SPM Training

Condition monitoring of ball and roller bearings using
the patented SPM method (Shock Pulse Method)
Vibration monitoring Machinery alignment Maintenance instruments

. Your Partner in Condition Monitoring . 2
A complete approach to condition monitoring
Engineering support Customer service Training
Planning Installation
Software
Instrument use
. Your Partner in Condition Monitoring .
DOWNTIME
CORRECTIVE MAINTENANCE
TIME BASED MAINTENANCE
PREDICTIVE MAINTENANCE
PROACTIVE MAINTENANCE
Work
Time
Many breakdowns - little planning
2
3
Introduction Predictive Maintenance

Few breakdowns - planning
Causes of machine failure

50% Bearing problems 20% Misalignment 20% Unbalance 10% Other reasons
5000 h
50 000 h
Causes of bearing failure

40% Lubrication
30% Vibration
20% Installation faults 10% Fatigue failure
10
11
12
Lubrication Machine Alignment
Bearing Installation Bearing Damage
Operating Condition
STATIC AND DYNAMIC LOAD
PRELOAD
ALIGNMENT
GEOMETRIC QUALITY OF BEARING HOUSE & SHAFT
BEARING GEOMETRIC QUALITY
LUBRICANT SUPPLY
LUBRICANT
TEMPERATURE
TOTAL LOAD
ROLLING VELOCITY
LUBRICANT FILM
14
Bearing condition Machine vibration Rotational speed
15
16
Shock Pulse Method
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Vibration
10 - 1000 Hz
20
21
22
23
24
26
27
28
29
30
31
32
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Instrument operation, Input data and Output results
Instrument operation
Input data required for Analyser:
1. Norm No. (10 - 58) : Calculated by instrument after giving bearing number and RPM
2. Type No. (1 - 8)
: Depends upon bearing geometry. : To calibrate the measuring point location
3. Comp. No. (-30 - +30)
4. Accumulation No. (1 9) : To define the instrument measuring cycle time
35
Instrument operation
Input data required for Tester:
1. Shaft diameter (Bearing inner diameter, Maximum 1999mm) 2. Rotational speed of bearing (RPM, 10 19999 RPM) 3. dBi Decibel initial value is calculated by the instrument after giving shaft diameter and RPM input. (-9 to 40)
36
Output results from the instrument

1. Normalized results - Needs certain input data to evaluate the bearing condition. - No need of any data input. Instrument displays the absolute shock pulse magnitude in decibel scale
2. Un Normalized results
37
Output results
Normalized results - Analyser:
1. Code
2. Lub No.
: A/B/C/D or E2/E3/E5
: 0 40 Indicates lubricant film thickness
3. Cond No. : 20 65 Indicates severity of bearing damage 4. LR : Lower occurrence rate, Decibel shock value of the shock pulses whose occurrence rate is 45 pulses per second. (-19 to 99 dBsv.) : Higher occurrence rate, Decibel shock value of the shock pulses whose occurrence rate is 1000 pulses per second. (-19 to 99 dBsv.)
5. HR
Output results
Normalized results - Tester:
1. dBm : Decibel maximum value, Decibel shock value of the shock pulses whose occurrence rate is 5 pulses per second. (-9 to 60 dBN) = dBsv dBi : Decibel carpet value, Decibel shock value of the shock pulses whose occurrence rate is 300 pulses per second. (-9 to 60 dBN)
dBm
2. dBc
39
40
Output results
-Un Normalized result
1. Analyser: Only LR and HR values are displayed when 0
NORM NO. input is given to the instrument. These values can be trended to evaluate the bearing condition.
2. Tester
: Only decibel shock values are displayed when -- dBi input is given to the instrument. These values can be trended to evaluate the bearing condition.
41
Evaluation Of Shock Pulse Readings
Three steps in evaluation of readings

