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Maintenance Manager
OWNER:
TITLE: Condition Monitoring Guideline
Mukhtarov M/
Markland D/
Preti A Hardacre T
Lead
A1 Issue for use 10/03/2017 Optimisation
Maintenance Maintenance
Performance Manager
Engineer
Superintendent
Rev Purpose Date Prepared Checked Endorsed
Condition Monitoring Guideline
Document No: KPO-AL-MAI-GLS-00017-E
Revision A1
Revision History
Markland D/
Mukhtarov M/
Balzhanov B Hardacre T/
Preti A
Lead Cristofori F
A1 Issued for use N/a 10/03/2017 Maintenance
Maintenance
Maintenance
Performance
Optimisation Manager
Superintendent
Engineer
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Condition Monitoring Guideline
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Document Distribution
Consulted Distribution List
Date Addressee / Job Title Company Location
RACIE Terms
R Responsible
The person who actually produces the document
A Accountable
The person who has the answer for success or failure of the quality and timeliness of the document.
C Consulted
Those who must be consulted before the document is published.
I Informed
Those who must be informed after the document is published.
E Endorsed
Those who must approve the document before publication.
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Condition Monitoring Guideline
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Executive Summary
This document details the minimum requirements for implementation of a Condition Based Maintenance (CBM)
approach for equipment within KPO
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Condition Monitoring Guideline
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Contents
REVISION HISTORY 2
DOCUMENT VERIFICATION 3
EXECUTIVE SUMMARY 5
DEFINITIONS/ABBREVIATIONS 7
1. PURPOSE 9
2. SCOPE 10
2.1 Description of Condition Based Maintenance 10
2.2 Objectives of Condition Based Maintenance 11
2.3 Benefits of Condition Based Maintenance 11
3. REFERENCES 12
5. PROCEDURES 16
5.1 Condition monitoring methods 16
5.2 Vibration Condition Monitoring 16
5.3 Oil / Fuel / Coolant Analysis 33
5.4 Infrared Thermography and Temperature Monitoring 38
5.5 Motor Current Signature Analysis 39
5.6 Partial Discharge Monitoring 40
5.7 Circuit Breaker Timing Analysis 40
5.8 HV Generators Insulation Assessment 40
5.9 New Technology 40
5.10 Selection of condition monitoring methods 41
5.11 Methodology for Setting the Monitoring Interval 42
5.12 Frequency for Condition Monitoring Activities 43
5.13 Implementation of condition monitoring 46
5.14 Implementation of Oil / Diesel / Coolant Condition Monitoring 47
5.15 Reporting of Condition Monitoring Results and Analysis 48
5.16 Review of the condition monitoring program 50
5.17 Assurance 52
7. APPENDICES 53
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Definitions/Abbreviations
Word/ Meaning
Acronym
ACHE Air Cooled Heat Exchanger
CM Condition Monitoring
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NDE Non-Drive End – For a driving unit, the end of the machine without
the output shaft. For a driven unit, the end of the machine opposite to
the input shaft.
NDT Non-destructive Testing
Non-process Equipment whose failure would result in no or minimal production losses
Critical – e.g. water sump pump
Equipment
OEM Original Equipment Manufacturer
Safety Critical Equipment whose function is to maintain the safety of the facility –
Equipment e.g. firewater pump
Service The service severity is how quickly the service initiates the common
Severity failure modes for a type of equipment. This is affected by the fluid and
how hard the equipment has to work (position on operating curve).
Equipment with a similar service severity is likely to see common failure
modes arise after similar operating hours.
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1. PURPOSE
This document details the minimum requirements for implementation of a condition based
maintenance approach for equipment within KPO. The various condition monitoring techniques
utilised to monitor equipment condition are described with minimum requirements specified. These
include:
· Look, listen, feel
· Vibration Analysis
· Oil, diesel and coolant Analysis
· Thermography
· Motor Current Analysis and Partial Discharge Testing
Non‐Destructive Testing (NDT) techniques such as pipe and vessel thickness testing are not covered
by this Standard and will be managed by the RBI process. Assessment of piping vibration is described
in KPO “Piping Design” document.
Performance Monitoring requirements are also not covered by this document and will be documented
in a separate Guideline.
This document also describes the process for determining monitoring techniques to be used, their
locations, frequency of use and the review cycle required to ensure the program is effective.
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2. SCOPE
Condition Based Maintenance or Predictive Maintenance is the process of using the operating
condition of equipment to determine the requirement to complete maintenance. A comprehensive
condition based maintenance approach involves an iterative process which identifies appropriate
condition monitoring methods, determining the frequency of completing the condition monitoring
activities, implementing the condition monitoring program and then assessing the program for
success. The outcome of the review drives improvement for the condition monitoring program. This
process is shown below:
Select
Condition
Monitoring
Methods
Review
Determine
Condition
Activity
Monitoring
Frequency
Program
Implement
Condition
Monitoring
Program
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The objective of the Condition Based Maintenance (CBM) Strategy is to minimize downtime and
intrusive maintenance in the most cost effective manner, by the implementation of Condition
Monitoring (CM) techniques. Techniques used should be practical, proven and targeted to provide
timely indication of equipment health, allowing adequate time to execute planned interventions by
using optimum scheduling. This also ensures that the maximum life of the equipment is achieved
before it is shut down and repaired.
An effectively managed condition based maintenance program brings numerous benefits. Condition
monitoring activities can be completed in the most part with the equipment online, allowing continued
operation until defects are detected and deteriorate. The use of condition monitoring allows
maintenance to be scheduled, and/or other actions to be taken to avoid the consequences of failure,
before the failure occurs.
The key benefits are:
Improved Revenue
· Optimised lifespan of machinery (full use of equipment residual life)
· Reduced maintenance costs
· Reduced intervention time (increased availability)
· Reduced downtime due to more scheduled opportune maintenance during planned
maintenance outages
Improved Reliability
· Optimised maintenance intervals
· Avoid production losses due to unexpected breakdowns
· Avoid dismantling at fixed intervals
· Identification and removal of the root cause of failures
· Less maintenance induced failures
· Predict pending failures
Improved Safety
· Early identification of potential failures
· Reduced crew workload
· Reduction in unplanned work
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3. REFERENCES
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ST RK 1744 Petroleum and natural gas industries. Test methods for acid number of
petroleum products
ST RK 1314 Crude petroleum. Determination of water content. Distillation methods
ST RK ISO 2719 Determination of flash point. Pensky-Martens closed cup method (ISO
2719:2002, IDT).
