Spm Training

• Condition monitoring of ball and roller bearings using the patented SPM method (Shock Pulse Method)

• Vibration monitoring • Machinery alignment • Maintenance instruments

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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

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A complete approach to condition monitoring

• Engineering support • Customer service • Training

• Planning • Installation

• Instrument use • Software

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DOWNTIME CORRECTIVE MAINTENANCE

TIME BASED MAINTENANCE

PREDICTIVE MAINTENANCE

PROACTIVE MAINTENANCE

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Work

Time

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Many breakdowns - little planning

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Introduction Predictive Maintenance

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Few breakdowns - planning ………. Your Partner in Condition Monitoring ……….

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Causes of machine failure • 50% Bearing problems • 20% Misalignment • 20% Unbalance • 10% Other reasons ………. Your Partner in Condition Monitoring ……….

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5000 h

50 000 h

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Causes of bearing failure • 40% Lubrication • 30% Vibration • 20% Installation faults • 10% Fatigue failure ………. Your Partner in Condition Monitoring ……….

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Lubrication

Bearing Installation

Machine  Alignment

Bearing Damage

Operating Condition ………. Your Partner in Condition Monitoring ……….

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STATIC AND DYNAMIC LOAD

LUBRICANT SUPPLY

PRELOAD

 ALIGNMENT

LUBRICANT

TEMPERATURE

GEOMETRIC QUALITY OF BEARING HOUSE & SHAFT

BEARING GEOMETRIC QUALITY

TOTAL LOAD

ROLLING VELOCITY

LUBRICANT FILM

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Bearing condition Machine vibration Rotational speed

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Shock Pulse Method

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Vibration

10 - 1000 Hz ………. Your Partner in Condition Monitoring ……….

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Instrument operation, Input data and Output results

Instrument operation • Input data required for Analyser: 1. Norm No. (10 - 58)

2. Type No. (1 - 8)

: Calculated by instrument after giving  bearing number and RPM

: Depends upon bearing geometry.

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

: To calibrate the measuring point location

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

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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)

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Output results from the instrument 1. Normalized results

- Needs certain input data to evaluate the bearing condition.

2. Un Normalized results

- No need of any data input. Instrument displays the absolute shock pulse magnitude in decibel scale

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Output results •  Normalized results - Analyser: 1. Code

: A/B/C/D or E2/E3/E5

2. Lub No.

: 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.)

5. HR

: Higher occurrence rate, Decibel shock value of the shock pulses whose occurrence rate is 1000 pulses per  second. (-19 to 99 dBsv.) ………. Your Partner in Condition Monitoring ……….

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Output results •  Normalized results - Tester: 1. dBm

dBm 2. dBc

: 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)

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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.

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Evaluation Of  Shock Pulse Readings

Three steps in evaluation of readings • Trending

• Comparing • Normalising

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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.

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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 ………. Your Partner in Condition Monitoring ……….

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Pressure variation translated into shock pulse pattern

The filtered transducer signal reflects the pressure  variation in the contact area.

 When the oil film i n the b earing is t hick, 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. potholes.

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Shock pulse pattern of a good bearing Good Bearing : Code : A (Green Zone) Lub No : 1 – 40 1.

Low LR and HR values

2.

LR – HR   = dB

3.

dB

4.

Trend shows no variation or 

value is ideal 4 – 8 dB

minor change in LR/HR 

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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.

High HR values, close to LR 

2.

LR – HR   = dB

3.

dB

4.

Trend shows gradual increase

5.

in HR reading. Increase in bearing temperature

value is < 4 dB

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Shock pulse pattern of a damaged bearing Damaged Bearing : Code : C or D (Yellow or Red) Cond No. : 30 to 65 1.

High LR values, Distinctive pea in shock pulse pattern.

2.

LR  – HR = dB

3.

dB

4.

Trend shows gradual increase

value is > 10dB

in LR reading. 5.

Increase in bearing temperature

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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.

