• 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 ………. 2 A complete approach to condition monitoring • Engineering support • Customer service • Training • Software • Planning • Installation • Instrument use ………. Your Partner in Condition Monitoring ………. 3 DOWNTIME CORRECTIVE MAINTENANCE TIME BASED MAINTENANCE PREDICTIVE MAINTENANCE PROACTIVE MAINTENANCE ………. Your Partner in Condition Monitoring ………. 4 Work Time 1 Many breakdowns - little planning 2 Introduction Predictive Maintenance 3 Few breakdowns - planning ………. Your Partner in Condition Monitoring ………. 5 Causes of machine failure • 50% Bearing problems • 20% Misalignment • 20% Unbalance • 10% Other reasons ………. Your Partner in Condition Monitoring ………. 6 5000 h 50 000 h ………. Your Partner in Condition Monitoring ………. 7 Causes of bearing failure • 40% Lubrication • 30% Vibration • 20% Installation faults • 10% Fatigue failure ………. Your Partner in Condition Monitoring ………. 8 ………. Your Partner in Condition Monitoring ………. 9 ………. Your Partner in Condition Monitoring ………. 10 ………. Your Partner in Condition Monitoring ………. 11 ………. Your Partner in Condition Monitoring ………. 12 Lubrication Bearing Installation Machine Alignment Bearing Damage Operating Condition ………. Your Partner in Condition Monitoring ………. 13 STATIC AND DYNAMIC LOAD PRELOAD ALIGNMENT LUBRICANT SUPPLY LUBRICANT TEMPERATURE GEOMETRIC QUALITY OF BEARING HOUSE & SHAFT BEARING GEOMETRIC QUALITY TOTAL LOAD ROLLING VELOCITY LUBRICANT FILM ………. Your Partner in Condition Monitoring ………. 14 Bearing condition Machine vibration Rotational speed ………. Your Partner in Condition Monitoring ………. 15 ………. Your Partner in Condition Monitoring ………. 16 Shock Pulse Method ………. Your Partner in Condition Monitoring ………. 17 Vibration 10 - 1000 Hz ………. Your Partner in Condition Monitoring ………. 18 ………. Your Partner in Condition Monitoring ………. 20 ………. Your Partner in Condition Monitoring ………. 21 ………. Your Partner in Condition Monitoring ………. 22 ………. Your Partner in Condition Monitoring ………. 23 ………. Your Partner in Condition Monitoring ………. 24 ………. Your Partner in Condition Monitoring ………. 26 ………. Your Partner in Condition Monitoring ………. 27 ………. Your Partner in Condition Monitoring ………. 28 ………. Your Partner in Condition Monitoring ………. 29 ………. Your Partner in Condition Monitoring ………. 30 ………. Your Partner in Condition Monitoring ………. 31 ………. Your Partner in Condition Monitoring ………. 32 ………. Your Partner in Condition Monitoring ………. 33 Instrument operation, Input data and Output results Instrument operation • Input data required for Analyser: 1. Norm No. (10 - 58) 2. Type No. (1 - 8) : Calculated by instrument after giving bearing number and RPM : 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 ………. Your Partner in Condition Monitoring ………. 35 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) ………. Your Partner in Condition Monitoring ………. 36 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 ………. 37 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 ………. 38 Output results • Normalized results - Tester: 1. dBm dBm 2. dBc : Decibel maximum value, Decibel shock value of the shock pulses whose occurrence rate is 5 pulses per second. (-9 to 60 dBN) = dBsv – dBi : Decibel carpet value, Decibel shock value of the shock pulses whose occurrence rate is 300 pulses per second. (-9 to 60 dBN) ………. Your Partner in Condition Monitoring ………. 39 ………. Your Partner in Condition Monitoring ………. 40 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. ………. Your Partner in Condition Monitoring ………. 41 Evaluation Of Shock Pulse Readings Three steps in evaluation of readings • Trending • Comparing • Normalising ………. Your Partner in Condition Monitoring ………. 43 • 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 ………. 44 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 irregular intervals. pulses at 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 ………. 45 Shock pulse pattern of a good bearing Good Bearing : Code : A (Green Zone) Lub No : 1 – 40 1. 2. 3. 4. Low LR and HR values LR – HR = dB dB value is ideal 4 – 8 dB Trend shows no variation or minor change in LR/HR ………. Your Partner in Condition Monitoring ………. 46 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. 2. 3. 4. 5. High HR values, close to LR LR – HR = dB dB value is < 4 dB Trend shows gradual increase in HR reading. Increase in bearing temperature ………. Your Partner in Condition Monitoring ………. 47 Shock pulse pattern of a damaged bearing Damaged Bearing : Code : C or D (Yellow or Red) Cond No. : 30 to 65 1. 2. 3. 4. 5. High LR values, Distinctive peak in shock pulse pattern. LR – HR = dB dB value is > 10dB Trend shows gradual increase in LR reading. Increase in bearing temperature ………. Your Partner in Condition Monitoring ………. 48 ………. Your Partner in Condition Monitoring ………. 49 ERROR CODES - E2 / E3 / 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. ………. Your Partner in Condition Monitoring ………. 51 ………. Your Partner in Condition Monitoring ………. 53 ………. Your Partner in Condition Monitoring ………. 54 1 ………. Your Partner in Condition Monitoring ………. 