GOST 5985 Petroleum products. Method for determination of acidity and acid
number
GOST 17216 Industrial Cleanliness. Grades Of Liquids Purity
GOST 30050 Petroleum products. Total base number. Perchloric acid potentiometric
titration method
GOST 4333 Petroleum products. Methods for determination of flash and ignition
points in open crucible
GOST 6370 Petroleum, Petroleum Products And Additives - Method For
Determination Of Mechanical Admixtures
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Production Manager Support the condition based approach to operation and maintenance of
equipment
Ensure production personnel are available to assist in the shut-down,
start-up and switchover of equipment as requested by condition
monitoring personnel
Central Maintenance Owner of Condition Monitoring Contract
Mechanical/Electrical Ensure adequate resources are available to implement the requirements
Superintendent of the standard
Ensure condition monitoring personnel have the minimum training
standards for the activities being undertaken
Ensure the CMMS is maintained for routine condition monitoring
activities and corrective work orders
Execute corrective maintenance as identified by condition monitoring
personnel
Ensures alignment between maintenance strategies, CMMS and
Condition Monitoring program
Maintenance Manager Endorse this Strategy
Maintenance Performance Be responsible for the correct compilation of data to produce this
Superintendent strategy
Lead Maintenance Facilitate meetings, gather data, draft, produce and be responsible for
Optimisation Engineer sign off of this strategy
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5. PROCEDURES
This process is not intended to be a standalone method of condition monitoring, but it is the most
frequent activity and provides a level of protection against serious failure when condition
monitoring frequency is being optimised.
Production personnel should complete a once per shift routine of areas for which they are
responsible, and cover all rotating equipment within that area. The routine should include a look,
listen and feel process for that equipment, with any observed change in condition reported via the
CMMS for further investigation by a condition monitoring technician, maintenance technician or
engineer.
In addition to this process, specific routine tasks for equipment should be developed for completion
by operations during rounds as determined by engineering. The recording of information during
these rounds should meet the following requirements:
· Be limited to information not available in the DCS or SCADA record
· A change in the recorded parameter should drive a maintenance response
· Is not detectable through other condition monitoring techniques that already form part of
the condition monitoring program. This includes recording of this information by
technicians during vibration condition monitoring routines.
Vibration condition monitoring is the process of using vibration created by mechanical equipment
to determine their actual condition. Vibration is caused within machinery due to forces generated,
and may:
· Change in direction with time, such as the force generated by a rotating unbalance
· Change in amplitude over time due to an increase in compliance of the machine
shaft/bearing system, or the support structure. This may bring about an increase in
amplitudes with or without a resonance condition
1 Note: Equipment should not be touched except in locations where it is determined safe to do so
and correct PPE is worn. Protective guarding is not to be removed or bypassed during “feel”
inspection activities.
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· Change in amplitude or intensity with time, such as the unbalanced magnetic forces
generated in an induction motor due to unequal air gap between the motor armature and
stator (field)
· Result in friction between rotating and stationary machine components in much the same
way that friction from a rosined bow causes a violin string to vibrate
· Cause impacts, such as gear tooth contacts or the impacts generated by the rolling
elements of a bearing passing over flaws in the bearing raceways
· Cause randomly generated forces such as flow turbulence in fluid-handling devices such as
fans, blowers and pumps; or combustion turbulence in gas turbines or boilers.
Some of the most common machinery problems that cause vibration include:
· Misalignment
· Unbalance of rotating components
· Looseness
· Deterioration of rolling‐element bearings
· Gear wear
· Rubbing
· Aerodynamic/hydraulic problems in fans, blowers, pumps, compressors and turbines
· Electrical problems (unbalance magnetic forces) in motors
· Resonance
· Eccentricity of rotating components such as "V" belt pulleys or gears
· Shaft Whirl
· Soft Foot
Vibration Analysis can be used to determine which of these problems are present using the following
two principles:
· All common failure modes have distinct vibration frequency components that can be
isolated and identified
· The amplitude of each distinct vibration component will remain constant unless there is a
change in the operating dynamics of the machinery.
There are three key approaches to the collection and analysis of vibration condition monitoring.
These are:
· Continuous Online Monitoring (which may also include protection systems)
· Intermittent Online Monitoring or Polling
· Intermittent Offline Monitoring (manual data collection).
The selection of which method is appropriate is based on a number of factors which include:
· Equipment Criticality (based on value, potential lost production, potential HSE impacts)
· Time for a fault to develop into a failure
· Cost of labour to collect data versus the cost to install an online system
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Unless agreed otherwise by the Engineering Manager, where vibration condition monitoring is required by the
maintenance strategy, all new projects should adhere to the following standard chart for vibration condition
monitoring:
Pump: Centrifugal
Y
(Critical)
Pump: Centrifugal (non-
Y
critical)
Pump: Positive
Y Critical unit may be online – N/A for
Displacement
piston/plunger pumps
Fan: Other Y
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The default units for all measurements should be SI units. Vibration specific data should be
expressed in the following measurement units:
· Frequency - Hertz (Cycle/Sec) or CPM (Cycle/Minute)
· Rotational Speed - Revolutions per Sec (RPS) or Revolutions per Minute (RPM)
· Displacement (Peak to Peak) – Micrometres
· Velocity – mm/s (RMS)
· Acceleration – g’s or mm/s2 (RMS)
A continuous online vibration condition monitoring system continuously monitors vibration levels
and will provide alarms and protective functions/output a signal to the ICSS when specified.
· Combined Orbit and Time base plots for orthogonal (XY) shaft observing displacement probe
vibration transducers
· Shaft X/Y Position History Plots
· Shaft Vector History plots
· Waterfall/Campbell spectrum trend plot.
· Time‐stamped Alarm List
· Possibility to select reference levels from historical data and overlay this on any plot of
current data
· Spectral band monitoring and alarming
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Online monitoring of equipment should follow the minimum requirements of API670. Any deviation to
these requirements should be subject to the approval of the Asset Technical Authority.
A centralised monitoring room/location shall be provided to enable efficient and timely monitoring of
the critical equipment.
An intermittent system involves the periodic transfer of vibration data to the online system for review
and analysis.
Monitoring locations should be assessed on a case by case basis. In general, monitoring locations
should be per API670, but may be reduced to optimise infrastructure costs or reduce the amount of
data transferred to extend battery life in wireless systems. The monitoring locations as a minimum
should be capable of alerting the technician to all credible failure scenarios, even if detailed analysis
and understanding of root cause cannot be achieved. Further evaluation using hand held data
collectors may be used to generate a complete understanding of the fault. For example, one
accelerometer may be used on a multiple bearing machine to highlight a bearing problem, but to
determine which bearing is the source of the high vibration, additional data using a portable hand held
data collector will need to be collected.
