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DOCUMENT

Maintenance Manager
OWNER:
TITLE: Condition Monitoring Guideline

DOCUMENT No: KPO-AL-MAI-GLS-00017-E

This is an uncontrolled copy unless it is being viewed on screen


from the KPO Intranet.

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

Rev # Purpose Changes Date Responsible Accountable Endorsed

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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Document Distribution
Consulted Distribution List
Date Addressee / Job Title Company Location

Informed 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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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

4. ROLES AND RESPONSIBILITIES 15

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

6. PROCESS FLOW DIAGRAMS/PROCESS MAPS 53

7. APPENDICES 53

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Definitions/Abbreviations

Word/ Meaning
Acronym
ACHE Air Cooled Heat Exchanger

ATA Asset Technical Authority


BNC Bayonet Neill–Concelman – a miniature quick connect / disconnect RF
connector used for coaxial cable
CBM Condition-Based Maintenance - a maintenance philosophy used to
actively manage the health condition of assets in order to perform
maintenance only when it is needed and at the most opportune
times. Also known as Predictive Maintenance

CM Condition Monitoring

CMMS Computerised Maintenance Management System – SAP

Company KPO. Karachaganak Operating b.v.

Contractor The person, firm or company undertaking to supply services plant,


or equipment to which his document applies.
CPB Constant Percentage Bandwidth

Criticality Asset Criticality is the ranking of the assets in order of importance to


the business as a whole. It incorporates a risk-based approach
considering potential consequences over several categories and the
likelihood of incurring those consequences.
DAQ Data Acquisition
DE Drive End / Driven End – For a driving unit, the end of the machine with
the output shaft. For a driven unit, the end of the machine with the
input shaft.
Equipment The equipment type is the generic equipment GWMS code used
Type in SAP. For example MPCP for centrifugal pumps and MCCR for
refrigeration centrifugal compressors.
FFT Fast Fourier Transform

GTA Global Technical Authority

GWMS Global Work Management System

HSE Health, Safety and Environment


HV High Voltage - means an operating voltage of more than 1000 V a.c. or
1500 V d.c. between phase conductors or between a phase conductor
and an earth as defined in Wiring Rules.
DCSICSS Distributed Control System and Integrated Control Shutdown System

LV Low Voltage - means an operating voltage that exceeds extra-low


voltage (ELV), but not exceeding 1000V a.c. or 1500V d.c. as defined in
Wiring Rules. Extra-low voltage means an operating voltage not
exceeding 50 V a.c. or 120 V ripple free d.c..
NaCEKs National Centre for Examination and Certification (Kazakhstan)

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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

PdM Predictive Maintenance – refer to CBM.

PPE Personal Protective Equipment

Process Equipment whose failure, assuming no installed spare, would result


Critical in unacceptable production losses – e.g. Condensate export pump.
Equipment
RBI Risk Based Inspection

RMS Root Mean Square

RTD Resistance Temperature Detector

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.

TTL Transistor-Transistor Logic

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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

2.1 Description of Condition Based Maintenance

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

Figure 1: Condition Based Maintenance Cycle


Condition Monitoring is a generally non-intrusive technique used in maintenance that allows the
measurement of equipment condition to identify: wear, fault development, deterioration that may lead
to failure. With regular condition monitoring it can be to determine the point where a machine is at risk
of failure and shutdown, before failure occurs. As this is a predictive maintenance technique it is
possible to schedule the shutdowns at the most convenient time to minimise interruption of
production and avoid catastrophic failure. It may require altering the operating regime, to achieve
Shutdown window therefore minimising risk of failure.
The key condition monitoring types that should be utilised in the condition based maintenance
program are as per below:
· Vibration Condition Monitoring
· Lubricant Analysis
· Cooling Fluid Analysis
· Diesel Fuel Analysis
· Thermography
· Motor Current Signature Analysis

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· Circuit Breaker Timing Analysis

2.2 Objectives of Condition Based Maintenance

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.

