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

………. Your Partner in Condition Monitoring ………. 22

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

………. Your Partner in Condition Monitoring ………. 22

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

………. Your Partner in Condition Monitoring ………. 33

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

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………. 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

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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.

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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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………. Your Partner in Condition Monitoring ………. 47

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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………. Your Partner in Condition Monitoring ………. 48

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

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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

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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 Normal

Inspection,

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 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. Speed reading RPM 3650 rpm

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………. 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

HR

TYPE 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 /s

Vibration severity

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………. 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 /s

Vibration severity

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SPM

VIB

RPM

Route

Input data

Readings

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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

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References

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