WELCOME

FAC CLASS ROOM

SHAFT ALIGNMENT

PROCEDURE OF P44 SERIES

FAC’S

PRESENTATION CONTENTS

• METHOD USED FOR ALIGMENT OF P44 SERIES FAC’S

• PRINCIPLE OF TELESCOPIC ALIGNMENT• EQUIPMENT USED• ACTIVITIES BEFORE ALIGNMENT• ALIGNMENT PROCEDURE• DIAMENSIONS/CLEARANCE LIMIT OF SHAFTING OF

P44 SERIES CRAFTS• PRECAUTIONS/IMPORTANT FACTORS TO BE

CONSIDERED IN TELESCOPIC ALIGNMENT• ENGINE TO GEAR BOX ALIGNMENT

METHOD USED FOR ALIGNMENT OF P44 SERIES FAC’S

DUE TO THE HIGH ACCURACY REQUIRED IN HIGH ROTATIONAL APPLICATIONS AND ONE REFERENCE POINT AVAILABLE IN P44 SERIES FAC’S IT IS MORE ADVISEBLE TO GO FOR TELESCOPIC ALIGNMENT

PRINCIPLE OF OPTICAL ALIGNMENT

EYE OR CAMERA

REFERENCE ELEMENT ELEMENT WHICH ALIGNMENT TO BE

DONE

LIGHT

REFERENCE AXIS

JOINING OF TWO POINTS WILL MAKE A STRAIGHT LINE. IF SOME OTHER POINT ALSO IN THE SAME LINE, IT IS SAID THAT ALL THREE POINTS ARE IN – LINED.

SAME PRINCIPLE USED IN OPTICAL ALIGNMENT METHOD AND THIS TO BE APPLIED IN RADIALY AS WELL AS AXIALY. (PARALLEL AND ANGULAR)

SPECIAL EQUIPMENT USED IN TELESCOPIC ALIGNMENT

• MICRO TELESCOPIC ALIGNMENT CAMERA WITH MOUNTING BASE

• DEFERANT TYPES OF TARGETS

WITH BEARING TARGETSWITH OUT BEARING TARGETS

STRUT TARGETS

STERN TUBE TARGETS

GEAR BOX TARGETS• CHART TABLE LIGHT

• ALUMINIUM TUBES

• JACK BOLTS (WITHOUT SHARP EDGES)

• LAMINATED SHIMS

• TWO NUMBERS HAND HELD COM SETS

• MICRO METER AND FEELER GAUGE

• ANTI-SIEZE COMPOUND OR “ENDARU THEL“ FOR JACK BOLTS

• BEARING PULLERS

ACTIVITIES BEFORE ALIGNMENT

• SLIPPING OF CRAFT WITH “ZERO BED”.• TAKE DOWN REQUIRED READINGS SUCH AS RUDDER

BUMPING CLEARANCE, CLEARANCE BETWEEN PROPELLER BOSS AND STRUT TUBE ROPE GUARD.

• REMOVE RUDDER AND PROPELLER.• CUTTING OF ROPE GUARDS.• TAKE DOWN BEARING CLEARANCES.• TAKE DOWN RAKE ANGLE.• REMOVE OF PROPELLER SHAFT.• INSPECTION OF SHAFT BEARINGS.• AS PER BEARING CONDITION AND CLEARANCE, REMOVE OF

SHAFT BEARINGS.• TAKE DOWN BEFORE ALIGNMENT READING.

AS PER THE BEFORE ALIGNMENT READING WE HAVE TO DESIDE THAT WETHER ALIGNMENT CORRECTION TO BE DONE OR NOT.

IF BEARING CLEARANCES WITHIN LIMITS (PREVIOUS BEARING CALCULATION TO BE REFERRED) AND BEFORE ALIGNMENT READING ALSO WITHIN LIMIT (GEAR BOX 0.2MM AND STRUT 0.3MM) WE CAN LEAVE ALIGNMENT.

IF BEARING CLEARANCE BEYOND LIMIT BUT BEFORE ALIGNMENT READING IS WITHIN LIMIT, WE HAVE TO INSTALLED NEW BEARINGS AND RE-CHECK ALIGNMENT.(MOST PROBABLY WE HAVE TO GO FOR ALIGNMENT CORRECTION).