The frequency of data collected through the intermittent system should be optimised to ensure the
following:
· Credible failure modes can be detected within a time that allows site personnel to initiate a
response (equipment changeover and/or repair plan developed)
· Battery life of wireless transmitters is maximised to reduce maintenance costs of
replacement
· Infrastructure costs to manage the volume of data are not excessive compared to the value
of the data collected.
The review of intermittent condition monitoring data should be at the same frequency as online
systems.
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An offline condition monitoring (or Balance of Plant) system involves the manual collection of data
using a portable hand‐held data collector. Data collection routes are loaded into the data collector for
collection, with results being downloaded back into a central vibration condition monitoring database.
Best option is always a screwed connection, then magnets and finally if no other
options then use the 9” wand.
Mass does make a difference it can attenuate frequencies becomes as issue if the user
holds the magnet whilst recording data
· Each monitoring location should have a unique identifier in the condition monitoring
database.
· Installation of tags or labels in the field is not a mandatory requirement, so long as the
systems are set up using appropriate locations markers
· Vibration measurement location should NOT be on a flexible cover or shield such as the fan
cover on an electric motor or a sheet-metal belt guard.
Permanently mounted transducers should be installed under the following circumstances:
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· It is unsafe to access the data collection point due to height, heat, awkward access or other
safety and health related reasons
Permanently mounted transducers should be hard wired back to a suitable BNC connection installed in
a waterproof SS316 junction box. (Recommended JB used for the zone EX rated)
Transducers/Sensors (Accelerometers) used in the collection of data should be certified, suitable for
the machine application and be provided with appropriate test certificates. The accelerometer should
be selected and attached to the machine in such a way that the minimum frequency (Fmin) and
maximum frequency (Fmax) are within the usable frequency range of the transducer and can be
accurately measured.
Integration is acceptable as a means of converting acceleration measurements to velocity or
displacement, or for converting velocity measurements to displacement.
Data Collectors
All vibration equipment used should be regularly calibrated in accordance with manufacturer
recommendations. Where possible calibrations should be completed by a NATA certified organisation
compliant with ISO 9001, and ISO 17025, or other accepted equivalent local regulations/calibration
company
Minimum requirements will be as follow:
· It should be a minimum 1 Channel input device with additional input for phase reference
measurements.
· Battery life should allow for collection for a full shift (12 hours). Minimum of eight hours is
required.
· Execute pre-defined routes
· Built-in alarming and diagnostic tools
· Capable of acquiring a signal without a route file
· Capable of adding new machines or points in the field
· Be usable with standard plant PPE – i.e. usable with gloved hands
· Capable of recording the following Signal Sources:
· Vibration: Acceleration, velocity or displacement, handheld or attached.
· Compatible with integral electronic piezoelectric accelerometers
· Phase Reference (external trigger) TTL level input rate of rotation or phase reference
· From installed monitoring system acceleration, velocity, and non‐contact shaft
displacement and axial position pickups
· Keyboard Measurement data entry from installed instruments or indicators.
· Non-measurement observations coded notes or plain language entered by keyboard into
note field.
· Temperature (not a mandatory requirement): Thermocouple, RTD with adapter, or non-
contact infrared (direct input).
· The data collector will be capable of displaying the following:
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The offline vibration condition monitoring database and analysis software should meet the following
minimum requirements:
· Information is time stamped to when it was collected
· Analysis types to include time waveform, FFT spectrum with spectrum enveloping, phase
analysis
· Bearing and gear mesh frequencies can be overlaid over vibration results
· Comparison to set criteria for alarming
· Trending of data over time to show gradual or fast changes.
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M 1 V
P 1 N
2
For horizontally mounted machines, X and Y measurement locations need to be orthogonal
horizontal/vertical, preferably in the plane at 45° from vertical
3
For vertically mounted machines, X and Y measurement locations need to be orthogonal and in the
inline/not inline plane preferably at 45° from not inline.
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Refer to the diagrams below for implementation of the naming convention. Where no specific
diagrams exist, the same numbering / labelling philosophy should be used for implementation in the
vibration database.
P3V
M1V M2V
P1V P2V
M2A P1A
Motor Pump
M1V M2V
P1V P2V
P1A
M2A
M1H P1H
M2H P2H
Motor Pump
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M1N
Motor
M2A
M2N
M1N
P1N
M2A
M2N
P2N P1N
Pump
XYN XYN
XYI XI
Where X = M or P and Y = 1 or 2
Figure 4: Monitoring Locations for Pump – Vertical with and without a coupling
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M2A
Fin Fan Support
Structure M2N
Motor M1N
M1I
F2N
F2I F1A
F1I
M2A
M2N
M2I
M1I
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M1V M2V
G1_ G4_
M2A
C1V C2V
G5_ G6_
M1H M2H
C1A
Motor
Driven machine
M1V M2V
C1V C2V C3V C4V
M1A C3A
C2A
Figure 8: Monitoring Locations for a Compressor Train with driver in the centre
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C3V
C1V C2V
C1A
Driver Jackshaft Rotor
C3A
C1H Rotor
C2H C3H
C4V
C1V C3V
C5V
C2V
C1A
Driver
C1H C5H
C2H
4 Example shown for two cylinder reciprocating compressor. In the case of additional cylinders, they
are to be numbered with the bearing locations from the drive end as indicated.
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The table below shows the recommended Baseline / Fault and Routine data collection for rotating
equipment. For axial readings, preference should also be to record data closest to the coupling – if
this is not possible due to physical constraints, readings may be taken from the opposite end of the
machine.
Equipment 5 5
Baseline / Fault Routine (minimum)
M1H, M1V
M2H, M2V, M2A M2H
Pump – Centrifugal Overhung (<15kW)
P1H, P1V P1V
P2V
M1H, M1V
M1V
M2H, M2V, M2A
M1H, M2H, M2A
Pump – Centrifugal Overhung (>15kW) P1H, P1V
P1V
P2H, P2V
P2H
P3V
M1H, M1V M2H
Pump – Rotary (<15kW) M2H, M2V, M2A P1V (may be taken at
P1H, P1V centre of pump)
M1H, M1V M1V
Pump – Centrifugal Between Bearings
M2H, M2V, M2A M2V, M2H, M2A
or Rotary (>15kW)
P1H, P1V P1V
Compressor
P2H, P2V P2H
M1I, M1N
M2I, M2N, M2A M2I
Pump Vertical – with Coupling (<15kW)
P1I, P1N P2N
P2I, P2N
M1I, M1N M2I, M2A
M2I, M2N, M2A P2N
Pump Vertical – with Coupling (>15kW)
P1I, P1N P1I
P2I, P2N P2N
M1I, M1N
M2I, M2A
Pump Vertical – direct Coupled (<15kW) M2I, M2N, M2A
P1N
P1I, P1N
M1I, M1N M1N
Pump Vertical – direct Coupled
M2I, M2N, M2A M2I, M2A
(>15kW)
P1I, P1N P1N
M1H, M1V M1H
Fan (Overhung) – Refer to diagram for M2H, M2V, M2A M2V, M2A
Pump Centrifugal Overhung F1H, F1V F1H
F2H, F2V F2V
M1I, M1N M1I
Fin Fan (Belt Drive with no permanent
M2I, M2N, M2A M2N, M2A
accelerometers)
F1N F1I
5 Note any location measurement which is related to a rotating gear or rolling element bearing should
be captured as demodulated as well as not demodulated.
