Introduction

• Glascoat reactors are manufactured for reliability, performance and longevity,

generally as per DIN standard 28136 and in accordance with ASME Section VIII Div.1
code of unfired pressure vessels.
• There are two types of reactors manufactured in the company:
– CE type reactors, are those reactors having monoblock vessel with large central
opening for impeller agitator.
– AE type reactors, are those reactors in which vessel is flanged with top cover and
pan for anchor agitator.
 Introduction
• In these reactors, there is problem on run-out of shaft. According to company, shaft
deflection should not be exceed 80 micron or 0.08mm
• If shaft is running out, it may causes
– Seal damage
– Damage in agitator either shaft failure or failure of shaft lining.
– Failure of vessel.
– Production will stops.
– Expose workers to chemical hazards.
 Objective
• Perform FEA of agitator assembly of glass lined reactor.
• Check acceptable run-out for given agitator.
 Methodology
• Method used: Failure Mode & Effect Analysis (FMEA)
• Possible failure modes of agitator analysis.

Possible failure modes of agitator analysis.

• Run out beyond permissible limit
• Improper Bearing selection or bearing housing design
• Rotating over permissible speed limit
• Lack of VFD
 Methodology

Effect analysis
• Catastrophic failure

• Worker being exposed to hazardous chemical

• Production loss
 Methodology
• FEA analysis of agitator assembly at different run out.
 Literature Review
Sr. no. Title of paper Publication details
1 Shaft alignment to R. Keith Mobley,
obtain common axis Maintenance Fundamentals
of rotation. (Second Edition), A
volume in Plant Engineering
2004, Pages 71–111
2 Taking the squint out PaulPoste, Volume 2001, Issue
of shaft alignment 418, July 2001, Pages 20-22, 24
techniques
Remark/Outcome
•Shaft alignment is the proper positioning of the shaft
centre lines of the driver and driven components.
• Alignment is accomplished through either shimming
or moving a machine component or both.
•Its objective is to obtain a common axis of rotation at
operating equilibrium for two coupled shafts or a
train of coupled shafts.
•Three methods, which are eye sight, using dial gauge,
laser based measurement
Sr. Title of paper
no.
3 Laser based
measurement for the
monitoring of shaft
Misalignment
4 Analysis of shafting
alignment for container
vessels based on
improved transition
matrix method
5 Comparative study on
optimum design of
rolling element bearing
6 Propulsion shaft
alignment method and
analysis for surface crafts
Publication details
Anthony Simm, Qing Wanga,
Songling Huang , Wei Zhao,
Measurement 87 (2016) 104–
116
Yong Yang, Wenyong Tang, Jie
Ma, Procedia Engineering 15
(2011) 5373 – 5377
S.Panda, S.N.Panda, P.Nanda,
D.Mishra, Tribology
International
Volume 92, December 2015,
Pages 595-604
K.H.Low, S.H.Lim, Advances in
Engineering Software
Volume 35, Issue 1, January
2004, Pages 45-58
Remark/Outcome
•This paper presents a method for real-time online monitoring of shaft
misalignment.
•This method is widely used in industries because it is non contact type
so that it can be used at some complicated places.
•In these paper transition matrix method is used for analysis of shaft
alignment
• With the transition matrix method improved, the shafting alignment
models are analyzed.
• According to the results analysis, the different gravity centres of
propellers and hull transfigurations in the process of shipbuilding
influenced the different shafting alignment results obviously.
•In this paper, others have built a design procedure for roller bearing,
developed a computer based programme for simulation, and by using GA
having a optimized design for roller bearing
•Furthermore, they have another new method developed which is,
constrained non-linear optimisation method
•This paper presents an approach to determine the changing
displacement of the propulsion shaft due to the vessel’s hull deflection.
•The objective of this paper
Sr. Title of Paper Publication details Remarks/Outcome
No.

7 The detection of wind Oliver Tonks, Qing Wang, CIRP •This paper details the proposal and validation of a potential temperature
turbine shaft Journal of Manufacturing monitoring technique for use in wind turbine condition monitoring.
misalignment using Science and Technology 17 •Through the creation of misalignment, a temperature rise at the coupling mid-
temperature monitoring (2017) 71–79 point was successfully detected using the technique
•This analysis shows that misalignment is a direct cause of temperature change.

8 Housed bearing units Sealing Technology •The Timken Company is introducing a new line of Type E tapered roller bearing
aim to reduce Volume 2010, Issue 4, April housed units.
maintenance costs 2010, Page 3 •These housed units are targeted at rugged applications and feature enhanced-
performance bearings, double lip seals, corrosion resistant housings and locking
collars.