2.3 Benefits of Condition Based Maintenance

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

Document No. Document


API 670 Machinery Protection Systems Name
AS 2374 Power Transformers
AS 2625 Mechanical vibration - Evaluation of machine vibration by
measurements on non-rotating parts
Note: This standard aligns with ISO 10816.
ASTM D1287 Standard Test Method for pH of Engine Coolants and Antirusts
ASTM D6595 Standard Test Method for Determination of Wear Metals and
Contaminants in Used Lubricating Oils or Used Hydraulic Fluids
ASTM D7042 by Rotating
Standard Disc
Test Electrode
Method Atomic Emission
for Dynamic ViscositySpectrometry
and Density of Liquids by
Stabinger Viscometer (and the Calculation of Kinematic Viscosity)
ISO 7919-1 Mechanical Vibration of Non-Reciprocating Machines - Measurements
on
ISO 7919-2 Rotating Shafts
Mechanical and Evaluation
vibration Criteria
— Evaluation - Part 1:vibration
of machine GeneralbyGuidelines
measurements on rotating shafts — Part 2: Land-based steam
ISO 7919-3 turbines andvibration
Mechanical generators in excess ofof50
— Evaluation MW with
machine normalby
vibration operating
measurements on rotating shafts — Part 3: Coupled industrial
ISO 7919-4 Mechanical vibration - Evaluation of machine vibration by
measurements on rotating shafts - Part 4: Gas turbine sets with fluid-
ISO 7919-5 Mechanical vibration Evaluation of machine vibration by measurements
on rotating shafts Part 5: Machine sets in hydraulic power generating
ISO 9001 and pumping
Quality plants Systems - Requirements
Management

ISO 10816-1 Mechanical Vibration - Evaluation of Machine Vibration by


Measurements on Non-Rotating Parts - Part 1: General Guidelines
ISO 10816-2 Mechanical vibration — Evaluation of machine vibration by
measurements on non-rotating parts — Part 2: Land-based
ISO 10816-3 steam turbines
Mechanical and generators
vibration in excess
— Evaluation of 50 MW
of machine with by
vibration normal
measurements on non-rotating parts — Part 3: Industrial machines with
ISO 10816-4 nominal power
Mechanical above- 15
vibration kW and nominal
Evaluation of machinespeeds between
vibration by 120 r/min
measurements on non-rotating parts - Part 4: Gas turbine sets with
ISO 10816-5 Mechanical Vibration - Evaluation of Machine Vibration by
Measurements on Non-Rotating Parts - Part 5: Machine Sets
ISO 10816-6 in Hydraulic Vibration
Mechanical Power Generating andofPumping
- Evaluation MachinePlants
Vibration by
Measurements on Non-Rotating Parts - Part 6: Reciprocating
ISO 10816-7 Machines
Mechanicalwith Power—
vibration Ratings Above
Evaluation of 100 kW vibration by
machine
measurements on non-rotating parts — Part 7: Rotodynamic pumps
ISO 13373-1 for industrial
Condition applications,
Monitoring including measurements
and Diagnostics of Machines -on rotatingCondition
Vibration shafts
Monitoring - Part 1: General Procedures
ISO 13373-2 Condition monitoring and diagnostics of machines Vibration condition
monitoring Part 2: Processing, analysis and presentation of vibration
ISO 17025 General requirements for the competence of testing and
calibration laboratories
ISO 17359 Condition monitoring and diagnostics of machines — General guidelines

ISO 18434-1 Condition monitoring and diagnostics of machines — Thermography


— Part 1: General procedures

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ISO 18436-1 Condition monitoring and diagnostics of machines - Requirements


for qualification and assessment of personnel - Part 1:
ISO 18436-2 Requirements for assessment
Condition monitoring bodies of
and diagnostics and the assessment
machines process
- Requirements
for Training and Certification of Personnel - Part 2: Vibration
ISO 18436-3 Condition
Condition Monitoring
monitoring and
andDiagnostics
diagnostics of machines - Requirements
for qualification and assessment of personnel - Part 3:
ISO 18436-4 Condition monitoring and diagnostics of machines — Requirements
for qualification and assessment of personnel — Part 4: Field
ISO 18436-5 lubricant
Conditionanalysis
monitoring and diagnostics of machines - Requirements for
qualification and assessment of personnel - Part 5: Lubricant
ISO 18436-6 laboratory technician/analyst
Condition monitoring and diagnostics of machines — Requirements
for qualification and assessment of personnel — Part 6: Acoustic
ISO 18436-7 emission
Condition monitoring and diagnostics of machines — Requirements
for qualification and assessment of personnel — Part 7:
NAS 1638 Thermography
Cleanliness Requirements Of Parts Used In Hydraulic Systems

KPO-AL-GOV-PHL-10001-E Policy for Document Management

KPO-AL-GOV-PHL-30001-E Document Retention Policy

KPO-AL-CPR-GLS-00001-E KPO Corporate Identity Guideline

KPO-AL-MAI-PHL-00001-E KPO Maintenance Philosophy

KPO-AL-OPN-PHL-00001-E KPO Maintenance Strategy

KPO-AL-OPN-SYS-10010-E Asset Maintenance Management

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 2423 Method of oil products distillation at atmospheric pressure

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 11362 Petroleum products and lubricants. Neutralization number.