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Baseline vibration data is the data collected in the period immediately following start‐up of new or
completely overhauled equipment. The intent of baseline data is to capture the vibration signal for a
piece of equipment that is in “as new”8 condition. All subsequent readings can be compared to the
baseline data to identify changes which may indicate that a fault has developed. The baseline vibration
signature can have enveloped alarms applied so that changes in the signature are automatically
detected. Baseline data should be collected as follows:
· Within 3 months of equipment start-up
· Under normal operating conditions (temperature, flow, pressure)9
· At locations identified in section 3.2.6.3
· A minimum of three (3) separate data collections (to ensure consistency in the vibration
signature).
Note: If vibration Site Acceptance Test has not been completed, the baseline survey will also assist in
identifying assembly and installation issues at an early stage.
6 Note not all screw compressors will have requirement or facility for measurement of the jackshaft at
the non-drive end. Manufacturer recommendations are to be consulted.
7
Note instrument location convention of an Engine is as per an Electric Motor.
8 “As new” condition can be considered to be when the machine is either new, or recently overhauled.
9
Where variable running speeds are considered normal, a set of measurements should be taken over
the normal range.
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Acceptable vibration limits for rotating equipment should generally be in accordance with ISO
10816:1995 (AS2625:2003).
As per ISO‐10816‐1 the following typical evaluation zones are defined to permit a qualitative
assessment of the vibration on a given machine and to provide guidelines on possible actions:
· Zone A: The vibration of newly commissioned machines would fall within this zone
· Zone B: Machines with vibration within this zone are normally considered acceptable for
unrestricted long-term operation
· Zone C: Machines with vibration within this zone are normally considered unsatisfactory for
long-term continuous operation. Generally, the machine may be operated for a limited period
in this condition until a suitable opportunity arises for remedial action
· Zone D: Vibration values within this zone are normally considered to be of sufficient severity
to cause damage to the machine.
All personnel involved in the vibration condition monitoring program should be trained to a level that
ensures quality execution of data collection and analysis. The following minimum training levels apply:
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2) The Lead Rotating Engineer (Lead Condition Monitoring Engineer) should complete a review of
all data analysed by an ISO184362 Level II person until that person has proven competence to
the satisfaction of the verifier.
A training and competency matrix should be maintained for all personnel involved in the collection,
analysis and verification of vibration condition monitoring activities.
Oil analysis involves sampling and analysing oil for various properties and materials to monitor wear
and contamination. If a lubricant has become contaminated, its chemical structure has begun to
deteriorate, or if components such as bearings have begun to wear‐out and release microscopic
metallic particles into the lubricant, then oil analysis will detect all of these changes in the lubricant.
Regular sampling and analysis establishes a baseline of normal wear and can help indicate when
abnormal wear or contamination is occurring.
The maintenance strategy and the RCM process should identify which equipment will need to have
routine oil sampling and analysis carried out as part of the complete condition monitoring program
(refer Section 4.0).The identification process should assess gearboxes, motors, pumps, compressors,
engines, turbines, hydraulic systems and transformers.
Oil sampling methods and locations should ensure that consistent samples are collected, free from
contamination and representative of the oil system being analysed. Each sample location should have
a unique identifier permanently affixed to the sampling location.
Sampling locations should be chosen in accordance with the criteria in the KPO Lubrication Guideline,
and be safe to access by the sampler.
All new sample valves should have a quick connect/disconnect system that allows for self-isolating
functionality wherever possible. Pre‐existing sample valves without this capability should have
appropriate methods to isolate the valve from the system. The method required is dependent on the
type of valve used and the requirements of the machine.
The sampling method should be documented in a procedure and be followed consistently for each
collection. Where specific requirements exist for an individual piece of equipment, generic procedures
should not be used. Procedures should highlight all safety concerns associated with the specific
collection activities.
Oil sampling routes should be developed to enable samples to be collected in a safe, unobtrusive
manner while the equipment is running at its typical full‐load levels. These routes should allow enough
time for the technician to collect, label, package and close out before beginning the next route. Where
on‐site analysis is required, the completion of this and subsequent reporting should also be allowed for
in the route development. Analysis of results from a laboratory should be a separate activity to the
collection route.
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Condition Monitoring Guideline
Document No: KPO-AL-MAI-GLS-00017-E
Revision A1
Where oil sampling and analysis has been specified in the maintenance strategy, it should include
testing for metals, contaminates / additives and undergo a number of physical tests. The specific
requirements depend on the equipment type, and should be as per the table below (R –
Recommended, O – Optional):
Generators /
Combustion
Test Test Standard General Turbines Compressors
Engines
/ Gearboxes
Total Acid Number ST RK 1744 or GOST
5985 R R R (1)
(TAN)
Total Base Number
GOST 11362 or O O R O
(TBN)
GOST 30050
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Condition Monitoring Guideline
Document No: KPO-AL-MAI-GLS-00017-E
Revision A1
Testing of oil can be completed using one of the following three methods:
1) Laboratory Testing
Samples are collected and sent to a certified laboratory for testing and analysis. This approach should
be used for all regular oil sampling. The attestation certificate is issued by NaCEks
Tests to be performed should be incorporated into a regular maintenance plan consistent with the
recommendations of the manufacturer and testing body. Some testing that requires offline access to
the transformers should be scheduled to be done when the plant is offline once per year, or as agreed
by Company.
Transformers should be assessed using National Standard, which includes the provision to address:
· Minimum Energy Performance Standard (MEPS) requirements for distribution transformers
· Temperature rise
· Ability to withstand short‐circuit’s
· Loading guide for oil‐immersed power transformers
· Application guides.
Oil testing (and monitoring) should be as per the table below (R – Recommended, O – Optional):
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Condition Monitoring Guideline
Document No: KPO-AL-MAI-GLS-00017-E
Revision A1
Notes:
1) Insulation breakdown test for possible leaks between main tank oil and Automatic tap changer
compartment oil
The above testing should apply to both the main tank oil and tap changer compartment oil.
All lab reports creating in LIMS data base, and sending in pdf format
The raw data should be up loadable into the oil analysis database for trending.
