 Copyright 1996 Shell U.K. Limited. All rights reserved.

Additional registered or controlled copies can be obtained

from Central Engineering Library.

Shell U.K. Exploration and Production

SHELL

ENGINEERING
REFERENCE DOCUMENT
ENGINEERING STANDARD
CONDITION MONITORING OF ROTATING MACHINES

Document Number : ES/077

Rev : 2

is appointed Author of this document and

should always be consulted for advice on
validity and currency by a user.
 ES/077
Rev 2 1996

CONTENTS
Para Page
APPROVAL 2
CONTENTS 3
PREFACE 5
GLOSSARY 6
1 INTRODUCTION 7
1.1 Scope 7
1.2 Interpretation of Specification 7
1.3 Conflicting Requirements 7
1.4 Alternative Supply 7
1.5 Selection of Options 8
1.6 Selection of ‘Bought-Out’ Items 8
1.7 Reference Documents 8
2 MEASUREMENT OF MECHANICAL MOVEMENTS 8
2.1 Shaft Vibration 8
2.2 Vibration from Gears 9
2.3 Shaft Axial Position 9
2.4 Angular Phase Measurement 9
2.5 Speed Measurement of Variable Speed Machines 9
2.6 Position Indication of Variable Geometry Machines 10
2.7 Provision for Periodic Monitoring 10
3 BEARING TEMPERATURE MEASUREMENT 12
3.1 Definition of ‘Active' and ‘Non-Active' Thrust Bearings 12
3.2 Tilting Pad Type Thrust Bearings 12
3.3 Fixed-Geometry Hydrodynamic Thrust Bearings 12
3.4 Radial Bearings - Hydrodynamic Type 12
3.5 Rolling Element Bearings 13
3.6 Bearing Temperature Sensors and Sensor Terminations 13
4 PERFORMANCE MONITORING - GAS TURBINES 13
4.1 General 13
4.2 Temperature Measurement 13
4.3 Pressure Measurement 14
4.4 Air Mass Flow Measurement 14
4.5 Speed Measurement 14
4.6 Output Power Measurement 14
4.7 Fuel Flow Measurement 15
4.8 Low Cycle Fatigue Life Monitoring 15
4.9 Accuracy/Repeatability 15
4.10 Signal Processing 15
5 PERFORMANCE MONITORING - COMPRESSORS AND PUMPS 15
5.1 Compressors 15
5.2 Pumps 16
6 LUBRICATING OIL ANALYSIS 16
7 WEAR DEBRIS DETECTION 17
8 TORQUE MEASUREMENT 17
9 CURRENT SPECTRUM MONITORING 17
10 DISCHARGE DETECTION 17
11 INSTRUMENTATION - MONITORING EQUIPMENT 18
11.1 General 18

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11.2 Functional Requirements 18

11.2.1 General 18
11.2.2 Data Collection 19
11.2.3 Calculations 19
11.2.4 Maintenance Alarms 19
11.2.5 Displays and Analysis Facilities 19
11.2.6 Storage and Reporting 20
11.2.7 Interface with Other Systems 20
11.2.8 System Configuration 20
11.3 System Architecture 21
11.4 Data Acquisition 21
11.5 Data Processing 23
11.5.1 Processor Performance 23
11.5.2 Scan Rates 23
11.5.3 Analogue Signal Processing 23
11.5.4 Data Compression 23
11.6 Open System Data Hand-Off 23
11.7 External Data Communications (Existing and Future) 23
11.8 Equipment Standards 24
11.8.1 System Hardware 24
11.8.2 System Software 24
11.8.3 Radio-Frequency Interference (Ref. IEC801-3) 24
11.8.4 Field Equipment 24
11.9 Installation Requirements 25
11.10 Maintenance Requirements 25
12 AMENDMENTS TO API 670:1986 AND API 678: 1981 26
12.1 Amendments to API 670:1986 26
12.1.1 API SECTION 1 – General 26
12.1.2 API SECTION 2 - General Design Specifications 26
12.1.3 API SECTION 3 - Conventional Hardware 26
12.1.4 API APPENDIX B - CABLES - Modification 27
12.2 Amendments to API 678:1981 27
12.2.1 API SECTION 1 - General 27
12.2.2 API SECTION 2 - General Design Specifications 27
12.2.3 API SECTION 3 - Conventional Hardware 27
12.2.4 API SECTION 4 - Transducer Arrangement 28
12.2.5 APPENDICES A and B – Substitution 28
APPENDIX 1 CONDITION MONITORING GUIDELINES 29
1 INTERPRETATION OF GUIDELINES 29
1.1 Guidelines For Equipment Types 29
1.1.1 Section 2.1 29
1.1.2 Section 2.2 32
1.1.3 Section 2.3 35
1.1.4 Section 2.4 37
1.1.5 Section 2.5 42
1.1.6 Section 2.6 44
1.1.7 Section 2.7 46
1.1.8 1 Introduction 46
1.1.9 2 Preferred Methods of Monitoring 47
1.1.10 3 Notes 47
1.1.11 Section 2.8 49

