SHOCK PULSE

MONITORING
AND ITS
APPLICATIONS

Presented By:
NIKITHA R
1MS20MSE06-T
 What is Shock Pulse Monitoring?

◦ Shock Pulse Monitoring also known as SPM is a patented technique of predictive

maintenance by measuring vibration and shock pulses of bearing in motors and to
identify their condition and operating life before the next overhaul procedure.
◦ From the innovation of the method in 1969 it has been further developed and
broadened and is a worldwide accepted philosophy for condition monitoring of rolling
bearings and machine maintenance.
Vibration analysis:

◦ vibration analysis has been used for motor

predictive maintenance on ships for many years.
◦ Traditionally marine engineers have been using a
listening rod to listen to the sound and ascertain
the condition of rotating machinery.
◦ Nowadays to avoid premature overhaul of motors
many companies are supplying vibration analysis
pens and SPM instruments on board ships.
◦ However there is a difference between vibration
analysis and Shock Pulse Measurement.
 Shock Pulse Signals and Vibration:
Shock Pulse Phase
◦ When two pieces of metal, in motion, contact each other two
interrelated yet distinct processes occur.
◦ On initial impact a shock or pressure wave develops and quickly
propagates through the metal.
◦ This Shock Pulse is in the ultrasonic frequency band and typically
occurs around a center frequency of 36 kilohertz.
◦ The amplitude of the Shock Pulse is relative to the velocity of the
impact.
◦ As the signal expands from its point of origin, it is dissipated by
carbon and other imperfections in the metal.
◦ This shock or pressure wave is what we are interested in measuring
using the Shock Pulse Method.
Vibration Phase

◦ As the impact continues to develop, the metal surfaces are compressed and deflected.

◦ As the objects recoil, the metal components then rebound and continue to flex for a number of cycles until
the energy is dissipated.
◦ This second phase of the collision is vibration and its frequency depends on the shape, mass, stiffness, and
dampening of the metal.
◦ Shock Pulse Method filters out this phase of the collision, as the magnitude of the vibration is structure and
material dependent.
 Measuring shock pulse:
To measure Shock Pulse we use filtering combined with a special Accelerometer, which is designed with specific
characteristics for Shock Pulse Measurements. If designed properly, this same accelerometer can be used to measure
normal vibration signals as well.
Step 1 - Amplification
◦ Shock Pulse signals are relatively small in amplitude and do not travel great distances.
◦ To amplify the small Shock Pulse signal the piezo electric crystal stacks, which are the actual element in an
accelerometer that generates signals, are constructed in such a fashion that they are excited by the 36 kilohertz
Shock Pulses.
◦ The Tandem-Piezo accelerometer uses a patented design, which enables the accelerometer to accurately measure
both Shock Pulse and Vibration.
◦ The Tandem-Piezo design is unique in our industry and provides many advantages over other compression or shear
type accelerometers.
Measuring shock pulse:
Step 2 - Filtering
◦ To distinguish the Shock vibration a band pass filter around the 36- kilohertz Shock Pulse signal
is used. This helps isolate the Shock Pulse from other interference created by machinery
vibrations.

Step 3 - Conversion to Pulses

◦ The last stage of signal processing is the conversion from a waveform to analog pulses. This
process provides a signal that can then be processed to determine bearing condition.
 Bearing Condition:
Shock Pulse is actually two readings. Carpet Value and Max Value.

Carpet Value (Lubrication Condition):

◦ Metal impacting metal always occurs in rolling element bearings.

◦ Even a new bearing under normal operating conditions starts its journey towards wearing out. If lubrication were
perfect, bearings would never wear out.
◦ When there is no damage to the bearing, the metal-to-metal contact creates a background noise of Shock
Pulse.
◦ This is referred to as the Carpet Value.

◦ When the lubrication begins to break down there is more metal-to-metal contact and the Carpet Value will reflect
this by increasing.
◦ This increase tells one that the bearing is experiencing more metal strikes in a given time frame.
◦ The most likely cause of increasing Carpet Value is a decrease in the protective properties of the bearing
lubrication.
Bearing Condition:
Max Value (Bearing Damage)

◦When a defect occurs on a bearing element, it is periodically hit by another element in the bearing.
◦ For example, a defect on the outer raceway of a bearing is hit each time a ball or roller passes over the
defect.
◦This periodic collision creates a high amplitude burst of Shock Pulse waves that stands above the carpet
value.
◦It is similar to hitting a pothole with your car.
◦This stands out above the normal road noise.
◦With the application of some peak hold signal processing, we can distinguish this peak from the carpet of
background Shock Pulse signal.
◦ As bearing damage first develops then propagates the Max Value increases.
◦Max Value thereby is an excellent indicator of damage in rolling element bearings.
 Processing shock pulse signals
◦ A shock pulse transducer reacts with a large amplitude oscillation to the weak shock pulses, because it is
excited at its resonance frequency of 32 kHz.
◦ Machine vibration, of a much lower frequency, is filtered out.

