Detection of the elastic bending of the crankshaft

under the crank webs discrepancy

This operation is based on revealing of distance changes between the

crankshaft webs, i.e. on the caps measurements. The cap is distance

difference between the crankshaft webs at two diametrically opposite bend

positions. The cap presence indicates the shaft axis deflection. One can judge

about the direction of shaft deformation in the area of this crank under the

crank webs discrepancy.

It the distance between the crank web in the top dead centre - Itdc more than Ibdc

the shaft axis is sagged by camber down. In this case the cap is positive and it is

pointed out with (+).If the distance between the crank web in the bottom dead

centre – Ihdc more than Itdc the shaft axis is sagged by chamber up. In this case the
cap is negative and it is pointed out with (-). If the cap is positive, in the case the

crank bearings should be raised, and if it is negative – they should be lowered.

Pic.1. Scheme of caps measurements between the crankshaft web

cranks a-caps(+) ; b- caps(-)

 Pic.2. Caps measurements indicator

One should measure the caps with micrometer rod gage or with indicator

Under four crank position ( 00,900,1800,2700 ), in the event of connecting rod

gear is being dismantled. In the event of connecting rod gear is not being dismantled

one should measure with angle 150 from the top dead centre and then 90,195 and
2700.

If cap measurements are carried out with indicator it stayed in its position

while crankshaft rotating. It is prohibited to touch indicator and rotate it during

measuring. One can read the instrumentation indications with a mirror if the dial

is turned down.

The instrumentation indications should be tabulated.

№ crank Cap measurements, mm

T.D.C. B.D.C. Difference Starboard Port side Difference

The operating cap meanings, its limiting value are carried out in the manufacturer’s

Instruction. If there is no such information one should use the following information.

The webs discrepancy must not exceed 0,0001S for all cranks, where S-piston
stroke, mm. There limiting cap value for the operating engine – 0,00015S. One should

Carry out shaft replacing with such cap measurements. It is prohibited to operate
engine if the cap is more than 0,00025S.

If the crankshaft caps are suddenly changed at the removed motion it denotes on
the crankshaft necks gapping to the lower bushes of the crankshaft bearings.
 It is much better to place the crankshaft in such a way that to increase the
purposive activity to heavy worn bearings ( for example, from the generator side or
middle engine bearings).

The following conditions influence on the cap size and its alterations:

- Wear of bushes of the crankshaft bearings;

- Ship’s loading;
- Beams anchor tightening;
- Quality of the engine alignment with power take off shaft;
- Outside temperature.

Alignment of internal combustion trunk engine movement

1.The necessary condition of responsible work of a driving mechanism is

coincidence in dead points of the piston and connecting rod with the cylinder axis.

2.To control alignment the piston together with the connecting rod are lowered
into the cylinder without piston rings. The right position of the piston in the cylinder
will depend upon crank bearing contact quality. To get more exact results a crank
bearing should be mounted without seals.

3.Piston position in the cylinder from the bow side and the stern. Measures are
produced with a probe from the top and upper piston faces. Besides, one should
control one-side board blocking, because in the position between top dead center and
low dead center the piston will be always pressed to the cylinder bush only from one
side.

4. Non-coincidence of axis in the bundle piston-connecting rod and cylinder are

eliminated by scraping of the crank bearing – the crankshaft neck is covered with a
thin layer of paint, by collecting a bearing, one may produce one-two revolutions of the
crankshaft and open the bearing and remove babbit in coloured parts.

5. Piston misalignment in the cylinder should not exceed 0,15 mm on 1 m long of

the piston. Mounting gaps between the piston and bush on the average are made up in
the diameter 250-750 mm from 1,6-4,5 mm in the piston head and from 0,2-0,65 mm in
its trunk part.
 Determining top dead center and low dead center

of modern low-speed diesels

1. To install the piston in the position of top dead centre, one should turn the
crankshaft partially up to matching an indicator pointer attached to the engine block
wall with the corresponding mark on the flywheel rim.

