4 Slope bore proposal0.3 mm/mBottom sideFig 1.Bearing seen from starboard side.The best way to make a slope in this case is to make a local increase of the bearing clearance at the forward-and aft end at the topside respective bottom side of the bearing.See sketch above/below.The area is to be gradually increased from the middle of the bearing at 1063/2 mm inside the bearing to 0.16 mm at the forward-and aft end by hand scrapping or by boring.In this way we do not make any other conditions worse.Fig 2.Bearing seen from starboard,3DPage 12 of 572007-07-12Alignment report PA0679 rev dDamen Okean,NB 7403/11962/C12Rolls-Royce3-5 Bearing load rangeThe recommended load range is+/-10%of the nominal load for all bearings in cold condition.Bearings not available for verification of alignment are listed in italic.For verification of alignment see on page 19.The nominal load is the load calculated in this report.The maximum admissible bearing load is specified by the bearing manufacturer.NOTE!The loads may increase or decrease for other draft conditions or/and in warm MCR condition,see the information on page 5 paragraph 1.5.For the difference between cold static and warm MCR condition see the calculation results on page 24.These influences need to be considered to get an alignment within the limits in the table below.Bearing No.Max loadunit10.8*MPa20.8*MPa242-93*kN320-53*kN*According to class.*Gearbox bearing,allowable load in vertical direction for static Warm/Cold condition.Page 13 of 572007-07-12Alignment report PA0679 rev dDamen Okean,NB 7403/11962/C12Rolls-Royce4 Instruction for installation and alignment of shaft and gear4.1 Before the final alignment startsNote!This report is only our instruction to the yard including all necessary values and procedures.It is the yard responsibility to physically install and align the shaft line.The yard can use our proposal of alignment procedure or they use their own procedure.The yards procedure should be shown as information for Rolls-Royce AB.Before the final alignment startsThe vessel must be afloat in sheltered waters and all heavy sections,modules and equipment must be placed in their final position.All essential welding works must be finished.For best result of the alignment the loading condition of the vessel should be similar to the most frequent sailing condition,the design condition.Experience shows that the draft related ship hull bending is an important factor influencing static bearing loads.If alignment is done at very light ballast or in dry dock,the ship draft influence on the bearing load needs to be considered by the yard to get an alignment that is within our recommended tolerances.To ensure that bearing loads are within our recommended tolerances it