Engineering Procedure
SAEP-414 2 February 2017
Configuration of Online Condition
Monitoring Systems for Rotating Machinery
Document Responsibility: Vibration and Lubrication Standards Committee
Contents
1 Scope ................................................................ 2
2 Applicable Documents ....................................... 2
3 Definitions and Acronyms .................................. 3
4 System Applications .......................................... 5
5 System Deployment ........................................... 5
6 System Configuration ........................................ 6
7 Data Storage...................................................... 7
Revision Summary................................................... 8
Appendix I - Minimum Required
Machinery Design Information ...................... 9
Appendix II - Anticipated Maximum Frequencies ... 10
Previous Issue: New Next Planned Update: 2 February 2020
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Contact: Aidarous, Mamdouh B. (aidaromb) on +966-13-8809718
©Saudi Aramco 2017. All rights reserved.
Document Responsibility: Vibration and Lubrication Standards Committee SAEP-414
Issue Date: 2 February 2017 Configuration of Online Condition
Next Planned Update: 2 February 2020 Monitoring Systems for Rotating Machinery
1 Scope
This procedure defines the minimum mandatory requirements governing the setup
and configuration of Condition Monitoring System (CMS) for existing rotating
machinery and for rotating machinery under commissioning. The user of this procedure
would be able to identify the required input data, configuration requirements and
monitoring method, intervals, parameters and configuration to effectively utilize the
CMS system. CMS is considered distinct and separate from the Vibration Monitoring
System (VMS). Although the CMS and VMS may be installed together or may even be
integrated with one another, the requirements in this standard do not in any way
supersede or eliminate the requirements of the 34-SAMSS-625 “Machinery Protection
System.” The implementation of a CMS shall not be in any way compromise or
interfere with the function of machinery protection. This document focuses only on the
vibration part of the CMS.
Note: This document cover only continuous CMS data collection. CMSs that collect periodic
data or share processing hardware for multiple measuring points are not a part of this
procedure.
2 Applicable Documents
The latest edition of the following references shall be used as applicable and referenced
within the body of this standard document. The selection of material and equipment,
and the design, construction, maintenance, and repair of equipment and facilities
covered by this standard shall comply with the latest edition of the references listed
below, to the extent specified herein.
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 Standards
SAES-J-604 Protective and Condition Monitoring Equipment for
Rotating Machinery
SAES-Z-010 Process Automation Networks
Saudi Aramco Materials System Specification
34-SAMSS-625 Machinery Protection Systems
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Document Responsibility: Vibration and Lubrication Standards Committee SAEP-414
Issue Date: 2 February 2017 Configuration of Online Condition
Next Planned Update: 2 February 2020 Monitoring Systems for Rotating Machinery
Saudi Aramco Best Practice
SABP-Z-030 Wireless Process Remote Monitoring and Control
Using SMS
Saudi Aramco Engineering Report
SAER-5659 Guidelines for Setting Acceptable, Alarm, and
Shutdown Vibration Limits
2.2 Industry Codes and Standards
American Petroleum Institute
API STD 670 Machinery Protection Systems
3 Definitions and Acronyms
3.1 Definitions
Condition Monitoring System (CMS): A computer based data processing
system which communicates with machine protection system and/or with other
plant monitoring data acquisition systems like DCS. CMS collects, stores,
processes, displays and prints the machinery management data in a variety of
formats. This data are typically used for historical trending, machinery
diagnostics and predictive maintenance purposes, not for machine protection.
System users include: Rotating machinery engineers, reliability engineers and
vibration technicians.
Continuous Monitoring: Data is collected and analyzed at all the time by the
system to detect and save data for parameters existing the predefined normal
range.
Dynamic Data: Data which contains that part of the transducer signal that
represents the dynamic characteristics of the measured variable and cannot be
represented by a singular value and is used to create complex plots such as time
base waveform, spectrums, orbits, etc.
Owner: The final recipient and end user of the CMS platform (typically a
senior rotating equipment specialist in the plant reliability team).
Periodic Monitoring: Data is collected and analyzed at predefined intervals
(typically in minutes or hours) by the system to detect and save data for
parameters existing the predefined normal range. This type of monitoring is
usually installed on less critical machines. The standard should specify when to
use this type of requirement.
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Document Responsibility: Vibration and Lubrication Standards Committee SAEP-414
Issue Date: 2 February 2017 Configuration of Online Condition
Next Planned Update: 2 February 2020 Monitoring Systems for Rotating Machinery
Process Critical Equipment: Rotating equipment including turbines, electric
driven pumps, compressors or generators handling combustible, flammable or toxic
materials and use drivers equal to or greater than 1,000 HP. Process critical
equipment also includes rotating equipment that is categorized as critical by a
process hazards analysis.