◦ The first frame shows the symbol for a transducer and, below, the vibration signal from the machine, with
superimposed transients at the resonance frequency, caused by shock pulses.
◦ The second frame shows the electric filter which passes a train of transients at 32 kHz.

◦ Their amplitudes depend on the energy of the shock pulses.

◦ The transients are converted into analogue electric pulses.

◦ The last frame shows the converted shock pulse signal from the

◦ bearing, now consisting of a rapid sequence of stronger electric pulses.

 Shock pulse patterns
◦ The filtered transducer signal reflects the pressure variation in the rolling interface of the bearing.

◦ When the oil film in the bearing is thick, the shock pulse level is low, without distinctive peaks.

◦ The level increases when the oil film is reduced, but there are still no distinctive peaks.

◦ Damage causes strong pulses at irregular intervals.

◦ There are three condition zones namely

1. Green for Good Condition,

2. Yellow for Caution and

3. Red for Damaged condition.

◦ The peak value measured by the operator gives the status

of the machine and the zone it belongs to.

 Measuring operating condition
◦ The shock pulse meters measure the shock signal on a decibel scale, at two levels. A micro processor evaluates the
signal. It needs input data defining the bearing type (ISO number) and the rolling velocity (RPM and bearing diameter).

◦ Surface damage in bearings causes a large increase in shock pulse strength, combined with a notable change in the
characteristics between stronger and weaker pulses. Shock values are thus immediately translated into measurements of
relative oil film thickness or surface damage, whichever applies.
The amplitude of shock pulses measured by the SPM meter is due to the
following factors:

• Rolling velocity which is a function of speed or rotation and size of bearing.

• The thickness of the oil film, which in turn depends on preload and the quantity of oil supplied as
well as the viscosity of the oil.

• The alignment of the system. That means between the prime mover and the load.

• Other mechanical factors like roughness of the raceways, the stress and damages.
 shock pulse meter
• A shock pulse meter is very sensitive to detecting any defects in the bearing, but can’t analyze the
vibration created after the initial shock pulse. A SPM instrument can be used after about 1-2 days
training and is more sensitive to bearing defects than the vibration pen *.

*The Vibration Pen measures the Average Vibration level while Vibration Analysis Presents the Whole Vibration Spectrum that Can Be
Interpreted
Applications
◦ Shock Pulse is not limited to determining the condition of rolling element bearings.
◦ Any piece of machinery with continuous metal-to-metal contact gives off Shock Pulse
signals.
◦ Equipment such as gearboxes, lobe compressors, screw compressors, and
centrifuges all give off Shock Pulse signals and can be effectively monitored using
Shock Pulse.
◦ The capacity of this reading to measure lubrication condition and damage makes it
one of the most popular measurements of machinery condition in the world.
Uniqueness of Shock Pulse Monitoring

• SPM specializes in determining accurate information on the mechanical condition of

the bearing surfaces as well as the state of lubrication on the bearing throughout the
life of the bearing.
• SPM instrument can measure both the vibration as well as shock pulses.
• As both the RPM as well as the shaft diameter are entered into the instrument
evaluation can be done independent of speed in variable speed drives.
• Advanced warning of lubrication problems can be given.
Uniqueness of Shock Pulse Monitoring

• As any machine with metal to metal contact will give shock pulses it is useful for analysis of
other machines like screw compressors, gear boxes, lobe compressors, centrifuges, purifiers,
centrifugal pumps apart from motors.
• SPM also gives an indication of faulty installation and alignment.
• SPM is not influenced by the size, speed, design, background noise or installation of the
machine.
• . In SPM the noise carpet is eliminated and the bearing as well as the lubrication condition is
continuously monitored after filtering out the vibration as well as the background noise, giving
sufficient warning to avoid breakdown and plan maintenance.
THANK YOU..