CONDITION MONITORING

EXPERTISE FOR EVERY INDUSTRY

Performance, Productivity, and Peace of Mind
SPM - CM solution provider & partner
History of leadership.
2019 / 22 Airius wireless / LTE solution
2017 – Intellnova Parallel INCEN System (IND.40)
2015 – HD ENV and Gearbox tool box
2012 – Diamond & Emerald (Intrinsically Safe available)
2010 – SPM HD Method
2008 – Introduces intellinova®, new online system
2004 – Line laser the shaft alignment introduced
2002 – SPM Spectrum enables the first true and calibrated shock spectrum analysis.
1997 – EVAM is introduced Successful applications in
various industries:
1990 – Shock pulse and vibration measurement are combined
Power, Petro-chemical,
1980 – SPM installs the one-millionth measurement point Iron & Steel, Pulp & Paper,
1970 – SPM is founded to develop the method Marine, Mining, FM, …
1969 – The Shock pulse method is patented
1965 – A Danish ship owner retains an inventor to find a method of detecting defective cargo pumps before
they break down.
SPM WorldWide SPM International
Sweden
• Over 50 years of experience with condition monitoring

• Head Office in Sweden SPM Instrument

SPM Instrument AB
(Asia) Pte Ltd
Sweden
• Research & Development (R&D) Singapore

• Production Facilities SPM Instrument BV SPM Instrument A/S

Netherlands Norway
• Training Center
SPM Marine &
SPM Instrument Oy
• Global support Offshore
Finland
Netherlands

• 12 Subsidiaries
SPM Instrument Int. SPM Instrument
GmbH SRL
• Global network of sales and service representatives covering more Austria Italy
than 60 countries to serve customer needs SPM Instrument SPM Instrument Inc.
EOOD
• Local Support Bulgaria
United States

• Local Language Personnel SPM Instrument SPM Instrument UK

Ltd.
PTY
South Africa United Kingdom
• Documentation and support

• About 100 professionals in Sweden and 240 worldwide

SPM Worldwide
Shock/Vibration Generator
Accelerometer Frequency Range
Bearing failure process
Bearing failure process-Healthy

1X

2X

20 KHz 40 KHz
Bearing failure process-Stage 1

1X

2X

20 KHz 40 KHz
Bearing failure process-Stage 2

1X

2X

20 KHz 40 KHz
Bearing failure process-Stage 3

1X

2X

20 KHz 40 KHz
Bearing failure process-Stage 4

1X

2X Random
frequencies

20 KHz 40 KHz
Bearing failure process-Spoil

1X

2X Random
frequencies

20 KHz 40 KHz
Envelope
Analogue to Digital Converter
The raw signal from an accelerometer mounted on a machine.

Signal at (1)

The first step is to digitize the analogue signal from the accelerometer.
The fixed sampling frequency of 102,400 Hz.

Signal at (2)
Envelope Filter
The purpose of the envelope filter is to remove the low frequency signals with high energy
content created by unbalance and misalignment, and to preserve high frequency signals with
low energy content originating from bearings and gears.

Signal at (3)
Recommend Filter
Detection of early faults Stage 1 - 2

Filter 4
5 KHz – 40 KHz

Detection of more developed faults Stage 2 - 3

Filter 3
500 Hz – 10KHz

Detection of severe faults Stage 3 - 4

Velocity
No filter
Rectifying
Rectifying, i.e. turning the negative parts of the signal into positive, is done digitally.

Signal at (3)

Signal at (4)
Low Pass Filter & Decimation
The cut-off frequency of the low pass filter is defined by the maximum frequency selected by the
user.
Comparing the peak amplitude of the rectified signal before and after the low pass filter is applied
shows a significant reduction of the peak value.

Signal at (4)

Signal at (5)

Signal at (6)
Anti-aliasing filter Effect
HD Envelope
Smoothing Filter
By processing the signal before the anti-aliasing filter and using a fixed low pass frequency (with a relatively
high cut-off frequency), the peaks from the original rectified signal are preserved (signal at 9). By identifying the
amplitudes of peaks of the signal at 9, a histogram containing the real peaks expressed as scalar numbers is
created.

Signal at (9)
Random Impact Rejection and HDrp
• All peaks found in the rectified signal are saved in a histogram.