Potentiometric titration method
GOST 2177 Petroleum products. Methods for determination distillation characteristics

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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GOST ISO 4407 Industrial cleanliness. Determination of fluid contamination by the


counting method using an optical microscope
ST RK ISO 11500 Hydraulic drives. Impurity determination with solid particles for process
fluid by means of automatic calculation using the principle of light
ST RK ISO 10336 absorption
Crude petroleum -- Determination of water -- Potentiometric Karl Fischer
titration method
ST RK ISO 10337 Crude petroleum -- Determination of water -- Coulometric Karl Fischer
titration method
ST RK ISO 12185 Crude petroleum and petroleum products. Determination of density.
Oscillating U-tube method

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4. ROLES AND RESPONSIBILITIES


Position Responsibilities
Central Maintenance Accountable for this guideline
Discipline Head – Approve deviations to this guideline
Mechanical/Electrical
Provide guidance where this guideline allows options
Data / Sample Collector Collect samples and data
Ensure procedures are followed to maintain quality of collection
Data / Sample Analyser Review and report on data
Raise Work Requests/Orders
Condition Monitoring Manage the condition monitoring program
Focal Point Ensure Contract personnel have the correct training for the activities
(Contractor) being implemented
Implement the requirements of applicable standards
Condition Monitoring Where there is no Contractor, complete responsibilities listed under
Focal Point (Company) Condition Monitoring Focal Point (Contractor)
– Central Maintenance Where there is a Contractor:
Mechanical/Electrical · Review and endorse contractor reports
Lead Engineers
· Ensure all corrective actions from analysis are added to
the CMMS and completed within the appropriate time frame
· Ensure Contractor compliance with this standard
Note: for review and endorsement of reports, a Site Engineering Focal
Point will be nominated for each asset due to the geographical
separation of assets

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

5.1 Condition monitoring methods

5.1.1 Look, Listen and Feel

A critical part of all condition monitoring of equipment is the process of:


· Looking at the equipment to observe any changes in condition
· Listening to the equipment to hear any changes in condition
· Feeling the equipment to detect any changes in the equipment movement / vibration /
temperature1

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.

All recorded information should be transferred into a database for trending.

5.2 Vibration Condition Monitoring

5.2.1. Description of Vibration Condition Monitoring

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.

5.2.2. Selection of Vibration Condition Monitoring

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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· HSSE Risk associated with measurement activities (accessibility of equipment,


remoteness of asset location).

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:

Vibration Condition Monitoring


Type of Machine Comments
Online Polled Offline
Aero-Derivative Gas Not Applicable in KPO
Y
Turbine

Heavy Duty Gas


Y
Turbine
Compressor: Axial or
Y In hydrocarbon service
Centrifugal
Criticality review and cost benefit
Reciprocating
N Y analysis required to determine
Compressor:
monitoring

Criticality review and cost benefit


Compressor: Other N Y analysis required to determine
monitoring

Diesel / Gas Engine Y Critical unit may be online.

Pump: Centrifugal
Y
(Critical)
Pump: Centrifugal (non-
Y
critical)
Pump: Positive
Y Critical unit may be online – N/A for
Displacement
piston/plunger pumps

Cost benefit analysis to be


Fan: ACHE Y completed for project to
determine requirement

Fan: Other Y

Gearbox Y Y As per driven equipment (On-Line


Critical Equipment only)

Motor Y Y As per driven equipment (On-Line


Critical Equipment only)

Table 3: Vibration Condition Monitoring Selection


Note: The definition of critical equipment should be determined during the criticality analysis for
the equipment.

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5.2.3. Vibration Measurement Units

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)

5.2.4. Continuous Online Vibration Condition Monitoring

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.

5.2.4.1. System Requirements

The installed system should have the following minimum capabilities:


· Current values of all measurements versus time including vibration, temperature and process
variables
· “Scalar” History Plots with adjustable scales
· Spectrum Plots including, minimum 800 FFT and 6%, 23% and 70% CPB. Increased lines
may be specified but data volume management should be considered
· Historical Waterfall 6400 line FFT and CPB Spectrum Plots for steady state
· Historical Cascade 6400 line FFT and CPB Spectrum Plots for transient conditions
· Bode Plots for vectors 1X – 10X
· Polar Format Acceptance Region representing vibration vector data as a function of time.
The selected vector may be 1X or 2X
· Polar Plots
· Shaft Centreline plot observing average position of a machine rotor within the bearing
· Scalar” versus Speed Plots (Transient)

· 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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· Journal entries for any measurement


· Critical event capture: a rolling data buffer in the safety rack triggered by an event (e.g. alarm
or sudden increase in vibration) which then captures the data and sends it to the database
for analysis. This will be able to show data before, during and after the event
· Delta rpm triggering for transient data capture
· Ability to measure data in velocity and acceleration for accelerometer channels
· Time synchronisation to 100ms with plant clock
· Facilitate setting rate of change alarms – so a sudden change in vibration below alarm levels
will trigger an alarm
· Monitor & trend non-1X vibration level.

