spm training

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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

• Planning• Installation

• Engineering support• Customer service• Training

• Instrument use

• Software

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DOWNTIMECORRECTIVE MAINTENANCE

TIME BASED MAINTENANCE

PREDICTIVE MAINTENANCE

PROACTIVE MAINTENANCE

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Work

Time

1 Many breakdowns - little planning

2 Introduction Predictive Maintenance

3 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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Machine Alignment

Lubrication Bearing Installation

Bearing Damage

Operating Condition

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STATIC ANDDYNAMIC

LOAD

PRELOAD ALIGNMENTGEOMETRICQUALITY OF

BEARINGHOUSE & SHAFT

BEARINGGEOMETRIC

QUALITY

LUBRICANTSUPPLY

LUBRICANT TEMPERATURE TOTAL LOAD ROLLINGVELOCITY

LUBRICANT FILM

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Bearing conditionMachine vibrationRotational 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

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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.

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.)

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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)

dBm = dBsv – dBi

2. dBc : 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.

Evaluation Of

Shock Pulse Readings

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Three steps in evaluation of readings

• Trending• Comparing• Normalising

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Three steps in evaluation of readings

• Trending1. Collect SPM & VIB readings over a period of time.2. Plot the graphs and see the variation.

• Comparing1. Compare readings of similar machines.2. Compare SPM readings with VIB readings and analyze.

• Normalizing1. 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 The filtered transducer signal reflects the pressure reflects the pressure variation in the contact variation in the contact area.area.

When the oil film in the bearing is When the oil film in the bearing is thick, the shock pulse level thick, the shock pulse level is low, without distinctive is low, without distinctive peaks.peaks.

The level increases when the The level increases when the oilfilm is reduced, but there oilfilm is reduced, but there are still no distinctive are still no distinctive peaks.peaks.

Damage causes strong pulses at Damage causes strong pulses at irregular intervals.irregular intervals.

One can liken the three shock One can liken the three shock pulse patterns to the pulse patterns to the vibrations felt in a car while vibrations felt in a car while driving on a) a smooth road driving on a) a smooth road surface, b) a rough road surface, b) a rough road surface, c) a road full of surface, c) a road full of potholespotholes..

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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 values2. LR – HR = dB 3. dB value is ideal 4 – 8 dB4. 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 1Cond : 20 to 30

1. High HR values, close to LR2. LR – HR = dB 3. dB value is < 4 dB4. Trend shows gradual increase

in HR reading.5. 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. High LR values, Distinctive peaksin shock pulse pattern.

2. LR – HR = dB 3. dB value is > 10dB4. Trend shows gradual increase

in LR reading.5. Increase in bearing temperature

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ERROR CODES - E2 / E3 / E5

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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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Scrapingcoupling

BearingReplacement

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VIBRAMETERISO 2372

KLASSE 3 4.8 mm/s

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Smallforce

Largeforce

Weakfoundation

Stifffoundation

Structurallooseness

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FrequencyHz

Displacementmm

Accelerationm / s

Velocitymm / s

2

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Class Class Class Class Limits II III IV V

II Medium size machines without special foundations

III Large machines on rigid foundations

IV Large machines on soft foundations

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ISO 2372 Class Class Class Class Class Class Limits

1 Step

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Vibration severity

+ 4 steps

+ 3 steps

+ 2 steps

+ 1 step

Normal

Inspection,minor repairs

Plan majoroverhaul

(Shutdown)Effect repaires

Routine maintenance(lubrication, etc.)

Report dangerous increase

Report large increase

Report change

Vibrationmeasurement

Maintenanceactivities

Breakdown

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Speed measurementRPM, optical:Distance max. 0.6 m

Reflectingtape

RPM, contact center:Hold against shaft center

Peripheral, contact wheel:Multiply reading by wheel factorTAD-12 0.1 m/min.TAD-13 0.1 yd./min.TAD-17 0.5 ft./min.

Speed reading

RPM

3650 rpm

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COMMUNICATIONTIMEVERSIONSETUP

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

BEARING TEST

dBm 15 dBc 4 dBi 9

VIBRAMETERISO 2372

CLASS 2 2.5mm/s

PC

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Mean diameter dmTYPERPMCOMP

LRHR

TYPE 3

TYPE 1

LR/HR

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SPM measurement - Analyzer

Evaluation frame,depending on TYPE

COMP = Compensation

Condition:red - bad, CODE Dyellow - caution, CODE B, Cgreen - good, CODE A

Bearing data

NORM -- ISO xx100

TYPE 3 rpm

COMP 4 Dm 87 mm

LR/HR reading

Basic data 2, Analyzer

Basic data 1, Analyzer

Bearing data

NORM 18 ACC 3

TYPE 1 TLT on

COMP 4

SPM

CODE B ACC 3

LUB 4 LR 27

COND -- HR 23

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Shock Pulse MethodShock Pulse Method

Good bearing

Dry running

Damaged bearing

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Limits Class Class Class Class

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

Vibration severity

Condition:redyellowgreen

Change class

VIB

ISO 10816

Class 2 2.76

mm /s

Vibration severityVibration severity

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COMMUNICATIONTIMEVERSIONSETUP

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

BEARING TEST

dBm 15 dBc 4 dBi 9

VIBRAMETERISO 2372

CLASS 2 2.5mm/s

PC

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TACHOMETER

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LEV

PEG 38

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BEARING TESTEARPHONE

VOLUME 5

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dBn

Peak indicator Earphone

Altered shock level Earphone display

SPM

dBm 43 (38)

dBc 26 dBi 26

SPM

Probe

Earphone

Level 69 dBsv

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Limits Class Class Class Class

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

Vibration severity

Condition:redyellowgreen

Change class

VIB

ISO 10816

Class 2 2.76

mm /s

Vibration severityVibration severity

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SPMVIB

RPM

RouteInput dataReadings

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SPM measurement - Tester

Normalized measuring scaledBsv - dBi = dBn

TLT = Transducer line test

19 and more good

15 - 18 acceptable

below 15 unacceptable

SPM

TLT 20

dBm 16

dBc 9 dBi 26

dBm/dBc display

Bearing data

TLT On

3000 rpm

90 dmm dBi 26

Basic data, Tester

dBn

dBm

dBi

dBc

dBsv

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dBm / dBcTESTER

same signalat

different levels

LR / HRANALYZER

dBc

dBm

HR

LR

Tester & AnalyzerTester & Analyzer

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MachineAlignment

Lubrication Bearing Installation

BearingDamage

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Shock Pulse MethodShock Pulse Method

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Bearing lifeBearing life