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PREFACE
The objectives of condition monitoring are fourfold:
(1) To indicate that a machine is healthy and, hence, give the operators confidence in continuing to use it.
(2) To give advanced warning of impending failure of a machine, so that major damage can be avoided and
the machine can be taken out of service in a planned rather than a `crash' manner.
(3) To provide quantitative data which will assist in diagnosing the fault and, hence, avoid unnecessary
maintenance effort.
(4) To indicate deterioration in the performance of a machine so that a trend can be established and
extrapolated to enable corrective action (cleaning, parts renewal etc.) to be planned to optimise
operations and maintenance.
The purposes of this Standard are as follows:
(1) To define the minimum requirements for devices to be mounted on, and generally purchased with,
rotating machines to monitor their condition.
(2) To identify the preferred means of condition monitoring for various equipment types.
Specific Condition Monitoring devices required for and supplied with a particular machine will be listed on the
appropriate data sheet for that machine.
This Standard does not cover portable or temporary equipment that may be used during testing or
commissioning or for trouble-shooting purposes. However, it does cover some provisions to be made on the
machines to facilitate the use of such portable or temporary equipment.
This Standard does cover the dedicated equipment used to support, supply power to, condition and display the
signals from the devices mounted on the machines. It also covers any downstream equipment which may be
installed to analyse or record these signals, and the provision of suitable outputs to be used in conjunction with
such downstream analysis or secondary equipment.
It is intended that this Standard should apply to machines where Condition Monitoring is shown to be
appropriate by 3806-004A Maintenance Strategy Review.
It is appreciated that some equipment may be involved where the outcome of the Maintenance Strategy Review
(MSR) is not known. Here, the Engineer specifying the equipment should ensure that adequate provision is
made to cover any likely outcome of the MSR process.
This Standard may be used directly by Shell UK Exploration and Production or by agents, consultants, or
contractors acting on its behalf.
It shall be used as it stands and shall not be reissued under a different cover or modified in any other way.
Where it is necessary to supplement or modify the Standard, this shall be done by suitable notes contained in
the order (or enquiry) or in the data sheets attached thereto and not by making any change to the Standard
itself.
Significant modifications, or any intent to use a different standard or specification in addition to or instead of this
Standard, shall be discussed with the Shell Technical Authority for the Field Unit concerned.
This Standard applies to both onshore and offshore installations. In preparing this Standard, the
recommendations of Royal Dutch/Shell Group Design and Engineering Practice standard specification have
been noted and included when considered to be appropriate. Refer to G-9-1 Condition Monitoring - Including
Failure Warning and Associated Systems for Rotating Equipment.