Static Data: Data that describes the quantitative characteristic of the measured
parameter with a singular value such as for temperature, pressure, vibration
overall magnitude, shaft speed, etc. This data is used to generate simple plots
like trend plots and tabular lists.
Steady State: Machine condition during running at a constant operating
condition. 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.
Technical Support Agreement (TSA): A contractual agreement between the
Owner and CMS supplier to provide aftersales services (e.g., free upgrade
patches, onsite system optimization) included in the agreement.
Transient Condition: In this document, transient is strictly for machine speed
change during startup or shutdown.
Vibration Monitoring System (VMS): An online system that senses,
measures, monitors and displays machine parameters indicative of its operating
condition. When parameter exceeds predefined limits, indicating abnormal
condition, the system will communicate the events to operator and/or emergency
shutdown system.
3.2 Acronyms
1X: Vibration at running speed is referred as 1X (=RPM/60) fundamental
component
BPFI: Ball Pass Frequency Inner Race (inner race defect frequency)
BPF: Blade Pass Frequency
CMS: Condition Monitoring System
CSD: Consulting Services Department
DCS: Distributed Control System
DE: Drive End
GMF: Gear Mesh Frequency
I/B: Inboard
LF: Line Frequency (60 Hz)
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Document Responsibility: Vibration and Lubrication Standards Committee SAEP-414
Issue Date: 2 February 2017 Configuration of Online Condition
Next Planned Update: 2 February 2020 Monitoring Systems for Rotating Machinery
NDE: Non-Drive End
O/B: Outboard
Pk: Peak
PMT: Project Management Team
P&ID: Piping and Instrumentation Diagram
RCA: Root Cause Analysis
RMS: Root Mean Square
RPM: Revolutions per Minute
TSA: Technical Support Agreement
VDC: Volts Direct Current
VMS: Vibration Monitoring System
VPF: Vane Pass Frequency
4 System Applications
4.1 CMS is not a mandatory standard requirement but it is essential to be installed
on critical machinery equipped with shaft relative transducers and phase
reference transducer (equipped with VMS) to enable proactive asset
management and diagnostic capability upon event occurrence.
4.2 The Project Management Team (PMT), proponent organization with the approval
of the Vibration and Lubrication Standards Committee Chairman shall determine
which rotating machinery, if any, recommended to be equipped with CMS.
Note: The primary target for CMS is the officially classified “A” equipment as defined
by the proponent. Other equipment can be added to the CMS after an
evaluation is conducted by the proponent and/or CSD. The CMS will be less
effective for machineries that are not equipped with phase reference transducer
or equipped only with seismic (casing) transducers, with limited functionalities,
i.e., without transient data or direct shaft motion representation.
5 System Deployment
5.1 PMT shall provide the CMS supplier with the all necessary machinery
configuration and machinery specifications/design information prior to
commissioning stage. The alarms in the CMS and resulting actions desired shall
be documented as part of the vendor documentation package. Appendix I
outlines the minimum required machinery information to be provided for proper
system configuration.
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Document Responsibility: Vibration and Lubrication Standards Committee SAEP-414
Issue Date: 2 February 2017 Configuration of Online Condition
Next Planned Update: 2 February 2020 Monitoring Systems for Rotating Machinery
5.2 PMT shall arrange for the system owner engineers/technicians all the necessary
training to be able to maintain and utilize the system professionally after
commissioning of the system ensuring plant teams are fully capable to run day
to day proactive activities.
5.3 The CMS asset owner shall regularly update the CMS software and maintain the
system functionality in regular basis. The maintenance shall include but not
limited to: the server, hardware, data backup, configuration backup,
configuration editing procedure, software backup, server hardware upgrades,
server Operating System upgrades, software version update, software
compatibility with company upgrades, etc.
5.4 Every effort shall be made to maintain all CMS servers at the same hardware /
software generation allowing ease of maintenance and consistency of user
experience.
6 System Configuration
The following information shall be prepared and made part of the CMS by the Supplier
based on equipment specifications, machine P&ID and documents provided by the
proponent:
6.1 Prior to CMS installation, a VMS review is mandatory to ensure the hardware
compatibility and capabilities to communicate with the CMS.
6.2 All CMS configurations files shall be approved by the asset owner before
implementation. The configurations are supplied in a spreadsheet for all
configurable fields in the CMS employed.
6.3 Machine tag (as per P&ID) and name shall be clearly defined (use two fields if
needed), for example: R84-GM-801B Motor.