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1

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2

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3A

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3B

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4

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5

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6

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Scraping  coupling 

Bearing  Replacement 

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VIBRAMETER ISO 2372 KLASSE 3 4.8 mm/s

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Small force

Weak foundation

Large force

Stiff  foundation

Structural looseness

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Frequency Hz

Displacement mm

 Acceleration m / s2

Velocity mm / s ………. Your Partner in Condition Monitoring ……….

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Limits

Class II

Class III

Class IV

Class V

II

Medium size machines without special foundations

III

Large machines on rigid foundations

IV

Large machines on soft foundations ………. Your Partner in Condition Monitoring ……….

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ISO 2372 Class

Class

Class

Class

Class

Class

Limits

1 Step

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Breakdown

Vibration severity

+ 4 steps

+ 3 steps

Vibration measurement

(Shutdown) Effect repaires

Report dangerous increase Plan major  overhaul

+ 2 steps

Report large increase

Inspection, minor repairs + 1 step

Normal

Report change Routine maintenance (lubrication, etc.)

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Maintenance activities

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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 ……….

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PC

COMMUNICATION TIME VERSION SETUP

T-500.01 GUIDE ROLL 01 TS 1st drying SPM 001

BEARING TEST dBm 15 dBc 4

dBi 9

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VIBRAMETER ISO 2372 CLASS 2 2.5 mm/s

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LR/HR TYPE 3

Mean diameter dm TYPE RPM COMP

TYPE 1 HR

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SPM measurement - Analyzer  Basic data 1, Analyzer  Bearing data

Evaluation frame, depending on TYPE

NORM 18

ACC

3

TYPE

1

TLT

on

COMP

4

Basic data 2, Analyzer  Bearing data

COMP = Compensation Condition: red - bad, CODE D yellow - caution, CODE B, C green - good, CODE A

NORM

--

ISO xx100

TYPE

3

rpm

COMP

4

Dm 87 mm

LR/HR reading SPM CODE

B

ACC

3

LUB

4

LR

27

COND

--

HR

23

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Shock Pulse Method

Good bearing Dry running Damaged bearing ………. Your Partner in Condition Monitoring ……….

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Vibration severity Machine class 1 to 6 according to ISO (VDI, BS)

Vibration severity VIB ISO 10816 Class 2

2.76 mm /s

Change class

Limits Class

Class

Class

Class

Condition: red yellow green

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PC

COMMUNICATION TIME VERSION SETUP

T-500.01 GUIDE ROLL 01 TS 1st drying SPM 001

BEARING TEST dBm 15 dBc 4

dBi 9

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VIBRAMETER ISO 2372 CLASS 2 2.5 mm/s

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TACHOMETER

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PEG 38

LEV

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BEARING TEST EARPHONE VOLUME 5

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Peak indicator 

Earphone

dB n

Altered shock level

Earphone display

SPM

SPM Probe

dBm 43

(38)

dBc 26

dBi 26

Earphone Level 69 dBsv

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Vibration severity Machine class 1 to 6 according to ISO (VDI, BS)

Vibration severity VIB ISO 10816 Class 2

2.76 mm /s

Change class

Limits Class

Class

Class

Class

Condition: red yellow green

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SPM VIB RPM

Route Input data Readings

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SPM measurement - Tester  TLT = Transducer line test

Basic data, Tester 

19 and more

good

15 - 18

acceptable

TLT On

below 15

unacceptable

3000 rpm

Bearing data

90 dmm

Normalized measuring scale dBsv - dBi = dBn

dBi

26

dBm/dBc display

dBs v

SPM

dBn

TLT

20

dBm

16

dBc

9

dBi

26

dBm

dBc

dBi

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Tester & Analyzer  dBm / dBc TESTER

LR / HR ANALYZER

same signal at different levels

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Lubrication

Bearing Installation

Machine Alignment

Bearing Damage

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Shock Pulse Method

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