In addition, the following general database requirements should be implemented:


· Database to have intelligent data storage capabilities which ensure that high resolution data
of interest (e.g. around an event) are not compressed or over written as new data is collected
· Automatic database back up capability to plant back‐up server of all servers, databases,
configurations and DAQ’s
· Facilitate multiple channel set up changes (e.g. can copy changes made on Pump A across
to other Pumps).

5.2.4.2. Monitoring Locations

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.

5.2.5. Online Intermittent Condition Monitoring

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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5.2.5.1. System Requirements

The installed system should have the following minimum capabilities:


· Must be able to capture data, using an accelerometer and displaying recorded amplitude in
units of both acceleration and velocity for all channels
· Time based polling (e.g. take a measurement every 12 hours, regardless of condition) and
triggered measurements (e.g. alarm in RMS velocity triggers measurement) – Currently not
applicable in KPO
· With wireless systems it should be simple and straight forward to install sensors on
machines of interest as required. They should join the wireless network and be collecting
data within a few hours.

5.2.6. Offline Vibration Condition Monitoring

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.

5.2.6.1. Hardware Requirements

Vibration Transducers/Sensors and Mounting Points


The set‐up for offline data collection points should ensure quality and repeatability in the results.
Where permanent accelerometers are not installed, the following minimum requirements should be
met:
· Where a magnet is used, permanently fixed magnetic stainless pads should be provided at
each collection location. Note: use of flat magnetic SS targets in conjunction with flat rare
earth magnets are the recommended set‐up. This combination is effective for up to 10 kHz.
Curved surface 2 bar magnets are effective only up to 2 kHz, regardless of the mounting
surface and are therefore not preferred
· Where a magnet is not used, a screw connection may be provided. Note that this connector
type is effective up to 6.5 kHz and should be considered in the selection of this type of
connector
· The mass of the accelerometer and its mounting should have minimal influence on the
frequency response of the system over the selected measurement range.

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

· Measurement locations should be on a rigid member of the machine, as close to each


bearing (or fault source) as possible. Bearing housings, bearing pedestals, machine casings
or permanently mounted pickup mounting blocks are examples of suitable mounting
locations.

· 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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· Machine guarding prevents access to the data collection point

· 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:

§ Spectrum plot display


§ Waterfall plots
§ Phase angle
§ Time waveform display

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· Capable of resolution up to 12,800 lines


· Capable of in the field FFT analysis
· Capable of forced response ‘bump’ analysis
· Capable of displaying proximity probe, gap volts
· The collector should be certified for use in Zone 2 areas and have an ATEX 3G rating.
Preference should be to obtain certification also in accordance with IEC 679 for use in this
Zone.

5.2.6.2. Software Requirements

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.

The vibration database should be set up to include:


· A listing of all machines included in the program
· Identification of the locations where readings will be taken on each machine, with
identification of locations to match field labelling (refer Section 3.2.6.1)
· Identification of the directions (horizontal, vertical and axial) where readings will be taken on
each machine
· Identification of the non-vibration parameters that will be recorded during the vibration data
collection route including bearing temperature, speed (RPM), amps, pressures, flow rates,
etc.
· Alarm or warning levels for each measurement
· Details for "spectral" (FFT), time wave data needed for vibration analysis
· Organisation of equipment into workable groups or "routes" for data collection
· Identification of the bearing number/types and number of teeth / gear ratios in gearboxes
where possible.

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5.2.6.3. Offline Vibration Monitoring Locations

Monitoring Location Naming Convention


The following naming convention should be followed for all horizontally orientated machines: (Site Specific)

M 1 V

Element Position Measurement


Describes what part of the
Identifies where on that element Identifies the orientation of the
machine train is to be
to measure probe mount
measured
M – Motor
V – Vertical
P – Pump
Numbering convention starts at H – Horizontal
F – Fan
non-drive end of driver unit, and A – Axial
C – Compressor
increments moving away from VD – Demodulated
G – Gearbox this point. HD - Demodulated
E – Engine
T - Turbine X, Y – Shaft readings2

Table 4: Naming Convention for Horizontally Orientated Machines


Note: If the driver is in the middle of the machine train, the non‐drive end is considered the end with
the lowest pressure driven equipment. If this is not applicable, then a site specific convention should
be applied. In all cases where there is a driver in the middle of the machine train, labels should be
placed on the equipment at monitoring points to ensure the correct data is collected. In addition, if
there are multiple pieces of equipment in a string, number should continue into position 3 and above
(refer example in Figure 8)
The following naming convention should be followed for all vertically orientated machines:(Site Specific)

P 1 N

Element Position Measurement


Describes what part of the
Identifies where on that element Identifies the orientation of the
machine train is to be
to measure probe mount
measured
M – Motor
I – Inline (refer note)
P – Pump
Numbering convention starts at N – Not Inline (refer note)
F – Fan
non-drive end of driver unit, and A - Axial
C – Compressor
increments moving away from ID – Demodulated
G – Gearbox this point. ND – Demodulated
E – Engine
3
T - Turbine X, Y – Shaft readings

Table 5: Naming Convention for Vertically Orientated Machines


Note: Inline should refer to the recording location being in line with piping. For a fin‐fan, this means
in line with the tube runs of the exchanger.