2. If the position of dead points is unknown, it is necessary to determine them.

For this the following operations are fulfilled:

- to turn the crankshaft in the direction of the forward motion in such a way that
the crank would not approach the top dead center approximately 30-40o and in this
position and to mark on the flywheel against sight pointer;

- the piston position at this moment is fixed from the crankcase side by means of
a rule, measuring the distance from the lower edge of the cylinder bush to the lower
edge of the piston (at crosshead diesels the side position is fixed);

- then the crankshaft is turned in the direction of the crank position 40-500 after
top dead center;

- further the crankshaft is made to rotate in the direction of the backward motion
up to the moment when the distance measured from the low bush edge to the lower
piston edge would not become equal to the fixed positions of the crank of 30-400 to
the top dead centre.

Compression Chamber height control

1. Compression chamber height ( from the top piston edge, located in the top
dead center up to cylinder cover ) is determined by means of lead stamps removing.

2. Lead stamps are removed as at the delectation process (without dismantling

the cylinder cover) and during installation the cylinder cover after engine repair.

3. Operations of compression chamber height control at crosshead engines are

the following:

- two lead small cubes of 52-55 mm high and having cross-section of 25x25 mm
are installed on the external edges of the piston head bottom ( the cube installation is
produced through scavenging ports of the cylinder bush or on orifice for discharge
valve);

- the crankshaft is turned in such a way as the piston would cross the top dead
center;

- after removing the lead stamps the thickness of the compressed past of a
stamp is measured by a micrometer and is compared with formular data.
 4.Characteristics and parameters taken into consideration at producing and repair

of the systems and their components.

Choice of tube materials, sealing materials, welding electrodes, solder.

The use of epoxy resins in repair and producting parts of tubes of different systems.

1. For pipelines seamless pipes of steel mark 10.20.water-gas-delivery pipes with

seams, steel 3,10кп,08кп, from low alloy steel 15х,20х,15хф, red cooper, brass Л62,
cooper-nicked НМЖ5-1, aluminium and aluminium alloys, from synthetic materials are
used. The use of this or that material depends upon the pipeline purpose, pumped
medium aggressiveness degree, pressure and not seldom is regulated by the rules of
classification society.

2. The main pipe defects are:

- corrosion in the welding places and along all the length;

- corrosion of flange parts and pipe connections,fittings;

- cracks;

- breaks;

- flaws and small orifices on pipes;

- wear and dents on some parts.

3. During pipe repair it is permissible flanges by surfacing, to bore them, to

correct dents on pipes, to weld flaws, to melt tubes after removing a defected part.

4. Repair of cooper pipes mainly consists of dent correction, connection

substitution, roasting, docking.

5. Attaching new flanges and connections is produced by soldering acetylene

oxygen or electric welding.

One of soft or hard solders (electrodes) is chosen as a welding rod depending

upon the necessity of the corrosion resistance of non-ferrous metal type and
operating pressure.For example, to solder copper and copper alloys providing
pressure up to 25 kg/cm2 solders ПСр25 are used.

6. Repair of oil tubes more often includes flanges replacement, thread correction
on connections, clearing of the sealing surfaces of nippels and flanges.

7. Making new pipes aboard consists of the following operations:

- preparation and making templets;

- blanks, cutting and bending of pipes;

- parts preparation;
 - pipe mantling with welding flanges and other parts;

- hydraulic tests;

- mounting on the spot.

8. Bending tubes aboard a ship is produced mainly by two ways; hot, that is,

In heated state and with the help of hand or hydraulic pipebender (if they are available
aboard a ship).

9. The process of not tube bending is the following:

- before bending a pipe is filled with dry sand;

- pipe tubes which are to be bend are heated with a gas burner. Temperature of
the beginning and ending of pipe bending from carbon steel 1050-650 0C, while tubes
of alloy steel 1050-950 0C;

- in the bending process the external side of a pipe is cooled with water for
uniform extension.

10. Cold bending on the pipebending latches is more economical and efficient
than hot bending.

Before cold bending to rise plasticity general or local annealing is produced by

means of steel pipe beating up to 800-940 0C with keeping 203 min on 1mm thick, as
for red copper and brass pipes the temperature is 550-650 0C with keeping to 1 min on
1 mm thick.

11. Adding flanges and different and different ends to pipes is produced with
electric or gas welding. Before welding parts and pipes are cleaned from mud, rust
and grease to pure metal.