• By extrapolating the histograms using the slope of the right hand side of the histogram, a value called High
Definition Real Peak(HDrp)is calculated.
HD Order Tracking

10 s (6 RPM) 7 s ( 8.6 RPM) 6 s (10 RPM) 4 s (15 RPM)

RPM 3 s (20 RPM) 1 s (60 RPM)

2 s (30 RPM)

60

6
HD Order Tracking

10 s (6 RPM) 7 s ( 8.6 RPM) 6 s (10 RPM) 4 s (15 RPM)

RPM 3 s (20 RPM) 1 s (60 RPM)

2 s (30 RPM)

60

6
HD Order Tracking

10 s (6 RPM) 7 s ( 8.6 RPM) 6 s (10 RPM) 4 s (15 RPM)

RPM 3 s (20 RPM) 1 s (60 RPM)

2 s (30 RPM)

60

6
HD Order Tracking

10 s (6 RPM) 7 s ( 8.6 RPM) 6 s (10 RPM) 4 s (15 RPM)

RPM 3 s (20 RPM) 1 s (60 RPM)

2 s (30 RPM)

60

6
Symptom Enhancer

Time [s]

40

Time [s]
8
Symptom enhancement
HD Envelope Overview

HD Real Peak

Random Impact Rejector

Digital HD Time Signal

Filter
Enveloping
Vibration
Transducer
HD Order Symptom
Tracking Enhancer HD Spectrum

RPM
Shock/Vibration Generator
Shock Pulse Transducer

The shock pulse transducer

5-7

32
f1 f2 fm kHz
Shock Pulse Transducer
SPM HD Algorithm overview
Overall Shock Pulse
Disturbance HDm
Rejector HDc

Transducer
Time Signal
Data BFO Pattern
Aquisition BFI Pattern
BSF Pattern
FTF Pattern
RPM
Spectrum Brg Symptoms

HD Order Symptom SPM Spectrum HD

Tracking SPM Time signal HD
Enhancer
The SPM principles
Signal after bandpass filter

After rectifying

After enveloping

0
SPM HD Result
The measuring result consists of two values on a decibel scale:
• HDm: the primary value to use to determine the severity of a bearing damage. It represents the highest shock pulses
found during the measuring cycle. This value is also used for triggering alarms.
• HDc: This value represents the level where 200 shocks/second are present. It is useful to determine lubrication condition.

60 HDn
50
40
HDm
30
20
HDc
10
0
Shock Level and Pattern

HDc HDm
HDc

Time Time Time

Overall Shock Pulse Measurement
HD Normalization 60 HDn

50

40
HDm
30

20

10 HDc
0
SPM Trend

September 1 January 28
SPM HD Algorithm overview
Overall Shock Pulse
Disturbance HDm
Rejector HDc

Transducer
Time Signal
Data BFO Pattern
Aquisition BFI Pattern
BSF Pattern
FTF Pattern
RPM
Spectrum Brg Symptoms

HD Order Symptom SPM Spectrum HD

Tracking SPM Time signal HD
Enhancer
HD Order Tracking
RPM

1500

Data acquisition time Time fOrders

[Hz]
1X
25
RPM

Time Orders
1X
HD Order Tracking - Advantages
RPM variation between 550 – 600 RPM (9.2 Hz- 10 Hz)

Order Tracking off

Order Tracking on
SPM Symptom Enhancer

Time [s]

40

Time [s]
8
SPM Symptom Enhancer
Frequency Spectrum Time Waveform

Off

On
Bearing Parameter Fundamentals
Load zone & Modulation
BPFO (Ball Pass Frequency Outer race)

Time

BPFI (Ball Pass Frequency Inner race)

1 Rev

Time

BS (Ball Spin frequency)

Load Zone
Time

FTF (Fundamental Train Frequency/

cage frequency)

Time
Time Signal – Field Example
Bearing change

October 2009 December2009

1 Rev Spherical Roller Bearing (FAG 22 320)

BPFO = 6,59
BPFI = 9,41
N = 16
Time Signal – Field Example

Bearing change

October 2009 January 2010

1 rev
Cracked inner race, spalling along entire
inner race

4 months’ forewarning
Note the typical, cracked inner race
pattern
Time Signal – Field Example
Bearing change

October 2009 February 2010

10 RPM

Cracked inner race, spalling on both inner and

outer races

Note the typical, cracked inner race pattern

Time Signal – Field Example
Bearing change

February 2010

Cracked inner race with deep spalling

About 10 months’ forewarning
Note: very severe damage for a long period
of time, high risk of complete machine
breakdown
Spectrum – Field Example

Outer race damage,

9.3 RPM
SPM® HD Overview
Overall Shock Pulse
Disturbance HDm
Rejector HDc

Transducer
Time Signal
Data BFO Pattern
Aquisition BFI Pattern
BSF Pattern
FTF Pattern
RPM
Spectrum Brg Symptoms