Oil analysis results should be reviewed independently to ensure issues are correctly identified and
resolved.
The oil analysis database should be set up with alert levels to automatically highlight potential
problems in machinery and electrical equipment.
A magnetic chip detector captures and retains particles within an oil system. The detector may alarm
back to a control system or simply be a removable magnetic plug for visual analysis. The inspection of
chip detectors should be identified in the preparation of maintenance strategies and work instructions
should be in place to inspect at regular intervals where practical. Photographic evidence of the
particles observed on the chip detector/collector should be recorded. Where a significant number of
particles are observed these should be transferred to a slide and examined in more detail, or
alternatively sent to a laboratory for analysis.
Other magnetic components such as key phasors should be routinely inspected to ensure no metallic
build‐up, and investigation if found.
Regular sampling and analysis of grease is not required. During renewal of grease the used grease
coming from the drain port should be visually inspected for signs of water or particulate contamination.
If any signs are present a sample may be collected. Samples may also be collected if other condition
monitoring techniques identify an issue that could be better understood through grease analysis.
Where a grease sample is collected, it may be subject to one or more of the following tests:
Test Standard
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Condition Monitoring Guideline
Document No: KPO-AL-MAI-GLS-00017-E
Revision A1
Diesel is subject to contamination from water, bacteria and other solid contaminants. This is
particularly of concern in fuel systems with low turnover. Contaminated fuel can reduce the engine
performance and may cause abnormal or catastrophic wear in engine components such as fuel pumps
and injectors.
A sampling and testing regime should be put in place to mitigate against these failures. This should be
in accordance with the table below (R – Recommended, O – Optional):
Local Local
Storage – Storage –
Test Standard Bulk Storage Safety Production
Critical Critical
Equipment Equipment
Water content ST RK ISO 10336, ST R R R
RK ISO 10337
ST RK 2423
Coolant sampling and analysis can indicate that the glycol mix/strength has fallen out of specification
and will also highlight the level of corrosion inhibitor present. A weak glycol mix or low corrosion
inhibitor levels could result in serious engine damage. Cooling fluid analysis identifies problems within
engine cooling system that can be detrimental to engine performance or lead to premature engine
failure.
Where coolant sampling and analysis is specified in the equipment maintenance strategy, testing
should be as per the table below (R – Recommended, O – Optional):
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Condition Monitoring Guideline
Document No: KPO-AL-MAI-GLS-00017-E
Revision A1
5.3.5. Competency for Oil and Fluid Sample Collection and Analysis
Persons reviewing and making recommendations from oil and fluid analysis results should be
trained in accordance with the following requirements:
Notes:
1) Samples may be collected by personnel with no formal qualification; however that person
should be deemed competent following informal on‐site training by a competent person
(trained to ICML Level II Machine Lubricant Technician / Analyst OR equivalent).
2) A person trained to ICML Level III Machine Lubricant Analyst OR equivalent should complete a
review of all data analysed by an ICML Level II Machine Lubricant Technician / Analyst OR
equivalent person until that person has proven competence to the satisfaction of the verifier.
Temperature monitoring of both electrical and mechanical components and equipment provides an
indication of a developing fault or problem. Most equipment will generate heat during normal operation
but where this heat cannot be dissipated an abnormal temperature rise may occur. For electrical
equipment problems include corrosion, loose connections or overload conditions. For mechanical
equipment problems include bearing defects, flow induced problems, heat exchanger blockage,
misalignment and overload conditions.
Thermographic cameras and IR temperature guns may be used to collect temperature data
intermittently while the equipment is running. Continuous monitoring through the use of
thermocouples should be employed where changes in temperature may happen quickly and require
immediate action.
The identification of specific equipment to have routine thermography carried out or bearing
temperature monitoring should be identified in the appropriate maintenance strategy and determined
through the RCM process.
Where online temperature monitoring of mechanical equipment is not economically justified, the
collection of thermographic images or point temperature using IR temperature guns for mechanical
equipment may be used. This should be specified in the maintenance strategy where it is a routine
requirement. In addition, non‐routine collection of temperature data on equipment may be used to
assist in fault diagnosis.
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Condition Monitoring Guideline
Document No: KPO-AL-MAI-GLS-00017-E
Revision A1
ISO 18434 should be used as a guide for the implementation of infrared thermography. Online
temperature monitoring of bearings should follow API 670.
The following requirements should be met for the collection and storage of routine and non‐routine
thermographic data:
· Thermographic images should be stored in a single database so that changes can be quickly
identified.
· Locations requiring consistent measurement should have spots identified on the equipment
so that when thermographic images are collected, the temperature at that point can be
trended.
· Routes for thermographic image collection should be created and identify the orientation
images are to be collected (to create consistency in data collection).
If a temperature gun is used for routine temperature measurements, the location on the equipment
should be clearly labelled with a unique identifier and referenced in the condition monitoring database.
Motor Current Signature Analysis (MCSA) is a technique used to determine the operating condition of
AC induction motors and their driven equipment by recording and analysing current in the frequency
domain. MCSA operates on the principle that induction motor circuits can, in essence, be viewed as a
transformer. By clamping a Current sensor on either the primary or secondary circuit, fluctuations in
motor current can be observed. MCSA techniques can be used in conjunction with vibration and
thermal analysis to confirm the following key faults:
· Rotor bar faults
· Winding faults
Completion of online or offline motor current signature analysis should be completed on HV motors.
LV motors between 15 kW and 200 kW should be assessed on a case by case basis with specific
requirements documented in the maintenance strategy.
This is carried out in KPO during the 48M service where the motor is removed to the workshop for full
bench test analysis.
On-Line MCSA is carried out by the Motor Monitor Relay – These provide protection, control and
monitoring functions with both local and remote human interfaces.
Current-Voltage Signature Analysis is a new and relatively unproven technology which compares a
“healthy” machine current and voltage signature to live data. The difference between these two sets of
data are then analysed in a power spectral density plot. This method has demonstrated the ability to
identify mechanical faults within motors and coupled equipment, and is most effective when used in
conjunction with vibration condition monitoring. This is derived from MCSA, but is considered a
separate method.
Current‐Voltage Signature Analysis should be utilised where additional levels of confidence are
required to give complete equipment condition, or where confidence in other monitoring systems is not
high or is unreliable (for example in LNG loading pumps located inside a long column). In addition,
Current‐Voltage Signature Analysis may be used to provide some online monitoring of equipment
where online vibration monitoring could not be financially justified or introduces HSSE risks.
On-Line CVSA is also carried out by the Motor Monitor Relay and is derived from its function of MCSA
– These provide protection, control and monitoring functions with both local and remote human
interfaces.