12. Welding of mid, structural and low-alloy steels is conducted with electrodes of
the type Э42, pipes and parts of steels marks 10 and 20 with electrodes of the type Э42
or УОНИ-13/45. Pipe welding and part welding of medium – carbon and alloy steels is
made with electrodes of marks УОНИ-13/15М, УОНИ-13/45МХ, УОНИ-13/11Ж and
others. Adding flanges, connections, nippels, nozzles made of non-ferrous metals is
produced mainly by means of soldering with acetylene oxygen flame.

13. The most common tubes are ones of polyethylene. Their repair consist of
cutting out damaged places and preparing a tube port to install on the place cut.
Welding is carried out with joint by an air spry with temperature 2500C and by welding
a rod of diameter 2-3 mm of polyethylene.

Bending polyethylene pipes or pipes of viniplast does not differ in principle

from bending metallic ones. They are also filled with sand and are bended in a heated
state at the temperature 110-1500C.
 14. Under marine conditions to protect pipe surfaces from corrosion they are
covered with bakelite lacquer, are primed and painted with minimum.

15. To protect tubes from corrosion and repairing them under marine conditions
the epoxy resin is often used as well as materials made on the base of epoxy.

At present the most commonly used materials are the following:

- Rapid P – two component epoxy material, designed for rapid repair of pipelines,
restoring threads, sealing orifices, cracks, eliminating corrosions of steel and cast
iron parts;

- Devcon A and B are used for the same purposes at the repair of steel and
nonferrous pipes and mechanism parts;

- Titanium P – to restore surfaces, damaged with corrosion or erosion ( screw

propeller, hulls and pump rotors). It is recommended to use in those cases when it is
impossible thermal action on the restored surface ( cylinders, bearing beds, directions
and so on);

- Super Keramik – is delivered in liquid and pasty state. It is used to restore parts
working under aggressive media conditions;

- Devcon Z – is a zincic anti-corrosion composition, by its protecting properties can

be compared with coatings received by method of not zincing. It is delivered in aerosol
packs or jars having 1(one) litres volume.

Safe precautions in repairing shops.

1. Safety precautions instructions should be put at every of lathe. The main

rules of safety precautions at the work at turning and drilling lathes are the following:

- All the lathes should be equipped with low-voltage local illumination,

providing good intensity of the operating zone.

- Facilities to start and to stop lattes should be located in a suitable manner

and in such a way that it would be impossible to switch them on by chance. Buttom
“Stop” should be of red colour.

- Turning and milling lathes should possess safety screens, preventing chip
scattering.

- Deck planking near a bathe should have non-sliding surface or be covered

with wooden grate.

- At work by centring drill to remove chips from the drilling orifice is allowed
only after stopping a lathe and removing a drill from a part which is processed.
 - At work at drilling lathes to fix processed parts should be used by special
clamping facilities or a machine vice.

- To work at metal cutting lathes in gloves, mittens and with bandaged hands,
with hair not collected under head-dress is prohibited.

- Sleeves of protective outer garments must have cuffs thickly fitted and
buttoned.

- Abrasive tools and rotating salient ends of spindle and timber parts should
be protected with protective cases.

- All grinding lathes with horizontal rotation of an instrument and hand

delivering a thing should be equipped with protective screens with inspection
windows connected to the starting devices. If screens are stationary, blocking is
unnecessary.

- At processing with abrasive disks of articles kept in lands arm rests should
be used. Arm rests should be mobile, providing possibility to install then in a
demanded position as the disk would work out.

- At the lathes where protective screen is absent, protective spectacles

should be used.

- Arm rests after each rearrangement should be strongly fixed.

Rearrangement of arm rests during work are not allowed.

- Arm rests should be installed so that the upper point of an article contact
with an abrasive disk are located at the horizontal surface passing through the circle
centre or above it, but not more than 10 mm.

- A gap between the edge of an arm rest and working surface of an abrasive
disk should be less the half of the thickness of the abrasive article and not more than
3 mm.

- Spindle pulsation of boring lathe should not exceed 0,03 mm. While
installing on the boring lathe disks should be centered.

- At work with two disks on one spindle diameters should not differ between
each other more than 10%.

- Work with disk side surfaces is not allowed, if a disk is not designed
specially for this kind of work.

- It is prohibited to work at the boring lathe if an abrasive disk has craves,

pulsation, excentricity of fitting.