HD Order Symptom SPM Spectrum HD

Tracking SPM Time signal HD
Enhancer
EVAM – Time Domain Analysis
EVAM – Condition Parameter
Time domain calculations

ROTATION SHOCK FRICTION

Forced vibration Periodic / non-periodic Periodic / non-periodic
transients random noise

ACCELERATION VELOCITY CREST KURT SKEW NL1 NL2 NL3 NL4

RMS-value RMS-value Crest Kurtosis Skewness

factor

• Unbalance
• Gear damage • Scraping parts
• Misalignment
• Bearing damage • Journal bearing
• Looseness
• Other shocks
• Wear
EVAM – Frequency Symptom
Symptom - Misalignment

0,04mm/s

0,99mm/s
Overall – Symptom Trend
 Component Symptom

3:RD SHAFT
BEARING SKF NJG2332 VH
(BPFO, BPFI, BPFIM, BSF, BSFM)
GEAR WHEEL Z63
(GM, GMMOD)

2:ND SHAFT
BEARING SKF NCF 2944V
GEAR WHEEL Z36
1:ST SHAFT
BEARING SKF 32320
GEAR WHEEL Z13
mm/s
v4
Symptoms 17,31 mm/s
as
VALUE
or COND

v3 v5

v2 v6
v1 v7

Broad band RMS-value = v

f
2
f

Symptom RMS-value = 2 2 2
v1 + v2 + v3 + v42 + v52 + v62 + v72
EVAM Method For Every Conditions
60
50
40
30
20
10
0

hardware
software
evaluation
Statistical calculation COND No.
mm/s 35 - 60 Red
> 5 std

21 - 34 Yellow
3 - 5 std

Mean value. 0 - 20 Green

up to 3 std

21 - 34 Yellow
3 - 5 std

35 - 60 Red
Time > 5 std
 10
20
30
50
60

0
40
Rotational forces

Vel

Acc

Shock

Crest

Kurt

Skew

Friction

NL1
1000 Hz

NL2

NL3

NL4
Overview Operating Condition

Symptoms

Gear mesh

Unbalance

Misalignment
Applying dynamic alarm limits
Color Spectrum
Amplitude e.g mm/s

Frequency
 Color Spectrum
Amplitude e.g mm/s

Frequency
Frequency

Spectrum 1
Spectrum 2
Spectrum 3
Spectrum 4
Spectrum 5
Spectrum 6
Spectrum 7
Spectrum 8
Spectrum 9
Frequency

Spectrum 10
16 pixels

Spectrum 11
Spectrum 12
Spectrum 13
Spectrum 14
Spectrum 15
Spectrum 16
20 pixels
Color Spectrum

8 X BPFO
7 X BPFO
6 X BPFO

5 X BPFO
4 X BPFO
3 X BPFO
2 X BPFO

1 X BPFO

August January
August

January
Color View
Condition Overview
Circular Plots
Circular Plots
HD Technology – Surface Condition
Vertical

Horizontal

Axial
HD Technology – Surface Condition
Horizontal Horizontal
HD Technology – Surface Condition
Gearbox Monitoring Toolbox

Time Synchronous Averaging

Pseudo Tachometer
HD Order Tracking VEL (RMS)
velocity
Circular Plots

Gear Surface Condition Dynamic Behavior

Bearing Condition Velocity measurements
Complete Gearbox Monitoring

Tachometer Transducer Type

Positioning / Positioning

HD Order Tracking FFT / Time Domain /

TSA Circular Plot
Pseudo
Time Synchronous Averaging
A

B
Vibration
Transducer

A+B+C
3
Time Synchronous Averaging

Tachometer

Vibration
Transducer C

A+B+C
3
Pseudo Tachometer
HD Order Tracking
HD Order Tracking off
1331 - 1350 RPM
HD Order Tracking
HD Order Tracking on
1300 - 1362 RPM
Intellilogic - Data flow

CondMaster® Ruby
Measurement Tasks

CES

OK
Measuring Logic Storing Logic Alarm Logic
-Time based -Time based -Absolute level
-Conditional -Value level -Trend
-Triggered -Value change -Criteria based
-RPM -When alarm (standard/flexible)
-Symptom alarm
Next Step
Data
Base
Customer Systems

OPC Client
OPC
Data
Client/
Access
Server OPC Server

Ethernet
Wireless
System Unit

Parallel MB Modbus