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

M1H P1H P2H


M2H

Motor Pump

Figure 2: Monitoring Locations for Pump – Centrifugal Overhung

M1V M2V
P1V P2V

P1A
M2A

M1H P1H
M2H P2H

Motor Pump

Figure 3: Monitoring Locations for Pump – Centrifugal Between Bearings or Rotary

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With coupling Direct coupled

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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Fan and Pulleys


F1N

M2A
Fin Fan Support
Structure M2N

Cooler Tube run


M2I orientation

Motor M1N

M1I

Figure 5: Monitoring Locations for Fin Fan – No installed accelerometers

F2N

F2I F1A

JB F1N Fan and Pulleys

F1I
M2A

M2N

M2I

Motor M1N Cooler Tube run


orientation

M1I

Figure 6: Monitoring Locations for Fin Fan – with installed accelerometers

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M1V M2V

G1_ G4_
M2A
C1V C2V
G5_ G6_
M1H M2H
C1A
Motor

Gearbox C1H C2H

Driven machine

Figure 7: Monitoring Locations for a Compressor Train with Gearbox

M1V M2V
C1V C2V C3V C4V

M1A C3A
C2A

C1H C2H M1H


M2H
C3H C4H
LP Compressor Motor HP Compressor

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

Figure 9: Monitoring Locations for a Screw Compressor

C4V
C1V C3V
C5V
C2V
C1A
Driver

C1H C5H

C2H

Figure 10: Monitoring Locations for a Reciprocating Compressor (2 cylinders)4

Required Monitoring Locations


The selection of offline vibration monitoring locations should ensure that all known failure modes can
be detected and that the use of data collection and analysis resources is optimised. To achieve this,
equipment monitoring should be split into two categories:
1) Baseline / Fault: this level of monitoring will provide a complete picture of the machine condition
to enable setting of vibration alert levels and diagnosis of all known faults
2) Routine: this level of monitoring will provide indication of a fault but may not be able to
specifically diagnose the fault. If alert levels are reached on these monitoring locations, it can
trigger the collection of the Baseline / Fault data to enable complete diagnosis of the fault.

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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Equipment Baseline / Fault5 Routine (minimum)5

M1I, M1N M1I


M2I, M2N, M2A M2N, M2A
Fin Fan (Belt Drive with permanent
accelerometers) + all other remaining points + all other remaining points
with accelerometers with accelerometers
installed installed
G1H, G1V, G1A G1H
G2H, G2V G2V
Gearbox
G3H, G3V G3H
G4H, G4V, G4A G4V
C1H, C1V, C1A
C1H, C1V
6 C2H, C2V
Screw Compressor C3H, C3V, C3A
C3H, C3V, C3A
C1H, C1V, C1A
C1H, C1V
C2H, C2V
C2H, C2V
Reciprocating Compressor C3H
C4H, C4V
C4H, C4V
C5H, C5V
C5H, C5V
E1H, E1V E1H, E1V
Reciprocating Engine7 E2H, E2V, E2A E2H, E2V

Table 6: Offline Vibration Monitoring


Locations

5.2.6.4. Baseline Data Collection

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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5.2.7. Vibration Limits

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.

The following specific requirements should apply:


· Vibration levels for all new equipment should not exceed the zone A/B boundary as set in
ISO10816 2 through 6. Specific vendor deviations to these levels should be subject to
approval on a case by case basis by the Lead Rotating Equipment Mechanical
Engineer/Mechanical Superintendent as agreed with the Site Condition Monitoring Focal
Point.
· The starting value for all alarms should not exceed the zone B/C boundary, and all trips
should not exceed 1.25 x the C/D boundary (per ISO10816 2 through 6). Alarm and trip
settings may be reviewed and altered in accordance with facility change management
procedures once sufficient operating history is available.
· Where equipment does not fall under the definitions contained within these guidelines, the
Lead Rotating Equipment Mechanical Engineer/Mechanical Superintendent should approve
the new equipment acceptable vibration levels. Proposed levels may be in accordance with
ISO10816 1:1995 Annex B.

