………. Your Partner in Condition Monitoring ……….2 Condition monitoring of ball and roller bearings using the patented SPM method (Shock Pulse Method) Vibration monitoring Machinery alignment Maintenance instruments

………. Your Partner in Condition Monitoring ……….3 A complete approach to condition monitoring Planning Installation Engineering support Customer service Training Instrument use Software

………. Your Partner in Condition Monitoring ……….4 DOWNTIME CORRECTIVE MAINTENANCE TIME BASED MAINTENANCE PREDICTIVE MAINTENANCE PROACTIVE MAINTENANCE

………. Your Partner in Condition Monitoring ……….5 Work Time 1 Many breakdowns - little planning 2 Introduction Predictive Maintenance 3 Few breakdowns - planning

………. Your Partner in Condition Monitoring ……….6 Causes of machine failure 50% Bearing problems 20% Misalignment 20% Unbalance 10% Other reasons

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………. Your Partner in Condition Monitoring ……….8 Causes of bearing failure 40% Lubrication 30% Vibration 20% Installation faults 10% Fatigue failure

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………. Your Partner in Condition Monitoring ……….13 Machine Alignment Lubrication Bearing Installation Bearing Damage Operating Condition

………. Your Partner in Condition Monitoring ……….14 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

………. Your Partner in Condition Monitoring ……….15 Bearing condition Machine vibration Rotational speed

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………. Your Partner in Condition Monitoring ……….17 Shock Pulse Method

………. Your Partner in Condition Monitoring ……….18 Vibration Hz

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Instrument operation, Input data and Output results

………. Your Partner in Condition Monitoring ……….35 Instrument operation Input data required for Analyser: 1.Norm No.( ): Calculated by instrument after giving bearing number and RPM 2.Type No. (1 - 8) : Depends upon bearing geometry. 3.Comp. No. ( ): To calibrate the measuring point location 4.Accumulation No. (1 – 9): To define the instrument measuring cycle time

………. Your Partner in Condition Monitoring ……….36 Instrument operation Input data required for Tester: 1.Shaft diameter (Bearing inner diameter, Maximum 1999mm) 2.Rotational speed of bearing (RPM, 10 – RPM) 3.dBi – Decibel initial value is calculated by the instrument after giving shaft diameter and RPM input. (-9 to 40)

………. Your Partner in Condition Monitoring ……….37 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

………. Your Partner in Condition Monitoring ……….38 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.)

………. Your Partner in Condition Monitoring ……….39 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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………. Your Partner in Condition Monitoring ……….41 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

………. Your Partner in Condition Monitoring ……….43 Three steps in evaluation of readings Trending Comparing Normalising

………. Your Partner in Condition Monitoring ……….44 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

………. Your Partner in Condition Monitoring ……….45 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.

………. Your Partner in Condition Monitoring ……….46 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 minor change in LR/HR

………. 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. 5.Increase in bearing temperature

………. 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 peaks in shock pulse pattern. 2.LR – HR =  dB 3.  dB value is > 10dB 4.Trend shows gradual increase in LR reading. 5.Increase in bearing temperature

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ERROR CODES - E2 / E3 / E5

………. Your Partner in Condition Monitoring ……….51 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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………. Your Partner in Condition Monitoring ……….58 3A

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………. Your Partner in Condition Monitoring ……….67 Scraping coupling Bearing Replacement

………. Your Partner in Condition Monitoring ……….69 VIBRAMETER ISO 2372 KLASSE mm/s

………. Your Partner in Condition Monitoring ……….70 Small force Large force Weak foundation Stiff foundation Structural looseness

………. Your Partner in Condition Monitoring ……….71 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 IV Large machines on soft foundations

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………. Your Partner in Condition Monitoring ……….76 ISO 2372 Class Class Class Class Class Class Limits 1 Step

………. Your Partner in Condition Monitoring ……….77 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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………. Your Partner in Condition Monitoring ……….80 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 m/min. TAD yd./min. TAD ft./min. Speed reading RPM 3650 rpm

………. Your Partner in Condition Monitoring ……….81 COMMUNICATION TIME VERSION SETUP T GUIDE ROLL 01 TS 1st drying SPM 001 BEARING TEST dBm 15 dBc 4 dBi 9 VIBRAMETER ISO 2372 CLASS mm/s PC

………. Your Partner in Condition Monitoring ……….82 Mean diameter dm TYPE RPM COMP TYPE 3 TYPE 1

………. Your Partner in Condition Monitoring ……….83 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 3rpm COMP 4Dm 87 mm LR/HR reading Basic data 2, Analyzer Basic data 1, Analyzer Bearing data NORM 18 ACC3 TYPE 1 TLTon COMP 4 SPM CODE BACC3 LUB 4LR27 COND --HR23

………. Your Partner in Condition Monitoring ……….84 Shock Pulse Method  Good bearing  Dry running  Damaged bearing

………. Your Partner in Condition Monitoring ……….85 LimitsClassClassClassClass Machine class 1 to 6 according to ISO (VDI, BS) Vibration severity Condition: red yellow green Change class VIB ISO Class mm /s Vibration severity

………. Your Partner in Condition Monitoring ……….86 COMMUNICATION TIME VERSION SETUP T GUIDE ROLL 01 TS 1st drying SPM 001 BEARING TEST dBm 15 dBc 4 dBi 9 VIBRAMETER ISO 2372 CLASS mm/s PC

………. Your Partner in Condition Monitoring ……….87 TACHOMETER

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………. Your Partner in Condition Monitoring ……….89 LEV PEG 38

………. Your Partner in Condition Monitoring ……….90 BEARING TEST EARPHONE VOLUME 5

………. Your Partner in Condition Monitoring ……….91 Peak indicator Earphone Altered shock levelEarphone display SPM dBm 43 (38) dBc 26 dBi 26 SPM Probe Earphone Level 69 dBsv

………. Your Partner in Condition Monitoring ……….92 LimitsClassClassClassClass Machine class 1 to 6 according to ISO (VDI, BS) Vibration severity Condition: red yellow green Change class VIB ISO Class mm /s Vibration severity

………. Your Partner in Condition Monitoring ……….93 SPM VIB RPM Route Input data Readings

………. Your Partner in Condition Monitoring ……….94 SPM measurement - Tester Normalized measuring scale dBsv - dBi = dBn TLT = Transducer line test 19 and moregood acceptable below 15unacceptable SPM TLT20 dBm 16 dBc9dBi 26 dBm/dBc display Bearing data TLT On 3000 rpm 90 dmm dBi 26 Basic data, Tester dBs v

………. Your Partner in Condition Monitoring ……….95 dBm / dBc TESTER same signal at different levels LR / HR ANALYZER Tester & Analyzer

………. Your Partner in Condition Monitoring ……….96 Machine Alignment Lubrication Bearing Installation Bearing Damage

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………. Your Partner in Condition Monitoring ……….105 Shock Pulse Method

………. Your Partner in Condition Monitoring ……….106 Bearing life