56 2 ………. Your Partner in Condition Monitoring ………. 57 3A ………. Your Partner in Condition Monitoring ………. 58 3B ………. Your Partner in Condition Monitoring ………. 59 4 ………. Your Partner in Condition Monitoring ………. 60 5 ………. Your Partner in Condition Monitoring ………. 61 6 ………. Your Partner in Condition Monitoring ………. 62 ………. Your Partner in Condition Monitoring ………. 63 ………. Your Partner in Condition Monitoring ………. 64 ………. Your Partner in Condition Monitoring ………. 65 ………. Your Partner in Condition Monitoring ………. 66 Scraping coupling Bearing Replacement ………. Your Partner in Condition Monitoring ………. 67 VIBRAMETER ISO 2372 KLASSE 3 4.8 mm/s ………. Your Partner in Condition Monitoring ………. 69 Small force Weak foundation Large force Stiff foundation Structural looseness ………. Your Partner in Condition Monitoring ………. 70 Frequency Hz Displacement mm Acceleration m / s2 Velocity mm / s ………. Your Partner in Condition Monitoring ………. 71 Limits Class II Class III Class IV Class V II Medium size machines without special foundations III Large machines on rigid foundations IV Large machines on soft foundations ………. Your Partner in Condition Monitoring ………. 72 ………. Your Partner in Condition Monitoring ………. 73 ………. Your Partner in Condition Monitoring ………. 74 ………. Your Partner in Condition Monitoring ………. 75 ISO 2372 Class Class Class Class Class Class Limits 1 Step ………. Your Partner in Condition Monitoring ………. 76 Breakdown Vibration severity + 4 steps + 3 steps Vibration measurement (Shutdown) Effect repaires Report dangerous increase Plan major overhaul + 2 steps Report large increase Inspection, minor repairs + 1 step Normal Report change Routine maintenance (lubrication, etc.) ………. Your Partner in Condition Monitoring ………. Maintenance activities 77 ………. Your Partner in Condition Monitoring ………. 78 ………. Your Partner in Condition Monitoring ………. 79 Speed measurement RPM, optical: Distance max. 0.6 m Speed reading RPM 3650 rpm 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. ………. Your Partner in Condition Monitoring ………. 80 PC COMMUNICATION TIME VERSION SETUP T-500.01 GUIDE ROLL 01 TS 1st drying SPM 001 BEARING TEST dBm 15 dBc 4 dBi 9 ………. Your Partner in Condition Monitoring ………. VIBRAMETER ISO 2372 CLASS 2 2.5 mm/s 81 LR/HR TYPE 3 Mean diameter dm TYPE RPM COMP LR HR ………. Your Partner in Condition Monitoring ………. TYPE 1 82 SPM measurement - Analyzer Basic data 1, Analyzer Evaluation frame, depending on TYPE Bearing data NORM 18 ACC TYPE 1 TLT COMP 4 3 on Basic data 2, Analyzer Bearing data NORM -ISO xx100 TYPE 3 rpm COMP 4 Dm 87 mm COMP = Compensation Condition: red - bad, CODE D yellow - caution, CODE B, C green - good, CODE A LR/HR reading SPM CODE LUB COND B 4 -- ………. Your Partner in Condition Monitoring ………. ACC LR HR 3 27 23 83 Shock Pulse Method Good bearing Dry running Damaged bearing ………. Your Partner in Condition Monitoring ………. 84 Vibration severity Machine class 1 to 6 according to ISO (VDI, BS) Vibration severity VIB ISO 10816 Class 2 2.76 mm /s Change class Limits Class Class Class Class Condition: red yellow green ………. Your Partner in Condition Monitoring ………. 85 PC COMMUNICATION TIME VERSION SETUP T-500.01 GUIDE ROLL 01 TS 1st drying SPM 001 BEARING TEST dBm 15 dBc 4 dBi 9 ………. Your Partner in Condition Monitoring ………. VIBRAMETER ISO 2372 CLASS 2 2.5 mm/s 86 TACHOMETER ………. Your Partner in Condition Monitoring ………. 87 ………. Your Partner in Condition Monitoring ………. 88 PEG 38 LEV ………. Your Partner in Condition Monitoring ………. 89 BEARING TEST EARPHONE VOLUME 5 ………. Your Partner in Condition Monitoring ………. 90 Peak indicator Earphone dBn Altered shock level Earphone display SPM SPM Probe dBm 43 dBc 26 (38) dBi 26 Earphone Level 69 dBsv ………. Your Partner in Condition Monitoring ………. 91 Vibration severity Machine class 1 to 6 according to ISO (VDI, BS) Vibration severity VIB ISO 10816 Class 2 2.76 mm /s Change class Limits Class Class Class Class Condition: red yellow green ………. Your Partner in Condition Monitoring ………. 92 SPM VIB RPM Route Input data Readings ………. Your Partner in Condition Monitoring ………. 93 SPM measurement - Tester TLT = Transducer line test 19 and more good 15 - 18 acceptable below 15 unacceptable Basic data, Tester Bearing data TLT On 3000 rpm 90 dmm dBi Normalized measuring scale dBsv - dBi = dBn 26 dBm/dBc display dBs v SPM TLT dBm dBc dBn 20 16 9 dBi 26 dBm dBc dBi ………. Your Partner in Condition Monitoring ………. 94 Tester & Analyzer dBm / dBc TESTER LR / HR ANALYZER same signal at different levels ………. Your Partner in Condition Monitoring ………. 95 Lubrication Bearing Installation Machine Alignment Bearing Damage ………. Your Partner in Condition Monitoring ………. 96 ………. Your Partner in Condition Monitoring ………. 97 ………. Your Partner in Condition Monitoring ………. 98 ………. Your Partner in Condition Monitoring ………. 99 ………. Your Partner in Condition Monitoring ………. 100 ………. Your Partner in Condition Monitoring ………. 101 ………. Your Partner in Condition Monitoring ………. 103 ………. Your Partner in Condition Monitoring ………. 104 Shock Pulse Method ………. Your Partner in Condition Monitoring ………. 105 Bearing life ………. Your Partner in Condition Monitoring ………. 106