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

Apparent hinge points

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Bending takes
place primarily
in the webs!
Web acts like a
hinge
Max stresses
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
web deflection zero

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Bearings misaligned
webs closer together
with pin up

Bearings misaligned
webs farther apart
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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