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T E C H N I C A L M AT T E R S
I
IN THIS ISSUE
3 Lubricating pump
failures
4 Propeller induced
noise
5 Intermediate bearing
6 Stabiliser fins
Fluorescent magnetic particle crack detection -
7 Furnace collapse the most sensitive means of detecting cracks
8 Gear Scuffing
10 Cylinder head
11 Thrust block
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2 T E C H N I C A L M AT T E R S June 2009
CASE STUDY 1
A common application of
CFD methods is to improve
the prediction of propeller
inflows, i.e. ship wakes. These
methodologies have been applied The result was a reduction in hull CFD analysis allows detailed
to a medium sized containership pressures radiated from the examination of flow features
which suffered from high collapsing sheet and tip vortex that would not be possible using
vibration and noise levels in the cavitation on the propeller. model tests. The flow can be
all-aft accommodation. To remedy visualised in various ways such
the high vibration and noise Two CFD models were analysed: as viewing of the vorticity in
levels, this ship was fitted with one with, and one without the wake and examination of
vortex generators to alter the vortex generators added. It was streamlines around the dynamic
inflow into the propeller. found that with addition of the ship form.
vortex generators a reduction in
propeller inflow velocities near
top dead centre was achieved, as
desired. The vortex generator
was also found to reduce the
axial velocity elsewhere in the
propeller disc.
June 2009 T E C H N I C A L M AT T E R S 3
CASE STUDY 2
• contamination of the
LESSON
lubricating oil with fine metal Quality control and
particles possibly extending cleanliness procedures
back to original construction.
must be followed
An extensive range of
during shipyard
modifications were made to the construction and
sump tank and the off-engine maintenance. While
lubricating oil pipework system.
it is preferable to
A thorough cleaning of the
entire system was also carried
eliminate problems
out to remove all metal debris. such as aeration
during the design
stage it is possible to
subsequently conduct
remedial work to
minimise occurrences
and impact.
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4 T E C H N I C A L M AT T E R S June 2009
CASE STUDY 3
LESSON
Conventional vibration
and noise
measurements are
often insufficient to
identify the types of
the cavitation and
such problems may be
solved by viewing the
blades and the tip
vortex structures with
a borescope and a
video capture system
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June 2009 T E C H N I C A L M AT T E R S 5
CASE STUDY 4
Intermediate bearing
During a partially laden voyage
a direct drive diesel powered
SUBJECT VESSEL Chemical Tanker suffered a severe
TYPE failure of the intermediate shaft
Chemical Tanker pedestal bearing. Significant
wiping damage occurred to the
bearing white metal surface
ISSUE requiring the ship to be towed
Failure of the to port for repair.
intermediate shaft
bearing The vessel had recently completed
a five yearly dry-dock survey
during which the propulsion
shafting had been dismantled for
inspection. The inspection had
load along the shafting system It was found by calculation
revealed no problems and the
length. In particular it was found that the satisfactory operation
shafting was refitted.
that the forward sternbush and of the shafting system could
the second aft engine bearing be achieved even though the
Following the failure bearing
had insufficient downwards load. forward sternbush was only
loads and shaft deflections were
The second aft engine main lightly loaded. This was
measured using the jack-up
bearing was considered to be supported by recent operating
technique. The results revealed
at risk of fatigue damage. experience.
an unsatisfactory distribution of
Flywheel
&
engine
coupling LESSON
Shafting systems require
Intermediate shaft careful alignment,
Propeller Main
shaft Sterntube fwd bearing Intermediate bearing
engine especially when the
shaftlines are short and
stiff. Appropriate
combinations of
Sterntube measurements and
aft bearing
analysis can enable
correct alignment
of the shafting
components.
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6 T E C H N I C A L M AT T E R S June 2009
CASE STUDY 5
Stabiliser fins
Two retractable stabilising fins
were attached to the sides of
SUBJECT VESSEL a Ro-Ro cargo and car carrier
TYPE where, by adjusting the angle
Passenger/Ro-Ro ship of attack, they could provide
a variable lifting force to reduce
vessel roll.
ISSUE
Stabiliser fin failure After three years in service one
of the stabilisers was found to
be missing, having failed due
to fatigue some time before.
It was calculated that the shaft shaft due to roll of the ship in Recommendations were made
had a low factor of safety against service. The low factor of safety that the stabiliser stocks on sister
the bending loads imposed on the was apparent from the fatigue vessels should be examined
pattern as the fatigue crack had visually and by non-destructive
propagated for only 15% of the testing for the presence of cracks.
shaft diameter before rapid brittle Recommendations were also
fracture finally occurred. given to fitting shafts with an
increased operating margin
During the initial stages of crack against imposed bending loads.
growth there were three distinct
bands of relatively slow
propagation interspersed with two
narrow bands of more rapid LESSON
propagation. These changes in Poor manufacturing
crack growth rate indicated practises and
significant changes in service
component selection
loading, such as loading induced
by especially rough sea conditions. can often lead to early
failure during service
life. Understanding the
mechanisms of failure
can lead to more
robust solutions.
TechMatters4_200509.qxd:TechMatters210708v5.qxd 20/5/09 15:42 Page 7
June 2009 T E C H N I C A L M AT T E R S 7
CASE STUDY 6
Furnace collapse
Following the collapse of an
Inert Gas Generator (IGG)
SUBJECT VESSEL furnace onboard a LNG carrier
TYPE an investigation was carried out
LNG Carrier into how the controls and
instrumentation could have
allowed the failure to occur.