6.4 Machine train diagram: The machine diagram shall display the train
configuration (layout), machine name, sensing element location/orientation and
the overall engineering values and units for each measurement point.
6.5 All transducer loops shall be verified to avoid swapping problems and to ease
troubleshooting in the future. The identification shall indicate the probe tag
(as per P&ID) and description of the physical location (use two fields if needed),
for example: R91-S9-XVE-1012A (Pump DE Horizontal).
6.6 Orientation of each transducer position (as per API STD 670) need to be
specified and checked physically during commissioning. Ensure phase
reference transducer association to appropriate points is checked (not swapped)
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Document Responsibility: Vibration and Lubrication Standards Committee SAEP-414
Issue Date: 2 February 2017 Configuration of Online Condition
Next Planned Update: 2 February 2020 Monitoring Systems for Rotating Machinery
in situations where a VMS rack may have two speeds sensors or more.
The direction of rotation needs to be specified and confirmed physically.
6.7 Thrust position reading, reading range and its polarity must reflect the
anticipated normal thrust direction.
6.8 Data shall be permanently stored on all configured alarm levels and for transient
data events (Startup and Shutdown). During transient condition the ∆ RPM data
collection rate shall not be less than (Max Speed/300) and capable of sampling
till (Max Speed /1,000) if so desired for hi-resolution capture.
6.9 The software alarm shall initially be set up to 25% above the machine
acceptance limit as a starting point, which shall be later optimized as required
(Acceptance limits shall be obtained from machine specification/applicable
standards).
6.10 Software alarms may be configured for any channels for overall, 1X, and gap
variables. The gap voltage alarm as example may be set to ±2.0 VDC from the
nominal gap voltage during operation.
6.11 Any CMS configuration change beyond commissioning completion shall follow
a documented change management approach to ensure all systems changed are
tracked and approved by “owner”.
7 Data Storage
7.1 Stored static data (collected 3 times per day) shall be retained in the database for
at least 3 years.
7.2 For normal operation, dynamic data shall be stored for 2 years collected 3 times
a day.
7.3 Data Storage for Transient Condition (Start-up and Shutdown): Coast-down and
start-up at a rate of every 50 RPM or less.
7.4 The auto archiving shall be set on quarterly basis to Saudi Aramco approved
online backup solution such.
7.5 Configuration and historical database backups before and after any
configuration changes shall also be backed up on the same solution, excepting
pre-commissioning and commissioning periods, only the last version will be
included in the backup.
7.6 Data shall be permanently stored on all configured alarm levels and for transient
data events (Startup and Shutdown) for at least 2 years.
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Document Responsibility: Vibration and Lubrication Standards Committee SAEP-414
Issue Date: 2 February 2017 Configuration of Online Condition
Next Planned Update: 2 February 2020 Monitoring Systems for Rotating Machinery
Revision Summary
2 February 2017 New Saudi Aramco Engineering Procedure. Saudi Aramco does not have document that
governs the online Condition Monitoring System (CMS) configuration. This situation is
leading to wrong confirmation of the online CMS throughout the company. It is important
that Saudi Aramco mandates plants to use configuration requirements for these very
complex and expensive online Condition Monitoring Systems.
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Document Responsibility: Vibration and Lubrication Standards Committee SAEP-414
Issue Date: 2 February 2017 Configuration of Online Condition
Next Planned Update: 2 February 2020 Monitoring Systems for Rotating Machinery
Appendix I - Minimum Required Machinery Design Information
Data Required Design Value Data Required* Design Value*
Asset Tag Manufacturer
Min. C. S. RPM1
Power Rating
Max. C. S. RPM2
DE Bearing Clearance NDE Bearing Clearance
No. of Rotor Bars No. of Poles
Coupling Type No. of bolts/teeth
No. of Stages No. of Blades/Vanes for each stage
Rotor Critical Speeds (1st & 2nd) I/B & O/B Bearings Types
Number of Teeth (for Gear Set) Gear Ratio
Alarm/Trip Limits
(*) at 100% Capacity Load
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Document Responsibility: Vibration and Lubrication Standards Committee SAEP-414
Issue Date: 2 February 2017 Configuration of Online Condition
Next Planned Update: 2 February 2020 Monitoring Systems for Rotating Machinery
Appendix II - Anticipated Maximum Frequencies
Shaft Relative Electric
Rolling
Machine Type (Proximity Gearbox Pumps Motors or Fans
Bearings
Probe) Generators
Measurement Unit mils pk-pk G’s RMS in/sec RMS in/sec RMS in/sec RMS in/sec RMS
F-max 10 x RPM 3.5 x GMF 5 x BPFI 3.5 x VPF 3.5 x 2 LF 3.5 x BPF
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