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Condition Monitoring Guideline
Document No: KPO-AL-MAI-GLS-00017-E
Revision A1
Partial Discharge is an electrical phenomenon, which causes electrical insulation to deteriorate and
frequently is the reason for breakdown of an electrical insulation system resulting in failure of the
equipment.
Partial Discharges can occur for a number of different reasons, for example, Partial Discharge can
occur when high voltage structures have sharp projections; internal discharge can occur in gas‐filled
voids and contact noise can occur if the ground connection to a bushing is poor. This discharge would
partially bridge phase to ground insulation or phase to phase insulation in an electrical apparatus, thus
causing the electrical equipment to fail.
A program of partial discharge monitoring of all HV equipment should be addressed in the
maintenance strategy for such equipment. This includes motors, generators, cables, switchgear and
power transformers. A justification should be provided in the strategy where partial discharge
monitoring has not been specified.
Circuit breakers can fail to perform within specifications for a number of reasons: mechanical
components can be worn or loose, lubrication can be sticky or dried up, contacts can be eroded or
dirty or the control circuit and/or batteries can be faulty.
Circuit Breaker Timing Analysis (or Kelman Profiling) can monitor circuit breaker performance by
analysing contact time, stroke, velocity, over‐travel, and contact wipe. Essentially, the analyser detects
the initiation of a Circuit Breaker operation or initiates the operation itself by feeding a signal to the
control circuitry, and then records the contact status, mechanical movement, coil current, dynamic
resistance etc.
Kelman Profiling should be incorporated into the maintenance strategy for circuit breakers. The
specific requirement should be assessed on a case by case basis and consider the cost to complete
versus the consequence of failure – This is currently not being directly carried out in KPO, but it is
covered as a sub-function of:
KPO employs Tan Delta Insulation Assessment of HV Generators to determine the insulation condition
of these critical machines stator windings. This is a 48 Month scheduled task.
New technology is continually introduced to industry through both equipment improvements and
analysis methods. KPO encourages implementation of new technologies where any of the following
outcomes are probable:
· Elimination or isolation of HSSE risks
· Reduction in condition monitoring costs for equivalent outcomes (e.g. wireless
instrumentation)
· Improvement in fault detection accuracy
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Condition Monitoring Guideline
Document No: KPO-AL-MAI-GLS-00017-E
Revision A1
In some cases, it is possible that the new technology is intended to replace a previously utilised
method which may be well established and proven. In cases where new technology is to replace an
existing condition monitoring method, a trial period is to be conducted to establish confidence in the
new product. Each case will be uniquely evaluated and the termination of using any existing
technology should be subjected to the MOC process.
The requirement to complete condition monitoring activities should come from the generic
maintenance strategy for the equipment type or specific maintenance strategy where applicable. A
Failure Mode, Effect and Criticality Analysis (FMECA) should be completed and a decision made
within the maintenance strategy of which maintenance method should be applied to each of the
identified failure modes:
· Preventive Maintenance
· Condition Based Maintenance
· Run to Failure
The appropriate maintenance method is driven by the type of failure, the regularity with which that
failure occurs (i.e. a known time interval), and the consequence of failure.
Where it has been identified in the maintenance strategy that a condition based maintenance approach
is appropriate, one or more condition monitoring methods should be selected from the list identified in
Section 3.0 above. Techniques selected will be based on their ability to detect failure modes identified
within equipment maintenance strategies and to maintain statutory compliance whilst providing
demonstrable lifecycle cost benefits.
The assessment of appropriate condition monitoring methods should be demonstrated by listing the
methods in a table against the key failure modes and then assigning detection likelihood in line with
the following categories:
· Low – the condition monitoring method may detect the fault but success is not assured. The
timing of detection is likely to be close to the failure point
· Medium – the condition monitoring method has a high likelihood of detecting the fault, but
may not detect the fault until it has deteriorated
· High – the condition monitoring technique will detect the fault within adequate time to
properly plan a repair.
A minimum of one high detection likelihood condition monitoring activity is required for each failure
mode where the maintenance strategy indicates condition monitoring is required to mitigate a failure
mode.
This assessment approach is further defined in ISO 17359.
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Condition Monitoring Guideline
Document No: KPO-AL-MAI-GLS-00017-E
Revision A1
The monitoring interval for a condition monitoring activity should be determined based on the time from
first detection of the fault to the time at which the equipment is no longer serviceable. Figure 11 below
represents the typical degradation process experienced by equipment and is known as a P‐F curve.
Following initial start‐up, the equipment will operate without issue for a period of time until eventually a
change occurs in the condition. The first time where the degradation can be detected is known as the
P‐ Point, or potential failure point. After this time failure can occur at any time. The condition of the
equipment continues to degrade until a point where it is not delivering the required performance, and
this functional failure point is known as the F‐point. Operation beyond this point will result in failure
causing unnecessary equipment damage.
New
Condition Defect
Detected,
(P-point)
Impending
Failure
(F-point)
Data Collection
Failure
Time
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Condition Monitoring Guideline
Document No: KPO-AL-MAI-GLS-00017-E
Revision A1
Information is unavailable; industry best practice should be used. The initial frequency should take into
account early life failures and adjustment to this frequency should be through a structured review
process, as defined in 5.16 (Review of Condition Monitoring program). It should be noted that even
with operating experience the exact P‐F curve may never be confidently known.
Other considerations for setting the initial data collection frequencies are:
· Collection sufficient data to form an accurate and complete baseline
· Develop historical data for early tailoring of alarm levels
· Provide exposure to the condition monitoring systems for personnel training purposes.
Frequency of condition monitoring activities should be set at somewhere between two limits:
1) Initial monitoring frequency: the frequency of condition monitoring activities immediately
following start‐up of the facility.
2) Minimum Monitoring Frequency: the minimum frequency which condition monitoring activities
should be undertaken following rigorous review of condition monitoring data. The structured
review process is defined in 5.17 (Assurance)
The tolerance between readings is the allowable time between initiation of the work order (for the
condition monitoring activity) and completion of the work order.
In line with the methodology described in Section 5.1, vibration data should be collected and analysed
in accordance with the table below:
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Condition Monitoring Guideline
Document No: KPO-AL-MAI-GLS-00017-E
Revision A1
Large oil tanks (>50L) should be checked every shift via the sight glass where visible. Operators
should look for indications of water in the oil and discolouration. This inspection frequency may be
reduced subject to engineering approval. In addition, where oil sampling and lab analysis is specified
in the maintenance strategy, it is recommended that sampling should be completed at the following
frequencies:
Minimum Tolerance
Initial Monitoring
Equipment Monitoring Between Notes
Frequency
Frequency Readings
OEM recommended
Rotating Equipment frequency to be
3 months (1) 6 months (1) 2 weeks
(Oil Volume >50L) implemented when
more frequent
Rotating Equipment Sampled during oil
12 months 12 months 2 weeks
(Oil Volume <50L) replacement
Diesel Engines 3 months 6 months 2 weeks
Transformers
12 months 12 months 2 weeks
(main tank)
Subject to greater
Transformers carbon and particle
(tap changer 6 months 12 months 2 weeks build up than main
compartment) tank (due to arcing
during switching)
Table 15: Frequency for Oil Sample Analysis
N.B. For Critical or high-speed rotating equipment consider monthly
1) RBOT / RULER testing frequency should be 12 monthly.