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GLOSSARY
Within the context of this Standard the following words shall have the meanings stated:
Shell Shell U.K. Ltd.
Shell Expro Shell U.K. Exploration and Production.
Purchaser The organisation responsible who carry out the purchasing function, e.g. Shell Expro
or a Shell Expro appointed Contractor, Consultant or Agent.
Vendor The supplier of materials or equipment - not necessarily the Manufacturer.
Manufacturer The company responsible for the manufacture - not necessarily the Vendor.
Contractor The Shell appointed main Contractor for a defined piece of work.
Sub-contractor A company awarded a contract by a Contractor to do part of the work awarded to the
Contractor by Shell Expro. The work of the Sub-contractor is carried out under the
direction and control of the Contractor. Under its model contracts Shell Expro has the
right to review all proposed Sub-contractors, and sub-contracts.
Consultant A company awarded a contract by Shell Expro for the company to advise or give
guidance on specific subjects. The Scope of Work may include instructions to act as
an Agent for Shell (see Agent).
Agent The legal status of any person or company authorised by Shell Expro to act on Shell
Expro's behalf on the matters specified in the agency agreement or contract. Third
parties can usually rely on the Agent as acting on behalf of and with the authority of
Shell Expro, provided that the Agent acts within the scope of his apparent authority
from Shell Expro.

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1 INTRODUCTION
1.1 Scope
This Standard covers the minimum requirements for equipment or devices to be permanently mounted
on machines, to monitor their condition.
The machines on which Condition Monitoring is used, and the methods to be employed, shall be
selected in accordance with 3806-004A Maintenance Strategy Review.
This Standard also covers some provisions to be made on the machines to facilitate the use of
portable or temporary equipment that may be used during testing or commissioning or for trouble-
shooting purposes.
In addition, this Standard covers the dedicated equipment used to support, supply power to, condition
and display the signals from the devices mounted on the machines and the provision of permanent or
temporary downstream analysis or recording equipment.
1.2 Interpretation of Specification
The intention of this specification is to provide guidance for the implementation of cost effective
Condition Monitoring for machinery. It must be recognised, for different equipment items, that the
importance to the process, the repair costs and the ease of maintenance vary widely. The level of
monitoring and signal processing that are appropriate will therefore also differ. It is therefore important
that a Maintenance Strategy Review is carried out on each equipment item to determine the strategy
to be adopted and hence the requirements for monitoring.
This document is written to identify the condition monitoring methods that should be applied to the
most important and high cost items of machinery. Users should be aware that for less critical
equipment, to obtain greater cost effectiveness, the MSR process may suggest a reduced sensor fit
with appropriately reduced signal processing.
1.3 Conflicting Requirements
The Vendor shall bring to the attention of the Purchaser any conflict between the requirements of this
Standard and those of the particular machine specification/standard or any other contractual
document.
In such cases of conflict, unless otherwise agreed, the following descending order of precedence shall
apply:
(1) The order (or, where no order has yet been placed, the enquiry document) and any schedule or
data sheet attached thereto.
(2) The appropriate Shell standard, where one exists, for the machine on which the equipment or
devices covered by this Standard are to be mounted.
(3) This Standard.
(4) Any other relevant Shell specification or standard.
(5) Any other specification or standard (e.g. API standards) referred to in this Standard or in any of
the other documents mentioned above.
1.4 Alternative Supply
Since the equipment covered by this is generally added to a major plant item, it is possible that the
design of this major equipment may preclude total compliance with this Standard. Where this occurs, a
potential Vendor shall draw this to the attention of the Purchaser and shall propose an alternative
arrangement which achieves the same objective. In all other cases, except where it has otherwise
been agreed, it will be assumed that the requirements of this Standard, as modified by the other
contract documents, will be met.
At the enquiry stage, a potential Vendor is of course free to offer alternative equipment, in addition to
offering equipment in accordance with this Standard, where he considers such alternatives to be
preferable in association with the particular machine in question.