- It is prohibited to adjust disks with tools which are not designed for this
purpose.
 - It is prohibited to work at metal cutting lathes in rolling with listing more
than 10%.

The main requirements of safety precautions

to the electric gas welding equipment and overalls of a welder

1. A welder should be provided with overalls and individual protection means.

2. To protect against cold metal in confined spaces welders should be provided

of cotton wool and canvas. While welding inside a boiler, tank and so on a welder
should have a helmet of dielectric materials.

3. Transformers, rectifiers and generators of direct alternating current, specially

designed for this may be used as sources of current. Direct current supply of welding
arc from the power or lighting net is prohibited.

4. Welding plants should be protected with safety devices from the supply net.

5. Voltage of idling in welding direct current generators should not exceed 80V.
For generators with rated current more than 350A is allowed to increase idling voltage
to 90V. Idling voltages of transformers at 350A and more should not exceed 70V and
transformers on 100A-75V.

6. The length of cables between the supply net and a mobile welding plant
should not exceed 10m.

7. Mobile welding plants during their movement should be switched of from

the net.

8. Adjoining a cable to the electric holder and reverse cable to the welding
article should be reliable and is carried out with mechanical clamps. At welding
currents exceeding 600A, current supplying cable should be connected to the electric
holder not using its knob.

9. Connection of welding cable should be produced by means of not soldering,

welding or with the help of coupling sleeves with isolating casing.

10. An electric holder should tightly keep an electrode. A knob of a electric

holder should be made of dielectric heat isolating material.

11. At operations in extremely dangerous premises the welding plant should

have electric blocking, providing automatic switching оп the welding circuit at the
contact of an electrode with а welded article and automatic switching off the welding
circuit at idling or decrease of welding circuit voltage to 12 V.
 12. Cases of welding plant, welding tables, plates and so on as well as the

reverse wires should be grounded. Earthing of mobile welding plants are carried

out before connecting them to the supply net and should not be violated before

their switching on to the net.

Gas-welding equipment

1. Burners, cutters, hoses, reductors, valves and other equipment should be in

the operating state. Valves should reliably overlap gas, and packing not to pass gas.
Equipment exploitation with leakiness is prohibited.

2. Hoses should be used in correspondence with their purpose. Use of oxygen

hoses for delivering acetylene or vice versa is not allowed.

3. The length of hoses, as a rule, should not exceed 20 m, sometimes 40 m.

4. The use of defective hoses is prohibited.

5. Cutters and burners are controlled for gas-tightness not rarer than once a
month and in cases of troubles. Not rarer than once a month inspection and test of
oxygen and acetylene reductors should be produced.

5. The use of manual.

Tools and instruments for dismantling, technical maintenance,

repair and assembling а marine power plant and equipment.

Manual Tools

The use of instruments and tools

То determine geometrical sizes of' а part different types and classes of

instruments. and tools are used. The main of them are: rulers, calipers, internal

gauges, slide gauges, micrometers, indicators, probes, templets and others.

1.Calipers are the simplest tools to measure external diameters of cylindrical surfaces.

2. Outside inside calipers are the simplest tools to measure internal sizes.
3. Slide gauges are the instruments. Slide gauges with the length of а ruler

100, 150, 200, 225, 500 mm with the measurement accuracy from 0, 1 to 0, 02 mm.

4. А micrometer serves for external measures . There are three classes of

accuracy in micrometers: zero, first and second.

- Measurement accuracy of micrometers is equal to 0,01 mm. Micrometers

11·ith measurement limits: 50-75, 75-100, 100-150, 150-200, 200-300,300-400

and to 1000 mm are being produced.

- Before measurement а micrometer check with the help of an etalon is

produced. In the case of non-coincidence of а zero dash with а horizontal line а

micrometer should be replaced in а certain order.

- А micrometer with measurement limits 0-25 mm is checked and regulated

without an etalon by means of measuring surfaces shifting.

- Measurement of thicknesses, lengths of parts is made iл such а sequence: а

measured part is pressed between measured surfaces, microscrew rotation (behind

а ratchet) to the position, in which а rated begins rotating ildling; а microscrew

is fixed 1vith an arresting device and а size sought for is counted by а scale.