5.2.8. Vibration Condition Monitoring Competency

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:

Minimum Training Standard


Activity Minimum Training Standard
for Governance
ISO 18436-2 Level I (1) ISO 18436-2 Level II
Data Collection
OR equivalent OR equivalent
ISO 18436-2 Level II (2) ISO 18436-2 Level III
Data Analysis
OR equivalent OR equivalent1
Management of Condition ISO 18436-2 Level III
Monitoring Program OR equivalent1
1
Preferable but Level II plus 5 Years Condition Monitoring experience acceptable

Table 7: Vibration Condition Monitoring Competency Requirements


Notes:
1) Data may be collected by personnel with no formal qualification only if that person has been
informally trained in the field by a competent person (trained to ISO 18436 2 Level II). In
addition, a competent person should verify the quality of the data collected.

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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.

5.3 Oil / Fuel / Coolant Analysis

5.3.1. Oil Sampling and Analysis

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.

5.3.1.1. Oil Sample Collection Methods and Locations

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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5.3.1.2. Oil Sample Analysis for Rotating Equipment

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

Viscosity @ 40°C ASTM D7042 R R R


Viscosity @ 100°C ASTM D7042 O O R R (2)
Colour N/A O O O O
Elemental ASTM D6595
R (5) R (5) R (5) R (5)
spectroscopy
Particle count ST RK ISO 11500, R R R R
GOST 17216, GOST
ISO 4407
Setaflash if fail
Flash point O O R O (3)
ST RK ISO 2719
Diesel Fuel Dilution N/A N/A N/A R (6) N/A
Oxidation stability N/A
O R O R
(RBOT)
N/A
Conductivity O R O

Water content ST RK ISO 10336, ST R R R R (4)


RK ISO 10337

Soot Index N/A N/A N/A O N/A


Saponification N/A O
PQ Index N/A

Table 8: Oil Testing Requirements for Rotating Equipment


Notes:
1) For generators, the testing standard is ST RK 1744 or GOST 5985
2) For generators, the testing standard is ASTM D7042
3) For generators, the testing standard is GOST 4333
4) For generators, the testing standard is ST RK ISO 10336, ST RK ISO 10337
5) If the oil additive content is of interest an Infra-Red spectral analysis should be included
(RULER, tests normally only carried out on the turbine and compressor oil). The oil supplier
should be consulted when analysing oil additives.
6) Not applicable for gas fired engines

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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

2) On‐site Testing – N/A to KPO


Samples are collected and tested on site using commercially available test equipment. This method
should be used only for indicative readings where quick results are required. All results should be
verified through certified laboratory testing.
3) Online Testing– N/A to KPO
Specialty meters (e.g. particle counters), moisture meters and dielectric testers are installed in a
circulating system in order to capture “live” lubricant conditions. Consideration for such systems
should be made in the design phase of facilities where frequent regular test results are required.

5.3.1.3. Oil Sample Analysis for Transformers

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):

Test Test Standard Requirement

Moisture Content – Water by Karl ST RK ISO 10336, ST RK ISO 10337 R


Fischer
Oil dielectric strength test (1) GOST 6581 KPC Chemical Lab
does not perform this
analysis

Transformer oil level, temperature and


N/A R
pressure
A Buchholz relay will monitor oil
bubbles caused by high temp / N/A R
electrical breakdown
Power Factor N/A O
Total Acid Number ST RK 1744 or GOST 5985 O

Total Base Number GOST 11362 or GOST 30050 O

Interfacial Tension N/A O


Dissolved Gas Analysis (DGA) N/A R
Elemental Analysis ASTM D6595 O

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Particle Count ST RK ISO 11500, GOST 17216, O


GOST ISO 4407
Colour N/A O
Check for PCB’s in Chromatography IEC 60926 KPC Chemical Lab
does not perform this
analysis

Table 9: Oil Testing Requirements for Transformers

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.

5.3.1.4. Oil Analysis Data

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.

5.3.1.5. Magnetic Chip Detectors

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.

5.3.2. Grease Analysis

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

Water content ST RK 1314

Table 10: Grease Analysis Requirements

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5.3.3. Diesel Fuel Analysis

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

Particulate Contamination/ GOST 6370 O R R


mechanical impurities

Appearance Visual Inspection O R O


Colour N/A
Density ST RK ISO 12185 O R O
Bacteria / Fungal Growth N/A R O (1) O
Distillation Range GOST 2177, O O O

ST RK 2423

Table 11: Diesel Fuel Analysis Requirements


Notes:
1) Testing for bacterial and fungal growth is only required where the turnover of fuel is greater than
6 months.

5.3.4. Coolant Sampling and Analysis

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):

Test Standard Requirement

Corrosion Products, Molybdate and N/A


R
silicate inhibitors
Buffer and Inhibitor Levels, N/A
Contamination and breakdown R
products
Glycol Content N/A R

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pH of Coolant ASTM D1287 O


Total Dissolved Solids N/A O

Table 12: Coolant Analysis Requirements

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:

Minimum Training Standard


Activity Minimum Training Standard
for Governance
ICML Level II Machine
Sample Collection (1) Lubricant Technician / Analyst
OR equivalent
ICML Level II Machine ICML Level III Machine
Sample Analysis Lubricant Technician / Analyst Lubricant Analyst
OR equivalent OR equivalent
ICML Level III Machine
Management of Oil Analysis
Lubricant Analyst
Program
OR equivalent
Table 13: Oil Condition Monitoring Competency 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.