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1.5 Selection of Options

Certain clauses in this Standard, or any associated standard or specification, may require the
Purchaser to make a selection between alternative options. When the Purchaser has omitted to make
such a selection in the enquiry or order documents, this omission shall be brought to the attention of
the Purchaser by a potential Vendor. Alternatively, at the enquiry stage, a potential Vendor may
assume a particular option but, in this case, shall clearly state this assumption in his tender.
1.6 Selection of ‘Bought-Out’ Items
Details of, and the proposed suppliers of, all items (except standard fasteners and other small items
covered by internationally recognised standards) which are not of the Vendor's own manufacture, shall
be disclosed to the Purchaser as soon as possible, in any case before the sub-orders for such items
are placed. The Purchaser shall have the right to request that a nominated supplier and/or type of
equipment be substituted for the Vendor's initial selection, for reasons of rationalisation, past
experience in similar service, technical superiority or other reasons.
The Purchaser may provide a list of acceptable sub-vendors for certain items at the time of the enquiry
or order. In such a case, the Vendor shall purchase the items in question from one or more of the sub-
vendors listed.
Unless otherwise agreed, all the items of monitoring equipment of a particular type (e.g. all proximity
probes, all accelerometers, all bearing temperature sensors) mounted on the one machine train, shall
be obtained from the same manufacturer and shall be of the same 'series'. These should be from an
approved vendor.
1.7 Reference Documents
National/International Standards
API Standard 670:1976 - Non-contacting Vibration and Axial Position Monitoring System.
API Standard 678:1981- Accelerometer-Based Vibration Monitoring System.
NOTE: It is expected that during the currency of this edition of ES/077 a Third Edition of API 670
will be published. The 3rd Edition will incorporate the content of API 678, and various
other modifications. When available, the revised document shall supersede the standards
referenced above, in this document.
Shell Documents
Maintenance Strategy Review: Maintenance and Inspection Standard 3806-004A No 1.001
DEP Standard Specification - Condition Monitoring - Including G-9-1 (1984) Failure Warning and
Associated Systems for Rotating Equipment.

2 MEASUREMENT OF MECHANICAL MOVEMENTS

2.1 Shaft Vibration
Vibration transducers of the non-contact, proximity type shall be in accordance with API Standard 670:
1976Non-contacting Vibration and Axial Position Monitoring System.
As modified by Amendments to API 670:1986 and API 678: 1981.
Where accelerometer type probes are used, they shall be in accordance with API Standard 678: 1981
Accelerometer-Based Vibration Monitoring System.
As modified by Amendments to API 670:1986 and API 678: 1981.
For each shaft, which is supported in hydrodynamic bearings, the relative motion between shaft and
bearing housing shall be measured adjacent to each bearing. Two, non-contact, proximity-type
transducers shall be used at each location, 90 ° apart, located in a position that is sensitive to any
likely mode of vibration.

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For each shaft supported in rolling element bearings, or where it has been agreed that the use of
proximity-type transducers is impossible or impractical, the absolute vibration of the bearing housing or
machine casing shall be externally measured adjacent to each bearing. Accelerometers of an
approved type shall be used at each location, arranged to measure the vibration in the directions of
the three major axes of the machine (horizontal, vertical and axial). Each accelerometer shall be rigidly
attached to the casing in such a position that there is a solid metal 'path' as short as possible between
it and the adjacent bearing. The frequency response of the transducers used shall be such as to allow
analysis of the high frequency vibrations resulting from bearing defects (e.g. use of Spike Energy
measurements).
On electric motors and alternators with hydrodynamic bearings, it may be found that stray magnetic
fields in the rotor affect the accuracy of measurements taken using proximity type detectors. Where
this occurs, the absolute vibration of the bearing housing or machine casing shall be externally
measured adjacent to each bearing. Accelerometers of an approved type shall be used at each
location, arranged to measure the vibration in the horizontal and vertical axes of the machine. Each
accelerometer shall be rigidly attached to this casing in such a position that there is a solid metal `path'
as short as possible between it and the adjacent bearing. Appropriate mechanical flat surfaces shall
be provided at each bearing housing, or on the machine casing adjacent to the bearing, to facilitate
attachment of these transducers if found necessary.
2.2 Vibration from Gears
The vibration emanating from each train of gears shall be measured in two directions 90° apart in a
plane normal to the axes of the shafts in the case of parallel shaft gears (preferably parallel to and at
90° to the line of contact of the gears), using accelerometers of an approved type. The preferred
location of these accelerometers is adjacent to each bearing.
On every train of helical gears, single or double helical, provision shall be made for the mounting of an
accelerometer to monitor axial vibration. The equipment and the arrangement thereof shall be in
accordance with API Standard 678: 1981Accelerometer-Based Vibration Monitoring System.
As modified by Amendments to API 670:1986 and API 678: 1981.
2.3 Shaft Axial Position
The axial position of each shaft, which is located by a thrust bearing or other device, shall be
measured by a non-contacting proximity-type transducer. Where possible, the transducer should `look
at' a surface which is an integral part of the shaft.
The equipment provided and the arrangement thereof shall be in accordance with API Standard 670:
1976 Non-contacting Vibration and Axial Position Monitoring System.
As amended by Amendments to API 670:1986 and API 678: 1981.
2.4 Angular Phase Measurement
At least one shaft in each train, plus all others that rotate at different speeds or can rotate
independently from the first shaft in the system, shall be fitted with a phase marker (key phaser). This
will generally take the form of a proximity-type transducer scanning a part of the shaft in which there is
a single discontinuity such as a notch or small projection. The equipment used for this purpose shall
conform to API Standard 670: 1976 Non-contacting Vibration and Axial Position Monitoring System.
As amended by Amendments to API 670:1986 and API 678: 1981.
(It is noted that compliance with this paragraph may not always be possible for aero derivative gas
turbines).
2.5 Speed Measurement of Variable Speed Machines
Every prime mover shaft, the speed of which may vary, other than during normal start-up and shut-
down, shall be provided with electronic speed measuring equipment. This will normally comprise a
toothed wheel on the shaft, scanned by one or more inductive transducers.
Where stated in the requisition, similar speed measuring equipment to (1) above shall be provided for
all shafts that can rotate at a different speed independently of the prime mover shaft.