Where diesel sampling and lab analysis is specified in the maintenance strategy, it is recommended
that it should be completed at the following frequencies:
Minimum Tolerance
Initial Monitoring
Equipment Monitoring Between Notes
Frequency
Frequency Readings
Bulk Storage 6 months 12 months 2 weeks
Safety Critical Only where volume is
Equipment – Local 3 months 12 months 2 weeks not consumed within
Storage monitoring frequency
Production Critical Only where volume is
Equipment – Local 6 months 12 months 2 weeks not consumed within
Storage monitoring frequency
Page 44 of 53
5.12.3. Frequency of Thermography
Notes:
1) For rotating equipment, initial monitoring should be completed at a frequency not exceeding twice
the vibration data collection frequency. Continued thermographic monitoring frequencies should be
reviewed to determine the appropriate long term frequency
2) Where not specified for routine thermography, mechanical equipment may undergo ad‐hoc
temperature surveys to assist in fault identification and to assist in root cause analysis
3) A baseline reading at normal operating conditions after start‐up should be collected prior to
initiating the normal collection routine
4) Subject to greater carbon and particle build up than main tank (due to arcing during on-line tap
changer switching).
Where offline motor current signature analysis is required, it should be completed at the following
frequencies:
Vibration data collection should be completed on a routine basis using work orders generated
from the CMMS. Data collection routes should be uploaded from the vibration condition
monitoring database with results downloaded back into the database upon completion of the
route. The work order should remain open until the data has been analysed and appropriate
action taken to deal with identified faults (e.g. Work Request raised in CMMS).
In the event that part of a route within a work order cannot be completed, and will likely exceed
the minimum monitoring frequency requirements, a corrective work request should be raised to
collect data. This will allow closure of the preventative maintenance work order.
Where alerts are activated on the hand‐held data collector during collection of Routine data,
additional points should be collected per the Baseline / Fault Diagnosis list. If the data
collector is experienced in fault diagnosis, the number of additional points may be less than
that required, but so long as sufficient data is collected to properly diagnose the fault.
Collection of phase data may be done to assist in the diagnosis process.
Upon the discovery and diagnosis of a fault, a Work Request should be raised in the CMMS
for rectification of the fault. The Work Request should include the following information:
· Equipment Tag Number
· A brief description of the analysis results
· The technicians understanding of what the root cause is
· The scope required to rectify the root cause. Where there are multiple possible root
causes, the work‐scope described should include a step by step of all activities
required to understand and rectify the fault.
· Expected time for the fault to deteriorate to the point where the equipment fails. This
may be listed as an expected time frame but should be conservative to ensure the
equipment does not fail, resulting in a more expensive repair. If an additional set of
data is expected to be collected prior to the repair being required, this should be
stated. The work request should be updated with a new priority and time to failure
once the additional data is collected. It is recognised that equipment failure is
subject to a degree of variability which impacts the ability for prognostics. As such
confidence factors may be provided with prognostics recommendations to assist with
planning and scheduling of repairs.
Following data collection and analysis, faults should be categorised into one of five condition
categories. Once the fault condition category is determined, the associated actions should be
completed:
The online condition monitoring system should have a site focal point for the management of
the system. Where the focal point is a third party Contractor, a Company focal point should
also be appointed to verify Contractor management of the system. System management
includes the following activities:
· Acknowledgment and rectification of system alarms
· Updates to software
· Changes to alarm settings
· Updates and modifications to calculations
All equipment monitored with the online system should have a dedicated focal point for the
review and analysis of the data. Where the focal point is a third party Contractor, a Company
focal point should also be appointed to verify Contractor review of the equipment and to review
Contractor prepared reporting on the equipment.
The system should be reviewed at least once per day where appropriately trained personnel
are available on site. This may be for a normal working week (excludes weekends and public
holidays) or every day of the week if a roster system or Contract for permanent site support is
in place. Continuous monitoring of alarms should be by operations personnel via the plant
control system.
Where alarms have alerted personnel to a potential issue, a detailed analysis of the data
should be completed.
Long term trending analysis of all equipment should be completed at least monthly, but may be
more frequent where issues have previously been identified.
Sampling of fluids from equipment will ensure that the sample is representative of the actual
operating fluid and free from contamination. The key aspect to controlling this is through the
use of carefully prepared and considered sampling procedures and through the use of
competent sampling personnel.
Oil sampling procedures should be developed for each equipment type. Where any
differences in process are identified for a specific piece of equipment, a specific oil sampling
procedure should be produced. The procedure should cover the following:
· Collection of the sample at normal operating conditions. The sample will not be
accurate if the oil is allowed to cool and settle as this will cause the heavier
contaminates to drop to the bottom of the compartment or sample line
· Ensuring there are no dead legs of fluid (allow for draining of dead legs before
collecting sample)
· Minimum volume of oil to be collected for the testing to be completed (this should be
understood through correspondence with the nominated oil/fluid testing laboratory).
· All HSE aspects of the sampling activity, including additional risks associated with
sampling from pressurised systems
· The need for oil clean‐up kits to be located nearby oil sampling locations.
Sample containers should be new and free from contamination. The sample should be
labelled with:
· Equipment number
· Sampling location unique identifier
· Date and time of collection
· Work Order number under which the work was performed
Samples should be sent away within 24 hours of collection. The laboratory shall analyse the
fluid in accordance with the specified testing requirements as defined in this procedure. The
laboratory should produce an electronic report stating all findings from the tests completed and
providing recommendations where appropriate. In addition, raw fluid electronic data should be
provided in a suitable format to enable uploading directly into the fluid condition monitoring
database.
The fluid analysis report should be reviewed by a competent person and combined with other
condition monitoring results to make accurate recommendations. This may include
recommendations to resample. Any rectification work should have a work request raised in the
CMMS.
Reporting of condition monitoring results and analysis will ensure that sufficient understanding
of risk is available to both management and support personnel. If reporting is done by
Company personnel, then only the monthly report should be generated. A weekly report
should be generated in addition to the monthly report where an external Contractor is
responsible for the condition monitoring reporting. Where the latter is the case, the Contractor
may propose an alternative reporting system to align with their standard reporting tools. This
approach should be approved by the site Technical Authority.