Trending
Comparing Normalising
43
Three steps in evaluation of readings

Trending
1. Collect SPM & VIB readings over a period of time. 2. Plot the graphs and see the variation.
Comparing
1. Compare readings of similar machines. 2. Compare SPM readings with VIB readings and analyze.
Normalizing
1. Establish own limits after hands on experience on the same machine
Pressure variation translated into shock pulse pattern
The filtered transducer signal reflects the pressure variation in the contact area.
When the oil film in the bearing is thick, the shock pulse level is low, without distinctive peaks. The level increases when the oilfilm is reduced, but there are still no distinctive peaks. Damage causes strong pulses at irregular intervals. One can liken the three shock pulse patterns to the vibrations felt in a car while driving on a) a smooth road surface, b) a rough road surface, c) a road full of potholes.
45
Shock pulse pattern of a good bearing

Good Bearing :
Code : A (Green Zone) Lub No : 1 40
1. 2. 3. 4. Low LR and HR values LR HR = dB dB value is ideal 4 8 dB Trend shows no variation or minor change in LR/HR
46
Shock pulse pattern of a Poor lubricated bearing

Poor Lubricated Bearing :
Code : B (Yellow Zone) Lub No : 0 or 1 Cond : 20 to 30 1. 2. 3. 4. 5. High HR values, close to LR LR HR = dB dB value is < 4 dB Trend shows gradual increase in HR reading. Increase in bearing temperature
47
Shock pulse pattern of a damaged bearing

Damaged Bearing :
Code : C or D (Yellow or Red) Cond No. : 30 to 65
1.
2. 3. 4. 5.
High LR values, Distinctive peak in shock pulse pattern. LR HR = dB dB value is > 10dB Trend shows gradual increase in LR reading. Increase in bearing temperature
48
49
ERROR CODES - E2 / E3 /
Error Codes
1. E2 External disturbance like cavitation, scraping of loose parts, gear noise, steam screaming, rubbing etc.
2. E3 Signal low.
3. E5 Norm No. too low. Norm No. should be more than 18 to obtain evaluated results with probe.
51
53
54
56
57
3A
58
3B
59
60
61
62
63
64
65
66
Scraping coupling
Bearing Replacement
67
VIBRAMETER ISO 2372 KLASSE 3 4.8 mm/s
69
Small force
Weak foundation
Large force
Stiff foundation
Structural looseness
70
Frequency Hz
Displacement mm
Acceleration m / s2
Velocity mm / s
Limits
Class II
Class III
Class IV
Class V
II III IV
Medium size machines without special foundations Large machines on rigid foundations Large machines on soft foundations
73
74
75
ISO 2372
Class
Limits
Class
Class
Class
Class
Class
1 Step
76
Vibration severity
Breakdown
+ 4 steps
Vibration measurement
Report dangerous increase
(Shutdown) Effect repaires

Plan major overhaul
+ 3 steps
+ 2 steps
Report large increase
Inspection, minor repairs

+ 1 step
Report change Routine maintenance (lubrication, etc.)
Normal
Maintenance activities
77
78
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Speed measurement
RPM, optical: Distance max. 0.6 m Speed reading
RPM 3650 rpm
Reflecting tape
RPM, contact center: Hold against shaft center
Peripheral, contact wheel: Multiply reading by wheel factor TAD-12 0.1 m/min. TAD-13 0.1 yd./min. TAD-17 0.5 ft./min. . Your Partner in Condition Monitoring . 80
PC
COMMUNICATION TIME VERSION SETUP
T-500.01 GUIDE ROLL 01 TS 1st drying SPM 001
BEARING TEST dBm 15 dBc 4
dBi 9
VIBRAMETER ISO 2372 CLASS 2 2.5 mm/s
81
LR/HR
TYPE 3
Mean diameter dm TYPE RPM COMP
LR HR
TYPE 1
82
SPM measurement - Analyzer

Basic data 1, Analyzer Evaluation frame, depending on TYPE
Bearing data NORM 18 ACC TYPE 1 TLT COMP 4
3 on
Basic data 2, Analyzer