5.4 Infrared Thermography and Temperature Monitoring

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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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.

5.5 Motor Current Signature Analysis

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.

5.5.1. Current-Voltage Signature Analysis

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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5.6 Partial Discharge Monitoring

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.

5.7 Circuit Breaker Timing Analysis

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:

· Motor Manager Relay


· Feeder Manager Relay

5.8 HV Generators Insulation Assessment

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.

5.9 New Technology

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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· Earlier detection of faults


· Introduce fault detection capability of previously unmonitored failure modes.

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.

5.10 Selection of condition monitoring methods

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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5.11 Methodology for Setting the Monitoring Interval

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.

Condition Monitor Repair or Replace Unusable


Functional Performance

New
Condition Defect
Detected,
(P-point)
Impending
Failure
(F-point)

Data Collection

Failure

Time

Figure 11: P‐F Curve


The monitoring interval should be sufficient to detect the fault prior to reaching the F‐point and allowing
sufficient time to properly plan for a repair, or put strategies in place to extend the time to failure (e.g.
through changes to loading of the equipment). The minimum interval should generally allow for at least
two data collections before reaching the failed condition. This allows for the impending failure to be
confirmed prior to putting repair or replacement plans in place.
It is acceptable to use the criticality (based on cost of repair and time to plan for a repair) to influence
the monitoring frequency, so long as there is a minimum of 1 data collection activity prior to reaching
the F‐ point. Larger more critical machines may require a longer period to plan for the repair and the
impact on production may be greater. In this situation, making certain that the fault is detectable with
sufficient time to plan the repair is extremely important. For less critical equipment, with a lower overall
value, there may not be a cost benefit of monitoring frequently to enable repair planning, but there may
be a cost benefit in monitoring less frequently purely to ensure that the equipment does not
catastrophically fail, resulting in a complete replacement rather than a repair.
Understanding the exact P‐F curve for a given piece of equipment requires extensive operating,
maintenance and failure data for that equipment. For a new asset, where this

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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.

5.12 Frequency for Condition Monitoring Activities

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.

5.12.1. Frequency for Offline Vibration Monitoring

In line with the methodology described in Section 5.1, vibration data should be collected and analysed
in accordance with the table below:

Minimum Monitoring Tolerance


Initial Monitoring
Equipment Frequency (running between readings
Frequency
equipment)
Safety Critical
1 month 2 months 1 week
Equipment
Process critical
1 month 2 months 2 weeks
equipment
Non-process critical
2 months 3 months 2 weeks
equipment

Table 14: Frequency for Offline Vibration Monitoring


It is recommended that in the absence of any overarching KPO Spared Equipment Operating and
Switchover Strategy that equipment that is spared should be switched over to collect performance data
and mitigate against false brinneling where applicable.. The minimum data collection frequency for the
spare unit should generally not be less than twice the current monitoring frequency (e.g. if the
monitoring frequency is 2 monthly, the offline spare unit will need to be operated at month 4 for data
collection). Where the implementation of this would require specific equipment starts, a basic risk
assessment should be completed to delay collection until the equipment is started per the schedule.
For safety and process critical equipment accumulating run hours, data should be collected at least
once per 6 months. For process critical equipment operating as a permanent standby with no false
brinelling risk, data should be collected at least once per three months or at a frequency which is
evaluated on a case by case basis.
Equipment that is operated intermittently should be started to allow collection of condition data in line
with the minimum monitoring frequency. Safety or process critical equipment which is routinely
operated for function testing is to be monitored in alignment with function testing activities.

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5.12.2. Frequency of Oil / Diesel / Coolant Sample Collection

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

Table 16: Frequency for Diesel Sample Analysis


Where coolant sampling and lab analysis is specified in the maintenance strategy, it is recommended
that it should be completed at the following frequencies:

Minimum Monitoring Tolerance


Initial Monitoring
Equipment Frequency Between
Frequency
Readings
Continuous Operation 6 months 12 months 2 weeks
Intermittent Operation 12 months 12 months 2 weeks

Table 17: Frequency for Coolant Sample Analysis

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5.12.3. Frequency of Thermography

Where routine thermography or offline temperature monitoring is specified in the


maintenance strategy, it should be completed at the following frequencies:

Initial Monitoring Minimum Tolerance between


Equipment
Frequency (3) Monitoring readings

Transformers 12 months 24 months 2 weeks (4)


Other Electrical
12 months 24 months (3) 2 weeks
Equipment
Heat Exchangers 12 months 24 months (2) 2 weeks
Rotating Equipment (1) (1, 2, 3)

Table 18: Frequency for 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).