· A summary of collection and analysis activities completed during the week. This
includes on/offline vibration, oil and thermography
· A short list of any problems identified and how they have been addressed
· Work requests that have been raised
The exact format of this report should be agreed between the Contractor and Company at the
beginning of any condition monitoring Contract.
A report should be produced once per month to define the current condition of the facility. This
report should incorporate all aspects of the condition monitoring program and be of a
consistent format (using a reporting template). The report should be split into the following
sections:
1) A summary section which highlights all facility risks (report by exception). This section
should enable management to have a clear understanding of the key risks for the
facility.
2) A detailed section which provides further detail of the risk items. This may include:
a. Problem descriptions and understanding of root cause
b. Rectification urgency
3) A complete equipment list (with equipment description) with a condition status for
vibration, oil and any other applicable condition monitoring parameters. In addition,
this list should state:
a. Date of last data collection / sample and date analysed
b. Name of analyst
5) Where a third party Contractor is used, a work summary for the month.
6) An action list for all issues to be followed over the next month.
To enable a focused review of the condition monitoring program all equipment identified for
CM
activities should be grouped together based on the following:
· Same Equipment Type
· Similar Equipment design (bearings, impeller, API designation – eg OH2)
· Same Criticality
· Similar Service Severity
· Size (<15kW, >15kW & 200kW, >200kW)
These groupings should be used in the review of the condition monitoring program. All
equipment grouped together should be reviewed together and a consistent frequency and
scope of condition monitoring should apply.
Any recommended changes as a result of any review should also encompass the maintenance
strategy, CMMS, etc. Any changes to maintenance activities, the CMMS or data collection
frequency or route must be approved by the KPO Operations Management of Change process
prior to implementation.
The review cycle for the condition monitoring program should involve two phases:
1) Post Start‐Up Review – Designed to transition from base‐line data collection and
initial frequency to routine data collection.
2) Normal Operation Review – Designed to review the routine data collection scope and
frequency to ensure it is cost effective while still identifying faults with sufficient time to
take action.
In addition, there may be a need for additional review if:
1) A piece of equipment fails for any reason and the failure was undetected.
2) A alarm / alert is found to not be set correctly
The review process for activity frequency should involve the following steps:
1) Identify all grouped equipment to be reviewed
2) List the key failure modes which are driving the condition monitoring scope and
frequency. This can be taken from the information generated in Section 5 – Selection
of Condition Monitoring Activities.
3) Identify all faults generated on the review group and align against the key failure
modes
4) For each fault, list the time between identification and equipment shutdown for repair,
and the time between identification and expected failure. Note that it may not be
possible to always use the residual life of equipment and get the exact F point.
5) Determine if the data collection frequency allows sufficient time between identifying the
P point and reaching the F point, whilst considering all points 5.13.1 (Implementation
of Condition Vibration Monitoring)
In the early phases it may not be possible to confidently decrease the frequency of data
collection as there may not have been sufficient failures to cover the key failure modes. As
such a risk based approach to decreasing collection frequency should be employed.
To ensure that this data is easily available, a record should be kept of all faults that are
detected and when the items are repaired / shutdown (this information will be available via
operating data and CMMS data.
In addition, a review of the scope of all condition monitoring activities should be completed.
This review should involve a reassessment of the tables produced as part of the original
condition monitoring identification activities in Section 5. This review should address the
following questions:
· Are the condition monitoring methods used adequate for the failure modes being
monitored?
· What would happen if one of the condition monitoring methods used was removed
from the plan?
· What would happen if additional condition monitoring activities were added to the
plan?
The post start‐up review should be considered as all reviews that take place in the first six (6)
months after equipment start‐up. This should involve the following:
Review T Scope
i Review the amount of data collected with the aim of
reducing total data collected from Baseline / Fault
1a 3-6 months after start-up
level down to Routine level. Minimum number of
data collections should be three (3).
1b 6 months after start-up Initial review of the data collection frequency.
The scope of Review 1a is not per the general approach described in 5.17.1 (Activity Level
Assurance) This review should involve assessing every piece of equipment in the condition
monitoring database individually. The collected data should be analysed to confirm a
consistent signature for the piece of equipment. The data should be sufficient to ensure alerts
for absolute values and envelopes can be confidently set for ongoing monitoring.
The scope of 1b is not intended to be a completed review 1. Instead, this review should be by
exception. Any equipment where faults have been successfully detected may be analysed to
provide confidence in reducing the collection frequency. In this period, there may have also
been a better understanding of the installed equipment which would allow the frequency to be
reduced. A record of any decisions should be made via a review report.
Following the completion of the Post Start‐Up Review, an annual review of the data collection
scope and frequency should be completed. The first review should be 12 months after
start‐up.
The review results should be reported with recommendations for changes to the condition
monitoring program. Any changes should be approved by the Company Site Condition
Monitoring Focal Point.
An additional part of the condition monitoring review should involve an evaluation of the
frequency of preventative oil change‐out for small volume oil sumps (<50L). Oil analysis
results should be used to determine if the oil change‐out frequency can be decreased or
whether it should be increased.
In the event that a piece of equipment fails without the fault being detected, a review of the
condition monitoring program for that equipment should be undertaken. This may also apply to
equipment with a “run to failure” strategy, where the serviceable life of the equipment is
determined to be too short. This review should look at both the types of condition monitoring
activities being completed and their adequacy for the failure modes, and the frequency with
which those activities are being undertaken. The result of this review should either be an
increase in the frequency or additional condition monitoring activities. Alternatively, additional
preventative maintenance may be required. The appropriate controls must be followed prior to
implementation of any change in strategy as described in 5.16.1. (Review Methodology)
Alarms and alerts within both online and offline condition monitoring systems should be
reviewed continuously throughout plant operation. There are two triggers to reviewing an
alarm setting:
1) A fault is detected without an alarm/alert being triggered – this would mean that the
alarm / alert level is too high for the faults that are meant to be detected or the
frequency of data collection is too low and the fault has developed between
collections.
2) An alarm/alert is triggered when it shouldn’t – this would mean that the alarm / alert is
set too low for the fault and therefore there may be justification to increase the alarm /
alert level.
All changes to alerts and alarms should follow the facility approved change management
process.
5.17 Assurance
Compliance with this operating standard should be assured through the following means.
The collection of all data / samples should be managed through the CMMS. Failure to
complete preventative maintenance work orders will be highlighted through the maintenance
process.
Reports are required to be generated for all condition monitoring activities and reviewed by the
site condition monitoring focal point. These reports will highlight data collection and analysis
gaps and results.
5.17.2 Audit
7. APPENDICES
Nil