Best Practice

SABP-G-023 11 May 2015

Recommended Setup for Existing Online Condition Monitoring System for
Rotating Machinery
Document Responsibility: Consulting Services Department

Saudi Aramco DeskTop Standards

Table of Contents
1 Introduction....................................................... 2
2 References...................................................... 2
3 Definitions......................................................... 3
4 System Configuration....................................... 4
5 Data Storage…………….................................. 6
6 Data Display………………............................... 6
7 CMS Reports……………….............................. 7
8 Acess to CMS.……………............................... 7
9 CMS Maintenance.………................................ 8
Appendix-A: Recommended Tagging Procedure..... 9
Appendix-B: Typical Machine Diagram and
Instrument Designations......................................... 10
Appendix-C: Recommeded Maximum Frequency. 11
Appendix-D: Sampling Requirements……............. 12

Previous Issue: New Next Planned Update: May 2018

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Primary contact: Khaleel M Al-Hussain or Ali Al-Shurafa at 966-3-8809720

Copyright©Saudi Aramco 2015. All rights reserved.

Document Responsibility: Consulting Services Department SABP-G-023
Issue Date: 11 May 2015
Next Planned Update: 11 May 2018

1 Introduction

This best practice defines the minimum requirements governing the setup and
configuration of existing online Condition Monitoring System (CMS) for rotating
machinery.

1.1 Scope

This best practice identifies the required input data, configuration requirements
and monitoring method, intervals, parameters, and configuration to effectively
use the CMS system in proactive asset management and Root Cause Analysis.
The requirements of 34-SAMSS-625 supersede this best practice. The
implementation of a CMS should not be in any way compromise or interfere
with the function of machinery protection. This best practice should not be
attached to or made part of purchase orders.

1.2 Disclaimer

Although this Best Practice is not mandatory, it does not relieve plants from the
responsibility or duty to confirm and verify the accuracy of any information
presented herein. The use of this information or material does not guarantee
results that will satisfy all online condition monitoring systems for rotating
machinery. CSD assumes no responsibility or liability for misuse of information
in this document.

1.3 Conflicts

In the event of a conflict between this Best Practice and other Mandatory Saudi
Aramco Engineering/Business Requirement, the Mandatory Saudi Aramco
Engineering Requirement shall govern.

2 References

The latest edition of the following references are applicable to this best practice.

2.1 Saudi Aramco Standards

Saudi Aramco Engineering Procedure
SAEP-302 Instructions for Obtaining a Waiver of a
Mandatory Saudi Aramco Engineering
Requirement
Saudi Aramco Engineering Report
SAER-5659 Guidelines for Setting Acceptable, Alarm and
Shutdown Vibration Limits

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Document Responsibility: Consulting Services Department SABP-G-023
Issue Date: 11 May 2015
Next Planned Update: 11 May 2018

Saudi Aramco Best Practices

SABP-Z-030 Wireless Process Remote
Monitoring and Control Using SMS
SABP-G-011 Air cooled fin fans

2.2 Saudi Aramco Engineering Standard

SAES-J-604 Protective and Condition Monitoring Equipment

for Rotating Machinery

SAES-Z-010 Process Automation Networks Connectivity

34-SAMSS-625 Machinery Protection Systems

2.3 Industry Codes and Standards

API STD 670 Machinery Protection System

3 Definitions

3.1 Condition Monitoring System (CMS) - A computer based information

processing system which communicates to the machine protection system and to
other plant monitoring data acquisition systems like DCSs. The CMS computer
collects, stores, processes, displays and prints the machinery management data
in a variety of formats. This data will be typically used for historical trending,
machinery diagnostics and predictive maintenance purposes, not for machine
protection.

3.2 Vibration Monitoring System (VMS) – An online system that senses, measures,
monitors and displays machine parameters (vibration and axial position)
indicative of its operating condition. When parameter exceeds predefined limits,
indicating abnormal condition, the system will communicate the events to
operator and/or shutdown system.

