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•
•
Condition monitoring of ball and roller
Condition monitoring of ball and roller
bearings using
bearings using
the patented SPM method (Shock Pulse Method)
the patented SPM method (Shock Pulse Method)
•
•
Vibration monitoring
Vibration monitoring
•
•
Machinery alignment
Machinery alignment
•
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•
•
Condition monitoring of ball and roller
Condition monitoring of ball and roller
bearings using
bearings using
the patented SPM method (Shock Pulse Method)
the patented SPM method (Shock Pulse Method)
•
•
Vibration monitoring
Vibration monitoring
•
•
Machinery alignment
Machinery alignment
•
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A complete approach to condition monitoring
A complete approach to condition monitoring
• Planning • Planning • Installation • Installation • Engineering • Engineering support support •
• Customer Customer serviceservice
• Training • Training • Instrument • Instrument use use • Software • Software
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DOWNTIME
CORRECTIVE MAINTENANCE
TIME BASED MAINTENANCE
PREDICTIVE 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
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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
………. Your Partner in Condition Monitoring ………. 14 STATIC AND
DYNAMIC LOAD
PRELOAD ALIGNMENT GEOMETRICQUALITY OF BEARING HOUSE & SHAFT
BEARING GEOMETRIC
QUALITY
LUBRICANT
SUPPLY LUBRICANT TEMPERATURE TOTAL LOAD VELOCITYROLLING
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Bearing condition
Machine vibration
Rotational speed
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Vibration
Instrument operation,
Input data
and
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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
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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
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Three steps in evaluation
Three steps in evaluation
of readings
of readings
•
•
Trending
Trending
•
•
Comparing
Comparing
•
•
Normalising
Normalising
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Three steps in evaluation
Three steps in evaluation
of readings
of readings
•
•
Trending
Trending
1. Collect SPM & VIB readings over a
1. Collect SPM & VIB readings over a
period of time.
period of time.
2. Plot the graphs and see the variation.
2. Plot the graphs and see the variation.
•
•
Comparing
Comparing
1. Compare readings of similar machines.
1. Compare readings of similar machines.
2. Compare SPM readings with VIB readings and
2. Compare SPM readings with VIB readings and
analyze.
analyze.
•
•
Normalizing
Normalizing
1. Establish own limits after hands
1. Establish own limits after hands
on experience on the same
on experience on the same
machine
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Pressure variation translated into shock pulse pattern
Pressure variation translated into shock pulse pattern
The filtered transducer signal reflects the pressure
The filtered transducer signal reflects the pressure
variation in the contact area.
variation in the contact area.
When the
When the oil film ioil film in the bn the bearing is tearing is thick, the hick, the shock pulseshock pulse
level is low, without distinctive peaks.
level is low, without distinctive peaks.
The level increases when the oilfilm is reduced, but there
The level increases when the oilfilm is reduced, but there
are still no distinctive peaks.
are still no distinctive peaks.
Damage causes strong pulses at irregular intervals.
Damage causes strong pulses at irregular intervals.
One can liken the three shock pulse patterns to the
One can liken the three shock pulse patterns to the
vibrations
vibrations felt felt in in a a car car while while driving driving on on a) a) aa
smooth road surface, b) a rough road surface, c)
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.
Low LR and HR values
2.
LR
– HR =
dB
3.
dB value is ideal 4 – 8 dB
4.
Trend shows no variation or
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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 value is < 4 dB
4.
Trend shows gradual increase
in HR reading.
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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 value is > 10dB
4. Trend shows gradual increase
in LR reading.
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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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Scraping
coupling
Bearing
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VIBRAMETER ISO 2372 KLASSE 3 4.8
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Small
force
Large
force
Weak
foundation
Stiff
foundation
Structural
looseness
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Frequency
Hz
Displacement
mm
Acceleration
m / s
Velocity
mm / s
2………. Your Partner in Condition Monitoring ………. 72
Class Class Class Class Limits II III IV V
II
Medium size machines without special foundations
III
Large machines on rigid foundations
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ISO 2372
Class
Class
Class
Class
Class
Class
Limits
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Vibration severity
+ 4 steps + 3 steps + 2 steps + 1 step NormalInspection,
minor repairs
Plan major
overhaul
(Shutdown)
Effect repaires
Routine
maintenance
(lubrication, etc.)
Report dangerous increase
Report large increase
Report change
Vibration
measurement
Maintenance
activities
Breakdown
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Speed measurement
RPM, optical: Distance max. 0.6 m Reflecting tape RPM, contact center: Hold against shaft centerPeripheral, 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. Speed reading RPM 3650 rpm
………. Your Partner in Condition Monitoring ………. 81 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
PC
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Mean diameter dm
TYPE
RPM
COMP
HRTYPE 3
TYPE 1
LR/HR
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SPM measurement - Analyzer
Evaluation frame, depending on TYPE COMP = Compensation Condition:red - bad, CODE D
yellow - caution, CODE B, C green - 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 Method
Good bearing
Dry running
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Limits Class Class Class Class
Machine class 1 to 6
according to ISO (VDI, BS)
Vibration severity
Condition: red yellow green Change class VIB ISO 10816 Class 2 2.76 mm /sVibration severity
………. Your Partner in Condition Monitoring ………. 86 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
PC
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LEV
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BEARING TEST EARPHONE VOLUME 5
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dB n
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 6
according to ISO (VDI, BS)
Vibration severity
Condition: red yellow green Change class VIB ISO 10816 Class 2 2.76 mm /sVibration severity
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SPM
VIB
RPM
Route
Input data
Readings
………. Your Partner in Condition Monitoring ……….
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SPM measurement - Tester
SPM measurement - Tester
Normalized measuring scale
Normalized measuring scale
dBsv - dBi = dBn
dBsv - dBi = dBn
TLT = Transducer line test
TLT = Transducer line test
19
19 and and more more goodgood
15
15 - - 18 18 acceptableacceptable
below
below 15 15 unacceptableunacceptable
SPM SPM TLT 20 TLT 20 dBm 16 dBm 16 dBc dBc 9 9 dBi dBi 2626 dBm/dBc display dBm/dBc display Bearing data Bearing data TLT On TLT On 3000 rpm 3000 rpm 90 90 dmm dmm dBi dBi 2626
Basic data, Tester
Basic data, Tester
dBn dBn dBm dBm dBi dBi dBc dBc dBs dBs v v
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dBm / dBc
dBm / dBc
TESTER
TESTER
same signal
same signal
at
at
different levels
different levels
LR / HR
LR / HR
ANALYZER
ANALYZER
Tester & Analyzer
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Machine
Machine
Alignment
Alignment
Lubrication
Lubrication
Bearing Installation
Bearing Installation
Bearing
Bearing
Damage
………. Your Partner in Condition Monitoring ………. 105