Bearing data NORM -ISO xx100 TYPE 3 rpm COMP 4 Dm 87 mm
COMP = Compensation Condition: red - bad, CODE D yellow - caution, CODE B, C green - good, CODE A
LR/HR reading
SPM
CODE LUB COND B 4 -ACC LR HR 3 27 23
83
Shock Pulse Method
Good bearing
Dry running Damaged bearing
Vibration severity
Machine class 1 to 6 according to ISO (VDI, BS) Vibration severity
VIB ISO 10816 Class 2 /s 2.76 mm
Change class
Limits Class
Class
Class
Class
Condition: red yellow green
85
PC
COMMUNICATION TIME VERSION SETUP
T-500.01 GUIDE ROLL 01 TS 1st drying SPM 001
BEARING TEST dBm 15 dBc 4
dBi 9
VIBRAMETER ISO 2372 CLASS 2 2.5 mm/s
86
TACHOMETER
87
88
PEG 38
LEV
89
BEARING TEST EARPHONE VOLUME 5
90
Peak indicator
Earphone
dBn
Altered shock level

SPM
Earphone display
SPM Probe
dBm 43 dBc 26
(38) dBi 26
Earphone Level 69 dBsv
91
Vibration severity
Machine class 1 to 6 according to ISO (VDI, BS) Vibration severity
VIB ISO 10816 Class 2 /s 2.76 mm
Change class
Limits Class
Class
Class
Class
Condition: red yellow green
92
SPM VIB RPM
Route Input data Readings
93
SPM measurement - Tester

TLT = Transducer line test 19 and more 15 - 18 below 15 good acceptable unacceptable Basic data, Tester
Bearing data TLT On 3000 rpm 90 dmm dBi
26
Normalized measuring scale dBsv - dBi = dBn dBs v

dBn
dBm/dBc display
SPM TLT dBm dBc 20 16 9
dBi
26
dBm dBc dBi
94
Tester & Analyzer

dBm / dBc TESTER LR / HR ANALYZER
same signal at different levels
95
Lubrication Machine Alignment
Bearing Installation
Bearing Damage
96
97
98
99
100
101
103
104
Shock Pulse Method
105
Bearing life
106

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Condition monitoring of ball and roller bearings using

the patented SPM method (Shock Pulse Method)

Vibration monitoring Machinery alignment Maintenance instruments

A complete approach to condition monitoring

Engineering support Customer service Training

. Your Partner in Condition Monitoring .

TIME BASED MAINTENANCE

. Your Partner in Condition Monitoring .

Many breakdowns - little planning

Introduction Predictive Maintenance

Causes of machine failure

. Your Partner in Condition Monitoring .

Causes of bearing failure

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

Lubrication Machine Alignment

Bearing Installation Bearing Damage

STATIC AND DYNAMIC LOAD

GEOMETRIC QUALITY OF BEARING HOUSE & SHAFT

BEARING GEOMETRIC QUALITY

. Your Partner in Condition Monitoring .

Bearing condition Machine vibration Rotational speed

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

Shock Pulse Method

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

Instrument operation, Input data and Output results

: Depends upon bearing geometry. : To calibrate the measuring point location

3. Comp. No. (-30 - +30)

4. Accumulation No. (1 9) : To define the instrument measuring cycle time

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

Output results from the instrument

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

. Your Partner in Condition Monitoring .

Evaluation Of Shock Pulse Readings

Three steps in evaluation of readings

. Your Partner in Condition Monitoring .

Three steps in evaluation of readings

Pressure variation translated into shock pulse pattern

. Your Partner in Condition Monitoring .

Shock pulse pattern of a good bearing

. Your Partner in Condition Monitoring .

Shock pulse pattern of a Poor lubricated bearing

. Your Partner in Condition Monitoring .

Shock pulse pattern of a damaged bearing