5.12.4. Frequency for Electrical Equipment Monitoring

Where offline motor current signature analysis is required, it should be completed at the following
frequencies:

Initial Monitoring Minimum Monitoring Tolerance


Equipment
Frequency Frequency between readings
HV Motors 12 months 12 months 2 weeks
LV Motors 12 months 12 months

Table 19: Frequency for MCSA


Where partial discharge testing is specified in the maintenance strategy, it should be
completed at the following frequencies:

Initial Monitoring Minimum Monitoring Tolerance


Equipment
Frequency Frequency between readings
Generators 12 months 48 months 2 weeks
Motors 12 months 48 months 2 weeks
Transformers 12 months 48 months 2 weeks
Switchgear 12 months 48 months 2 weeks
Cables Fault finding only

Table 20: Frequency for Partial Discharge Testing


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5.13 Implementation of condition monitoring

5.13.1. Offline Vibration Data Collection

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:

Category Description Action

Immediate notification of Operations


Significant fault detected Control
5 requiring prompt Room if urgent equipment shutdown is
maintenance intervention to required.
avoid secondary damage Prompt notification of engineering focal
point and production supervisor
Raise maintenance work order in
CMMS
Fault detected requiring Raise work order in CMMS
4
maintenance intervention Notification of engineering focal

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Fault or abnormality No action, include evaluation in


3
detected requiring ongoing vibration monitoring reports.
2 monitoring
Equipment in good condition (Increase
No action frequency)
required )?
Confirm equipment will be available for
data collection at next scheduled
1 Data not able to be collected
collection date. If not, make
arrangements to ensure equipment is
operating.
Table 21: Fault Condition Categories
Once the corrective maintenance activity has been raised (Fault Condition Category 4 & 5) in
the CMMS, the Production and Maintenance staff will further evaluate the production risk and
maintainability to rank and schedule the corrective actions accordingly. It should be noted that
this evaluation will be dependent on current operating factors, spares availability, redundancy,
etc. which will continuously change.
Where an integrated service Contractor is used to report on vibration results, they may
propose an alternative reporting category definition which should be approved by the site
Engineering Focal Point. This approach should only be accepted where a vibration monitoring
system reporting tool has been approved for use and already has predetermined reporting
fields.

5.13.2. Online Vibration System Monitoring and Review

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.

5.14 Implementation of Oil / Diesel / Coolant Condition Monitoring

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.

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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.

In addition, the following should be included for transformers:


· All testing of transformers should observe the safety protocol and requirements
· Strict control of any items that could conduct or attract an electric charge (i.e.
metallic items) should be assessed prior to entry of the transformer area.

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.

5.15 Reporting of Condition Monitoring Results and Analysis

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.

5.15.1. Contractor Weekly Reporting


To ensure that the Company has a regular update of plant status and Contractor activities, a
weekly condition monitoring report should be produced. This report should contain the
following information:

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· 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.

5.15.2. Monthly Reporting

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

c. Recommendations for rectification and improvements

d. Plots (any combination of detailed trends, spectrums, time weighted


frequencies, waterfall plots and detailed comparison plots)

e. Incorporation of thermographic images and oil analysis results

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

c. Date due for next data collection / sample

d. Calibration certificate reference for equipment used

e. Work request numbers

4) Online monitoring system reviews, including:


a. System alarms and issues

b. A detailed description of the analysis and results for each


equipment in the online system that was reviewed.

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.

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5.16 Review of the condition monitoring program

5.16.1 Review Methodology

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.

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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?

5.16.2 Post Start-Up Review

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.

Table 22: Post Start‐Up Condition Monitoring Reviews

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.

5.16.3 Normal Operation Review

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.

5.16.4 Post Failure Review

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

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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)

5.16.5 Alarm and Alert Reviews

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.

5.17.1. Activity Level Assurance

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

The following additional audits should be completed:

Audit Frequency Responsible


Check CMMS activity closeout against CM data-
Condition Monitoring
base information for consistency. Coverage to 12 months
Focal
include vibration, oil and thermography.
Point
Competency of Contractor personnel should be Condition Monitoring
12 months
verified through a review of training records Focal
Point
At
Gap analysis between the standard and actual site Condition Monitoring
document
activities Focal
review
Point
frequency
Gap analysis between the maintenance strategy,
24 months Reliability Engineer
CMMS, and condition monitoring program.

Table 23: Auditing requirements against this standard

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6. PROCESS FLOW DIAGRAMS/PROCESS MAPS


Nil

7. APPENDICES
Nil

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