IF BEARING CLEARANCES WITHIN LIMIT BUT BEFORE ALIGNMENT READING BEYOND LIMIT, WE HAVE TO CARRY OUT ALIGNMENT CORRECTION.

TELESCOPIC ALIGNMENT PROCEDURE

SCHEMATIC DIAGRAM OF SHAFTING ARRANGEGEMENT P44 SERIES CRAFTS

CAMERA

STRUT

STERN TUBE

GEAR BOX

PREPARATION OF SURROUNDINGS

ALIGNMENT PLACE SHOULD BE COVRED PROPERLY TO MINIMIZE EFFECTS OF WIND AND LIGHT

MINIMIZE MOVEMENTS TO CRAFT

SURROUNDING SHOULD BE CALM AND QUIT

COMFORTABLE CHAIR IS REQUIRED FOR PERSON WHO DONE THE ALIGNMENT

ALL REQUIRED TOOLS TO BE BROUGHT TO THE PLACE

ATOMOSPHERIC TEMPERATURE SHOULD BE MINIMUM (SHOULD BE AT NIGHT TIME)

TELESCOPIC CAMERA INSTALLATION

TRAVERSING SCREW OF CAMERA SHOULD BE IN MIDLE POSITION

SAFETY LINE SHOULD BE CONNECTED TO CAMERA BRACKET FOR THE PREVENT ANY FALL DOWN OF CAMERA

CAMERA HOLDING BEARING SHOULD BE TIGHTEN BY USING PROPER TOOL

INSTALLATION OF STERN TUBE TARGETS

IN THIS ALIGNMENT METHOD WE CONSIDER STERN TUBE TARGET AS THE REFERENCE TARGET

ZERO THE CAMERA WITH STERN TUBE TARGET

THERE ARE FOUR ADUSTMENT SCREWS THAT WE CAN USE FOR THE TASK. 02 NO’S ON CAMERA BRACKET AND OTHER 02 NO’S ON MOUNTING BASE

INTALLATION OF GEAR BOX TARGETS TO THE GEAR BOX FLANGE PROPERLY

INSTALLATION OF CHART TABLE LIGHT

WHITE PAPER SHOULD PASTE OF GEAR BOX FLANGE

INSTALLATION OF STRUT

INSERT OF STRUT WITH HELP OF THE 08 NO’S CROSS BOLTS TIGHTEN TO TORQUE 16.5 KG/M

ALIGN THE STRUT BY ADJUSTING JACK BOLTS AND MEASURING DISTANCE BETWEEN STRUT HOUSING AND MOUNTING.

INSERT SHIMS ACCORDING TO READING AND REMOVE JACK BOLTS

TIGHTENING MOUNTING BOLTS

INSERT WEDGES BETWEEN STRUT AND STRUT HOUSING

ALIGNMENT CORRECTION OF GEAR BOX

GEAR BOX BED TO BE DP TESTED

DO THE ALIGNMENT USING 08 NO’S JACK BOLTS AND PULLER BOLTS

MEASURE THE HIGHTS AND INSERT THE SHIMS ACCORDINGLY

REMOVE JACK BOLTS AND TIGHTEN MOUNTING BOLTS

02 NO’S LOCKING PLATES TO BE WELDED TO BOTH AFT MOUNTING SHOES TO STOP SLIDING MOVEMENTS TOWARDS AFT

INSERT SHAFT BEARINGS IF REQUIRED

INSERT PROPELLER SHAFTS

SOAP SOLUTION TO BE USED

WHEN RELEASED, SHAFT TO BE SLIDED DOWNWARDS

JOINING PROPELLER SHAFT TO GEAR BOX

A CONE NUT WITH LOCKING PLATE AND SCREWS TO BE INSERT (CONE NUT TORQUE 150 KGM)

COUPLE GEAR BOX FLANGE WITH SHAFT FLANGE(18KGM)

INSTALATION OF PROPELLER

INSERT CONE NUT WITH LOCKING ARRANGEMENT(135 KGM)