3.3 Critical Machinery – Rotating equipment sensitive to production or safety

including turbines, electric driven pumps, compressors or generators handling
combustible, flammable or toxic materials. Process critical equipment also
includes rotating equipment that is categorized as critical by a process hazards
analysis or potential production loss. Equipment criticality is defined by the
equipment owner.

3.4 Owner - The final recipient and end user of the CMS platform (typically a
senior rotating equipment specialist in the plant reliability team).

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Document Responsibility: Consulting Services Department SABP-G-023
Issue Date: 11 May 2015
Next Planned Update: 11 May 2018

3.5 Steady State - Machine condition during running at a constant operating

condition (typically with minor speed changes). In this operating mode CMS is
collecting data based on delta time and/or delta amplitude, alarm activation or
when meaningful change in data pattern is detected.

3.6 Transient - Machine condition during changing speed due to startup, shutdown
or process change leading to a significant speed change. In this operating mode
CMS begins to collect data based on delta rpm and delta amplitude.

3.7 Transducers that convert mechanical motion to an electrical signal thereafter

processed by VMS.

3.8 Static Data - Data that describes the quantitative characteristic of the measured
parameter with a singular value such as for vibration overall magnitude, phase
angle, gap, shaft speed etc. This data is used to create simple plots like Trend
Plots and tabular lists.

3.9 Dynamic Data - Data that represents the dynamic characteristics of the measured
variable and cannot be represented by a singular value. This data is used to
create complex plots such as timebase waveform, spectrums, orbits etc.

4 System Configuration

The following information should be prepared based on rotating equipment

specifications and VMS considering applicable docuents such as machine’s drawings,
P&ID, ILD, ESD set points.

4.1 Machine name, description and complete tag. For example: R84-GM-801B Sea
Water Intake Pump Motor.

4.2 Machine train diagram: The machine diagram should display the train
configuration (layout), machine name, sensing element location/orientation and
the overall engineering values and units for each measurement point. The
CMS’s machine trains diagram are drawn as close as possible to the DCS view
with additional diagnostic details.

4.3 Make sure all transducer loops are tagged to avoid swapping problems and to
ease troubleshooting in the future. Tagging should match machine P&ID/ILD
and validated physically on site. Identification of measurement type and
physical locations is essential. The identification should indicate the probe tag
and description of the physical location for example: R91-S9-XVE-1012A
(Pump I/B Horizontal). Tagging procedure is summarized in Appendix-A.

4.4 Orientation and relative transducer position (e.g. Horizontal 45o) need to be
specified and checked physically. Ensure speed sensor association to appropriate

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Document Responsibility: Consulting Services Department SABP-G-023
Issue Date: 11 May 2015
Next Planned Update: 11 May 2018

points is checked (not swapped) in situations where a VMS rack may have two
seeds sensors or more. The direction of rotation needs to be specified and
confirmed physically. Appendix-C shows typical machinery vibration
instrumentation including: Tagging, identification, location, orientation,
rotation.

4.5 Thrust position reading, reading range and its polarity must reflect the
anticipated normal thrust direction.

4.6 For the temperature points connected to the CMS, the user needs to clearly
identify the actual sensing point on the field as it is a source of misinterpretation.
For example, the temperature on the NDE of a compressor could be on the radial
bearing pad, on the active thrust bearing par, inactive thrust bearing pad or in the
lube oil drain.
4.7 The sampling for the trend plot (static data sampling) during normal steady state
machine operation (no alarms) shaould be based on a system assessment of
meaningful change of each data value being received from the VMS or a
minimum/maximum time elapsed since last stored sample i.e. If a meaningful
change in amplitude is observed then such sample should be always stored,
otherwise CMS will store only at the minimum/maximum intervals specified. A
typical delta apmplitude is 2-5% of the full scale of the point being measured.
Dynamic data shall be stored at least 4 times a day when the machine is at a
normal condition (below alarm).
Data collection cases:
 Dela time exceeded: new data collected.
 Dela time not exceeded and delta amplitude <2% of scale  No
datacollection.
 Dela time not exceeded and delta amplitude >2% of scale  New data
collected.
4.8 The CMS Synchronous sampling for waveform data should not be less than 64
samples per revolution for normal speed machines (<15,000 rpm) and 16
samples per revolution for high speed machines (>15,000 but 60,000<). The
Asynchronous Spectrum maximum frequency should be selected carefully to
optimize spectrum resolution and the time base plots while covering key
expected failure mode frequencies. Typical values are shown in Appendix-C:
Anticipated Maximum Frequencies and Appendix D: Sampling Requirements.