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Where the possibility exists of the shaft overspeeding, this electronic speed measuring equipment may
be used as a basis for overspeed protection. However, in such a case, three completely independent
transducers shall be fitted. These three transducers may scan the same toothed wheel but that
toothed wheel shall be mounted on the shaft on which the power is transmitted and should be an
integral part of that shaft.
The speed probes (transducers) shall be designed to be replaceable without significant disassembly of
the machine or the need to move it from its operating position.
2.6 Position Indication of Variable Geometry Machines
All machines fitted with arrangements to vary the geometry of one or more components (e.g. variable
inlet guide vanes), in service, in order to modify the performance of the machine, shall be provided
with devices to continuously indicate the position of the movable components at a remote location.
2.7 Provision for Periodic Monitoring
For some equipment, the evaluation and selection process outlined in the Maintenance Strategy
Procedures may indicate that the permanent installation of vibration monitoring equipment is not cost-
effective. There may still, however, be a benefit in periodic vibration monitoring using portable
equipment. It is likely that this situation will apply on smaller items of plant.
Where periodic vibration monitoring using a portable accelerometer and data collector is to be used,
provision shall be made at each bearing for these measurements to be taken in horizontal, vertical and
axial directions. To ensure consistency in the vibration measurements obtained, studs shall be fitted
onto which the accelerometer may be fitted.
Accelerometer Mounting Studs
To ensure commonality and maximum utilisation of existing monitoring equipment, standard stud
dimensions and a standard quick-locking accelerometer connection shall be used. Dimensions of
studs shall be as shown in 'Figure: Accelerometer Mounting Studs', below.
Where vibration at high frequencies is expected, studs shall be mounted using a tapped connection. In
other situations, fixing using a high temperature adhesive may be acceptable. In all cases, the
mounting shall be such that the vibration frequencies present are accurately transmitted to the
accelerometer.

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20.0

M24 x 3
Thread
14.0

19.2

BONDED STUD

20.0

M24 x 3
Thread
14.0

6.5

M8 or
5/16in UNF

19.2

THREADED STUD (illu5580181)

Figure 1 Accelerometer Mounting Studs

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3 BEARING TEMPERATURE MEASUREMENT