DIMENSIONS/CLEARANCE LIMITS OF SHAFTING OF P44 SERIES CRAFTS

SHAFT DIAMETER – 95.25 MM

STRUT AND STERN TUBE INNER DIA – 115 MM

RUDDER BUMPING CLEARANCE – 15 MM

CLEARANCE BETWEEN ROPE GURD

AND PROPELLER - 10 ± 1MM

SHAFT BEARING CLEARANCE – REFERED TO PREVIOUS BEARING CALCULATION SHEET

ALIGNMENT TOLERANCE – GEAR BOX – 0.2 MM

STRUT – 0.3 MM

RAKE ANGLE - 120

ENGINE TO GEAR BOX ANGLE - α=8.0 ± 0.50, α= β ±0.25

PRECAUTIONS/IMPORTANT FACTORS TO BE CONSIDERED IN TELESCOPIC ALIGNMENT

PERSON WHO CARRY OUT ALIGNMENT SHOULD BE VERY EXPERIENCED, COULD BE ABLE TO WORK LONG DURATION WITHOUT GET TIRED. OTHER PERSONS IN HIS TEAM ALSO HAVE SAME CHARACTERISTICS.

ONLY ONE PERSON SHOULD INVOLVE IN TAKING ALIGNMENT READING TO MINIMIZE HUMAN ERRORS.

GREASE JACK OR SHIP BUILDERS PULLER TO BE USED FOR REMOVE OF PROPELLER.

SAME SIZE WOODEN SHAFT RESTING BLOCKS TO BE USED WHILE TRANSPORTATION OF PROPELLER SHAFT FROM SLIPWAY TO SME FACTORY AND VICE VERSA.

ALL JACK BOLTS SHOULD BE WITHOUT ANY SHARP EDGES EXCEPT END POINT . ALL JACK BOLTS SHOULD BE IMMERSED IN “ENDARU THEL” TO PREVENT ANY SEIZE DURING TIGHTENING. IF WE FABRICATE NEW MOUNTING BOLTS WE HAVE TO CARRY OUT SHAMPERING TO ELIMINATE SHARP EDGES. ALL JACK BOLTS TO BE CLEAN WITH KEROSINE AND KEEP IT IN LUBE OIL CONTAINER. DO NOT REAMER HOLES. WE HAVE TO FILLED BY WELDING AND GRIND TO LEVEL. BEST FITTER IN SME FACTORY TO BE UTILIZED FOR DRILLING OF MOUNTING SHOES. STRUT TO BE TESTED FOR BENDING AND TWISTING IN SME FACTORY AND CORRECTED BY HEATING.

STRUT HOUSING AND GEAR BOX BED TO BE DP TESTED BEFORE ALIGNMENT COMMENCED.

ALLWAYS USE PROPER TOOL BOXES.

OIC OF CRAFT SHOULD BE PRESENCE THROUGH OUT ALIGNMENT.

ALL JACK BOLTS AND MOUNTING BOLTS TO BE NUMBERD FOR EASY COMMUNICATION BETWEEN PERSON WHO TAKE ALIGNMENT AND PERSONS WHO ARE INVOLVED IN TIGHTENING BOLTS.(A1,A2,B1,B2)

ACTIONS TO BE INITIATED TO OBTAIN SPECIAL RATION FOR PERSONS INVOLVE IN ALIGNMENT.

RAKE ANGLE TO BE OBTAINED BY USING INCLINO METER AND IF THERE IS ANY ALTERATION, WE HAVE TO CUT ASTERN TUBE AND CORRECT THE RAKE ANGLE.

MOVEMENTS TO THE CRAFT AND MOVEMENTS INSIDE CRAFT SHOULD BE MINIMIZED.

DO NOT TOUCH ALIGNMENT CAMERA OR BASE AFTER ZERO THE CAMERA WITH STERN TUBE TARGETS.

POINT TO POINT ALIGNMENT (ENGINE TO GEAR BOX)

α=8.0 ± 0.50 α= β ±0.250

POINT TO POINT METHOD IS USED TO CARRY OUT ALIGNMENT BETWEEN GEAR BOX AND ENGINE.

INSTALLATION OF 02 NO’S FLANGES TO GEAR BOX AND ENGINE FLANGES WITH POINTERS PLACED CENTER SUCH A WAY THAT BOTH POINTERS FACED TO EACH OTHER

SHIFT LOCATION OF ENGINE BY JACK BOLTS USING SAME METHOD AS FOLLOWED IN GEAR BOX ALIGNMENT SUCH A WAT THAT BOTH POINTERS MAKE PROPER CONTACT

TAKE DOWN ANGLE READING BY USING BEVEL PROTECTER