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

Software

Instrument use

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DOWNTIME
CORRECTIVE MAINTENANCE

TIME BASED MAINTENANCE

PREDICTIVE MAINTENANCE

PROACTIVE MAINTENANCE

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Work

Time

Many breakdowns - little planning

2
3

Introduction Predictive Maintenance

Few breakdowns - planning
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Causes of machine failure

50% Bearing problems 20% Misalignment 20% Unbalance 10% Other reasons
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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
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Lubrication Machine Alignment

Bearing Installation Bearing Damage

Operating Condition
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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

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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
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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

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

2. Un Normalized results

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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.)
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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

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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.

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
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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 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.

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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

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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. 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
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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.
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
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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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3A

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3B

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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
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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
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ISO 2372
Class
Limits

Class

Class

Class

Class

Class

1 Step

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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

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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

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LR/HR
TYPE 3

Mean diameter dm TYPE RPM COMP

LR HR

TYPE 1

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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

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Shock Pulse Method

Good bearing
Dry running Damaged bearing
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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

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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

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

dBn

Altered shock level

SPM

Earphone display
SPM Probe

dBm 43 dBc 26

(38) 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 /s 2.76 mm

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 19 and more 15 - 18 below 15 good acceptable unacceptable Basic data, Tester
Bearing data TLT On 3000 rpm 90 dmm dBi

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Normalized measuring scale dBsv - dBi = dBn dBs v

dBn

dBm/dBc display
SPM TLT dBm dBc 20 16 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 Machine Alignment

Bearing Installation
Bearing Damage

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Shock Pulse Method

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Bearing life

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