4.9 Data should be permanently stored on all configured alarm levels and for
transient data events (Startup and Shutdown). During transient condition the ∆
RPM data collection rate should not be less than (Max Speed/300).

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Document Responsibility: Consulting Services Department SABP-G-023
Issue Date: 11 May 2015
Next Planned Update: 11 May 2018

4.10 Software alarms are highly encouraged to set to obtain the real benefits of the
CMS. These alarms give early warnings on faults and can be tailored to
parameters that are not available to operations. These alarms are not
automatically communicated to operations. Software alarms may be configured
for any channel and any variale of the channel such as for Direct, 1X, and gap
variables. Following are typical examples:
 Gap voltage: +/- 2 Vol from the normal gap
 Direct (overall) amplitude: 80% of alarm and 80% of shutdown set points
 Filtered amplitudes for 1X, 2X and other key components: 80% of alarm
4.11 Any CMS configuration change should follow a documented change
management approach to ensure all systems changed are tracked and approved
by “the owner”.

4.12 Data Storage for Transient Condition (Start-up & Shutdown): Coastdown and
start-up at a rate of every 50 rpm or less.

5 Data Storage:

 Data should be retained for at least 5 years. All data collected should be stored.
 Server hard disk and space availability must be annually checked by the owner in
order to take proper action before the spaces is fully occupied.

6 Data Display

6.1 Each plot should indicate the selected measurements point, specified period of
time, measurement point location, orientation, historical range, measurements
value and units. The plot should also indicate all alarm and trip limit.

6.2 Alarm/System event list: CMS should be used to view specific events and its
severite such as alarms, machine startup and shutdown speed transients,
software connections, and instrument communications .

6.3 Time Waveform and Orbit: Time waveform should display measurement point,
date and time, overall amplitude, 1x amplitude, speed and direction of rotation.
The highest quality time base and orbit plots should be selected with
maintaining high-resolution spectrum plots. The display should be selected to
display not less than 4 revolutions. The time base plots should include the
following:
 Time waveform plots of unfiltered data;
 Time waveform plots of time synchronous averaged data (filtered and/or
unfiltered);

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Document Responsibility: Consulting Services Department SABP-G-023
Issue Date: 11 May 2015
Next Planned Update: 11 May 2018

 Orbit plots of unfiltered data;

 Orbit plots of synchronous (1X, 2X) or running speed data;
 Time synchronous averaged orbit plots;
 Runout compensation capabilities for synchronously sampled data (i.e. slow-
roll compensation, thermal bow, etc.).
6.4 Frequency domain plotting:
 Frequency spectra in which linear amplitudes, accelerations, velocities, or
displacements are plotted versus linear frequency expressed as cycles per
second (Hz).
 Waterfall plots with at least 50 spectra plotted versus time.
 Cascade plots with at least 50 spectra plotted versus speed.

6.5 Transient plot should be saved for all transient events for overall, 1x & phase
and 2x & phase. The transient plots include:
 Bode plot for speed-transient data.
 Polar plots for speed-transient data.

6.6 Shaft centerline plots, polar plot of shaft centerline position within bearing.
Shaft Centerline plot should be configured to show the bearing clearances and a
manual sample should be collected before startup of the machine to reference
shaft zero position. The shaft centerline should be plotted with respect to time
and RPM, separately. During the analysis of special fluid film bearing types
(e.g. lemon) necessary additional data (e.g. clearances in both directions) should
be provided.

7 CMS Reports
Generating reports is recommended to be done by the owner to list the machines with
any abnormal status on a regular basis (weekly or monthly based on the population of
the equipment covered in the CMS). This report is a competently part of the routine
report generated from the offline data collection systems for high vibration cases. The
proactive action based on software alarm triggered by the CMS is a fundamental benefit
from the system and should be emphasized.