ISSUE
Inert gas generator The IGG was cooled using
furnace collapse seawater taken from the ballast
system, and the hot discharge
water was returned to the sea
through a position controlled
effluent regulating valve.
Fwd
Top
1250mm
The inert gas and effluent It was therefore possible for
pressures were compared using the IGG burner to continue
1720mm
Port Stbd
a Proportional Integral (PI) to operate with no apparent
controller which controlled the external indication that failure
position of the effluent valve. had occurred.
It was found that the two
pressure transducers of the PI A number of recommendations
Aft controller were both blocked were made to modify the method
Fwd IGG
combustion chamber with debris, giving false and manner by which the system
damage readings, therefore causing the shut off the burner if the cooling
effluent valve to be incorrectly water were to be reduced or
positioned. At the time of the blocked. It was also recommended
730mm furnace collapse the valve was to include a mechanical fail safe
1 metre
found to be fully closed. device which would allow the
Port Stbd
continued flow of cooling water
1270mm
8 T E C H N I C A L M AT T E R S June 2009
CASE STUDY 7
Gear scuffing
Severe scuffing damage occurred
on the teeth of the two input
SUBJECT VESSEL pinions and main wheel of the
TYPE main propulsion gearing during
LNG Carrier trials of a newly built diesel
electric LNG carrier. The
propulsion system consists of
ISSUE twin electric motors driving a
Scuffing of the main single output main propulsion
reduction gearing shaft and fixed pitch propeller
through single reduction, single-
helix gears. Lloyd’s Register
Technical Investigations (TI) was
asked to attend onboard at the
newbuilding yard to inspect the
tooth flank damage and assist
with the failure investigation.
The scuffing damage was machining including design
Failure of the gears was traced due to a breakdown of the modifications to the gear tooth
from trial records to occurring elasto-hydrodynamic oil film flank. The main wheel tooth
during a rapid acceleration test. which should normally be flanks were polished in-situ.
In this test, the propulsion plant present between mating gear
was accelerated from stationary teeth. The breakdown resulted Following repair, the reduction
to full away in a little over from a combination of the gearing successfully completed
eleven minutes. selection of the pinion gear sea trials. This was achieved by
tooth-end design and the rapid modifying the pinions helix
rate of torque input to the correction and end relief. The
pinion gears from the electric propulsion electric motor speed-
propulsion motors. It was torque characteristics had also
considered likely that the been modified to reduce the
damage was initiated at the initial rate of torque delivery
starboard mesh and then to the pinion gears.
transferred to the port mesh
in way of the main wheel.
June 2009 T E C H N I C A L M AT T E R S 9
CASE STUDY 8
• the air start valves fitted to • during engine operation the manifold, igniting the mist and
the engine had air leaks in all air start manifold contained oil deposits and hence causing
valves in way of the valve seat: a large amount of mist the explosions.
and smoke.
• the starting air manifold The system was repaired
and the air inlet pipes had It was found that the air by replacement of the air
an internal coating of distributor, which provides the distribution system along with
a black oily/sooty substance timing for opening the air start machining and lapping of the air
(consistent with the physical valves, was worn excessively start valve seat. The air start
characteristics often found by the ingress of hard foreign manifold, piping and associated
after an explosion). Oil sludge objects. The wear allowed air to machinery were also thoroughly
deposits were removed from enter unintended air start pilot cleaned. Recommendations were
the air start manifold and lines, opening both correct and also made to overhaul the main
sent for analysis, proving incorrect air start valves. Firing air compressor lubrication system,
that the source of the oil from the main engine cylinder to prevent the air start manifold
contamination was the main had then allowed an ignition becoming contaminated with
air compressor lubricating oil: source into the air start lubricating oil.
LESSON
Good maintenance
and cleanliness
procedures should
always be followed.
Prevention can often
avoid not only an
expensive breakdown
but a dangerous
situation from arising.
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10 T E C H N I C A L M AT T E R S June 2009
CASE STUDY 9
Cylinder head
A diesel electric propelled cruise
ship sustained extensive damage
SUBJECT VESSEL to a cylinder head, valve and
TYPE running gear in one of its
Cruise Ship auxiliary engines. A subsequent
engine inspection revealed
cracks in the cylinder head of
ISSUE an adjacent engine cylinder.
Cylinder head damage Lloyd’s Register Technical
Investigations were asked to
investigate the damage and
establish whether the two
incidences had a common cause.
June 2009 T E C H N I C A L M AT T E R S 11
CASE STUDY 10
Thrust block
A twin screw diesel electric oil
tanker experienced repeated
SUBJECT VESSEL failures of the starboard shaftline
TYPE axial thrust bearing. The two sets
Oil Tanker of propulsion shafting consisted of
an electric motor directly coupled
to a thrust shaft, intermediate
ISSUE shaft, propeller shaft, and fixed
Repeated failure of pitch propeller. Each thrust shaft
thrust block bearings was supported by oil lubricated
white metal bearings each side
of the thrust collar with the
ahead and astern thrusts taken
by eleven tilting pads each side
of the collar. Overheating and
wiping of the white metal of
the tilting pads occurred on three
separate occasions early in the
life of the vessel.
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June 2009
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