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-While counting an integer is а number of fully watched divisions in the

lower part of a scale under а line. If between the last determined division and а

drum edge а dash is located оп the top part оf а scale of а stem (over а line) 0,5

mm is added to the received number. Hundredth fractions are determined by a

drum, the number of hundredth fractions is equal to the figure of а drum division,

coinciding with а horizontal line on the stem.

5. Tubular type inside micrometer is used to measure inner sizes. lt has а

micrometric head with measurement limits of а scale from 50 to 63 mm, and

changeable attenuators with the help of which tubular type inside micrometer

may be made up to the limited size 1500 mm.

- Adjustment of tubular type inside micrometer before measurement is produced

in the following sequence. Tubular type inside micrometer is installed for the

size of 50 mm, and is fixed with an arrested screw. А real size of the heaad is

controlled with а micrometer. Zero division of а drum should coincide with

longitudinal scales, while а drum edge coincides with the first dash of the

longitudinal scale.

- Measurement bу means of tubular type inside micrometer is produced in

such а way. А tubular type inside micrometer is installed оп the size sought for

and is introduced in-to the measuring orifice. One end of а tubular type inside

micrometer is supported by the measured surface, the oilier end of it is produced

by swinging in horizontal and vertical surfaces. Swinging is matched with

simultaneously screwing up of a micrometric screw up to the moment when the

farthest point (from the stationary end of а tubular type inside micrometer) in

the horizontal plane and the closest to the vertical one is determined. The size

sought for is fixed with an arrested screw; tubular type inside micrometer is

removed from the orifice and the scale readings are produced.

6. An indicator of the clock type is used to measure the relative deflection of

the parts sizes and to determine deflection from geometrical form of parts

(ovality, dгaught

and so on), or deflection of mutual arrangement of part surfaces

(parallelism, perpendicularity, coaxiliaty апd so on). An indicator of the clock

type-is produced in three classes with measurement limits 0-3, 0-5, 0-10 mm.

- One revolution of а large pointer of an indicator corresponds to the

displacement of а measuring rod for 1 mm. The number of full millimeters is

marked with а small pointer.

- Indicators of the clock type are used in combination with special devices.
 7. An indicator with an internal gauge (an indicating internal gauge) is used to

control

deflection of parts from geometrical form at inner measurements. The

measurement is made in the following way;

а) the rated size of the orifice measured is determined (by an internal gauge or

а slide gauge) and the corresponding insert is selected;

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b) an internal gauge is installed by а micrometer at the minimal size in such а

way that а small pointer of an indicator is between the second and third divisions

of a scale;

с) а stationary insert is fixed, an indicator pointer is installed on zero by the

turn of the dial;

d) an indicator internal gauge is inserted into а measured orifice and

measurement is produced Ьу several bands in diametrically opposed points.

Minimal readings are selected by means of rolling а device in the vertical plane.

8. Probes are used to measure gaps in the combinations of parts. They are

technical plates from 0,03 to 1 ,О mm. Probes are made up in а set with the plate

length 30, 1 00, 200 mm.

Set №1 has thicknesses of plates 0,03-0,1 mm.

Set №2 has thicknesses of plates 0, 03-0, 09 mm.

Set №3 has thicknesses of plates 0, 03-0, 5 mm.

Set №5, 6, 7 has thicknesses of plates 0, 05-1 mm.

When checking а gap one may consider it equal to the platc size (а sum of

plates connected together), if this plate passes between surfaces, forming а gap,

by all the length with easy friction without cutting, pressing jerks, sticking.
 9. Thread templates are used to estimate thread wear of parts and to determine

type and size of the thread.

Thread templates (thread gauge) are а set of flat separate plates with cut profiles,

thread of different pitch. Plates are gathered in а general cassette and are

connected to each other hinged. Cassettes have two sets of plates: one for metric

thread, consisting of 20 plates, the other - for inch thread, consisting of 16

plates. When using templates а profile of thread checked coincides (by а

generatrix ) with one of the set plates. If the state of thread is good, clearance

among thread turns and template teeth should not exist or it should bе the same

everywhere.

Choice and use of means in delectation

1. In delectation parts are considered to be suitable if \\'ears of them by

instrument readings are in limits of permissible standards by technical conditions.

in this connection it is not in different what instrument а part is measured by.

2. Measuring instruments are used depending upon the sizes of parts and limits.

3. Surfaces of parts being defected while measuring should be clean.

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