8 Access to CMS
The server on which the CMS application resides is critical and shall have a limited
access only to the users and administrator (usually the DCS/control engineer). The
department owning the system shall provide an internal control procedure for both user
types: Administrator and Display User. No configurations changes can be made through
the display users.

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Document Responsibility: Consulting Services Department SABP-G-023
Issue Date: 11 May 2015
Next Planned Update: 11 May 2018

9 CMS Maintenance
The department owning the system shall establish a procedure for the maintenance
required on both hardware and software. The hardware includes the server and any
interfacing parts. The software includes the updates and fixing problems. An annual
assessment for both hardware and software is recommended.

Revision Summary
11 May 2015 New Saudi Aramco Best Practice.

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Document Responsibility: Consulting Services Department SABP-G-023
Issue Date: 11 May 2015
Next Planned Update: 11 May 2018

Appendix A: Recommended Tagging Procedure

Figure 1

Point Tagging:

All transducers loops shall be tagged to prevent swapping.

Tagging shall be in accordance to P&ID.

Example: LP Compressor_ K002

 1, 2 and 3: Point ID: VXE-343A-Y

 4: Junction Box ID: JB3_LP_K002
 5: Field Wiring ID:
o VT-_VXE-343A-Y
o COM_VXE-343A-Y
o OUT_VXE-343A-Y

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Document Responsibility: Consulting Services Department SABP-G-023
Issue Date: 11 May 2015
Next Planned Update: 11 May 2018

Appendix-B: Typical Machine Diagram and Instrument Designations

Figure 2
 Normal Thrust Direction

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Document Responsibility: Consulting Services Department SABP-G-023
Issue Date: 11 May 2015
Next Planned Update: 11 May 2018

Appendix-C: Recommended Maximum Frequencies

Shaft Relative Motors or

Rolling
Machine Type Gearbox Pumps Fans
Bearings
(Prox. Probe) Generators

Measurement Unit mils pk-pk G’s RMS in/sec RMS in/sec RMS in/sec RMS in/sec RMS

F-max
12 x RPM 3 x GM 5 x BPFI 3 x VP 3.5 x 2 LF 3 x BP

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Document Responsibility: Consulting Services Department SABP-G-023
Issue Date: 11 May 2015
Next Planned Update: 11 May 2018

Appendix-D: Sampling Requirements

Spectra sampling requirements shall be as follows:

 Minimum of 400 spectral lines shall be used for start-up or coast-down recordings (cascade
and waterfalls).
 Minimum of 800 spectral lines shall be used for steady state spectra measurements.
 Fmax for proximity probes shall provide resolution no less than 2.5 Hz.
 For standard vibration measurements, linear averaging with six averages shall be used.
 The sample rate is automatically determined through the selection of the frequency range
and the resolution.

Example:
Fmax = 2,000 Hz.
No. of lines = 800
No. of samples required, N = 2.56 x 800 = 2,048 (A/D = 2,048)
Resolution, df = Fmax / #lines = 2,000/800 = 2.5 Hz.

Waveform Sampling Recommendations

The system should be capable of both synchronous and asynchronous sampling. Synchronous
sampling should have the following:

 No less than 100 sample points per revolution at full speed

 No less than 8 revolution sample length
 X and Y probes simultaneously sampled with phase reference
 Band-pass filtering available for 1/2X, 1X, 2X, and 3X shaft speed.

Example:
A motor of 3600 rpm shall have a dlta rpm =FS/300 = 12 rpm

This means a total of 300 samples will be colelcted during the start up from 0-3600 rpm
with speed change of 12 rpm.

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Document Responsibility: Consulting Services Department SABP-G-023
Issue Date: 11 May 2015
Next Planned Update: 11 May 2018

Acknowledgement
CSD wishes to acknowledge the support of the following subject matter experts for their guidance and
comments:
Ali M. Al-Shurafa
Mamdouh Al-Aidarous
Fathi I. Al-Salem
Hadi A. Al-Qahtani
Mokhtarudin Abdul Razak

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