9 Fatigue and fracture Jenni Herrmanna, This Rauerta, •This paper is related to reduce uncertainties associated with the fatigue
mechanical behaviour of Peter Dalhoffa, Manuela Sander behaviour of the highly safety relevant wind turbine rotor shaft and also to review
a wind turbine rotor today’s design practice the fatigue life time is tested on a full scale test rig.
shaft made of cast iron
and forged steel
 Design of bearing housing

Bearing Housing Bearing housing top cover Bottom plate

 Assembly of Bearing Housing

Bearing housing with top and bottom cover Bearing housing with bearing
Assembly of agitator
 Components of agitator assembly

Muff Coupling Muff Coupling Top view Lanternt Mounting

Stand
Final Assembly
Finite Element Analysis of agitator assembly

Fig.: Meshing of Model

Finite Element Analysis of agitator assembly

Fig.: Analysis of Run-out @0.09mm

Finite Element Analysis of agitator assembly

Fig.: Analysis of Run-out @0.08mm

Finite Element Analysis of agitator assembly

Fig.: Analysis of Run-out @0.07mm

 Properties of Material
Bearing material Chrome Steel
Strength of material 2033 MPa
Allowable Strength 677.67 MPa
Factor of Safety 3

Shaft material SA 106 Gr B

Strength of material 138 MPa
Allowable Strength 47.59 MPa
Factor of Safety 2.9
 Finite Element Analysis
Shaft run-out (mm) Generated Stress on Shaft(MPa)
0.09 48.996
0.08 46.345
0.07 46.345

Shaft run-out (mm) Generated Stress on Bearing (MPa)

0.09 21.776
0.08 20.598
0.07 20.598

Shaft run-out (mm) Deflection (mm)

0.09 3.9466
0.08 3.8796
0.07 3.8135
 Conclusion
• There is Chrome Steel used for Bearing having strength 2033MPa, and by considering Factor
of Safety (i.e. 3), so permissible value of stress is 677.67MPa. Form FEA, generated stress is
21.776MPa for 0.09mm shaft run-out and 20.598MPa for 0.08mm & 0.07mm shaft run-out.

• And Material used for shaft is SA106 Gr. B having strength 138MPa, and by considering
Factor of Safety (i.e. 2.9), so permissible value of stress is 47.59MPa. From FEA, generated
stress is 48.996MPa for 0.09mm shaft displacement and 46.345MPa for 0.08mm & 0.07mm
shaft run-out.

• Therefore, conclusion made from above analysis is, this design of agitator assembly is
preferable up to 0.08mm shaft run-out, because stresses on shaft is exceeds permissible
value of stress at 0.09mm displacement of shaft which is 48.996>47.59MPa.
 References
1. Chap .7: SHAFT ALIGNMENT, R. Keith Mobley, Maintenance Fundamentals (Second
Edition), A volume in Plant Engineering 2004, Pages 71–111

2. Taking the squint out of shaft alignment techniques, PaulPoste, Volume 2001, Issue
418, July 2001, Pages 20-22, 24

3. Laser based measurement for the monitoring of shaft misalignment, Anthony Simm, Qing
Wanga, Songling Huang , Wei Zhao, Measurement 87 (2016) 104–116

4. Analysis of shafting alignment for container vessels based on improved transition matrix
method, Yong Yang, Wenyong Tang, Jie Ma, Procedia Engineering 15 (2011) 5373 – 5377
 References
6. Comparative study on optimum design of rolling element bearing, S.Panda, S.N.Panda,
P.Nanda, D.Mishra, Tribology International, Volume 92, December 2015, Pages 595-604

7. Propulsion shaft alignment method and analysis for surface crafts, K.H.Low, S.H.Lim,
Advances in Engineering Software Volume 35, Issue 1, January 2004, Pages 45-58

8. The detection of wind turbine shaft misalignment using temperature monitoring , Oliver
Tonks, Qing Wang, CIRP Journal of Manufacturing Science and Technology 17 (2017) 71–7

9. Housed bearing units aim to reduce maintenance costs, Sealing Technology Volume 2010,
Issue 4, April 2010, Page 3

10. Fatigue and fracture mechanical behaviour of a wind turbine rotor shaft made of cast iron
and forged steel, Jenni Herrmanna, Thes Rauerta, Peter Dalhoffa, Manuela Sander
 References
11. http://researchspace.csir.co.za/dspace/bitstream/10204/2053/1/fernandes_1997 .pdf.txt
[Doa: October 6th 2012]

12. Williams JA. Wear and wear particles-some fundamentals. Tribol Int 2005; 38(10):863-870.

13. Hiraoka N. On grease leakage from rolling bearings. Tribol Int 2012; 50:45-50

14. Bearing failure: causes and cures: BARDEN PRECISION BEARINGS.

15. Farcas F, Gafitanu MD. Some influence parameters on greases lubricated rolling contacts
service life. Wear 1999;225-229(part 2):1004-1010
 References
16. The Most Common Causes of Bearing Failure and the Importance of Bearing Lubrication.
RKB Bearing Industries - Advanced Software Engineering.

17. http://www.skf.com/in/products/bearings-units-housings/ball-bearings/self-aligning-ball-
bearings/self-aligning-ball-bearings/index.html?designation=1222%20K
 Gantt Chart
Tasks Dec Jan Feb Mar Apr
Problem definition

Understand assembly of
reactor

Identifying problem in product

Literature review

FEA of agitator assembly

implementation