spm training
DESCRIPTION
SHOCK PULSE MONITORTRANSCRIPT
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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