3.1 Definition of ‘Active' and ‘Non-Active' Thrust Bearings
Where, under all anticipated conditions of loading, inlet and outlet pressures, fluid properties, normal
deterioration etc., the net residual axial thrust on the shaft is confidently expected to be always in the
same direction, the thrust bearings locating the shaft shall be designated as the `active' and `non-
active' bearings.
When the direction of the net residual thrust is uncertain or may change as a result of variations in
load, pressures, fluid properties, deterioration etc., both thrust bearings shall be treated as `active'
thrust bearings.
3.2 Tilting Pad Type Thrust Bearings
Active thrust bearings of the tilting pad type shall have a temperature sensor mounted in each of not
less than two pads, distributed around the bearing, in accordance with API Standard 670: 1976 Non-
contacting Vibration and Axial Position Monitoring System.
Non-active thrust bearings of the tilting pad type shall have a temperature sensor mounted in each of
not less than two pads, one in the top half and one in the bottom half of the bearing.
When the Manufacturer has a proven standard method of fitting temperature sensors to his bearings,
which achieves the objective of accurately and rapidly responding to changes in bearing metal
temperature, such a system may, by agreement, be supplied; otherwise the following method shall be
used.
The sensors shall be inserted into drilled holes in the steel backing of the pads. Each hole shall
terminate as close as possible to the white metal (babbit) or other facing, but shall not penetrate into
the facing material, in a location close to the expected area of highest temperature. Each sensor shall
be clamped in position and held securely in good contact with the metal of the pad.
The leads from the temperature sensors shall be routed and arranged so as not to interfere with the
normal functioning of the pads to which they are attached, whilst also permitting normal maintenance.
3.3 Fixed-Geometry Hydrodynamic Thrust Bearings
Active thrust bearings of the fixed-geometry type shall be fitted with two temperature sensors
distributed around the bearing, in accordance with API Standard 670: 1976 Non-contacting Vibration
and Axial Position Monitoring System.
Non-active thrust bearings of the fixed-geometry type shall have two temperature sensors, located
approximately diametrically opposite each other, one in the top half and one in the bottom half of the
bearing.
Where the Manufacturer has a proven standard method of fitting temperature sensors to his bearings,
which achieves the objective of accurately and rapidly responding to changes in bearing metal
temperature, such a system may, by agreement, be supplied; otherwise the following method shall be
used.
Each sensor shall be inserted into a drilled hole in the steel backing of the bearing and clamped in
position in good contact with the metal. Each hole shall terminate as close as possible to the white
metal (babbit) or other facing but shall not penetrate into the facing material, in a location close to an
expected area of high temperature.
3.4 Radial Bearings - Hydrodynamic Type
Each hydrodynamic radial bearing shall be fitted with temperature sensors arranged in accordance
with API Standard 670: 1976 Non-contacting Vibration and Axial Position Monitoring System.
Where the Manufacturer has a proven standard method of fitting temperature sensors to his bearings
which achieves the objective of accurately and rapidly responding to changes in bearing metal
temperature, such a system may, by agreement, be supplied; otherwise the following method shall be
used.
The sensors shall be inserted into drilled holes in the steel backing of the bearing or bearing pad, in
the case of a tilting pad type of bearing, and held securely in good contact with the metal of the
bearing. Each hole shall terminate as close as possible to the white metal (babbit) or other facing but
shall not penetrate into the facing material.

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In a fixed geometry bearing or a ‘load-on-pad' tilting pad bearing, the temperature sensor shall be
located in the bottom half or pad in an area just ‘downstream' from the area of maximum
hydrodynamic pressure.
In a ‘load-between-pads' type of tilting pad bearing, the sensor shall be inserted in the ‘downstream'
pad of the two which share the load located just `downstream' from the area of maximum
hydrodynamic load.
3.5 Rolling Element Bearings
Temperature sensors shall be arranged close to each rolling element bearing, preferably held in
contact with the outer race by spring pressure. The objective is to detect any rise in the temperature of
the stationary race. The number and exact location of such sensors shall be agreed with the
Purchaser.
3.6 Bearing Temperature Sensors and Sensor Terminations
Bearing temperature sensors shall be one of the following types:
Stainless steel sheathed, mineral insulated Chromel/Alumel, type K thermocouples, with insulated
junctions and sheath outside diameter of not greater than 2mm.
Platinum resistance temperature detectors, resistance 100 ohm at 0°C, in accordance with API
Standard 670: 1976 Non-contacting Vibration and Axial Position Monitoring System.
The purchaser shall specify which type of detector is to be used in each case. Similar sensors shall be
used on both driver, gearbox (if any) and driven equipment.
The temperature sensors shall terminate in junction boxes mounted on the outside of the machine or
its supports. The arrangement shall be such as to provide the minimum interference with maintenance
operations, whilst not providing a route for oil leakage from the bearing housing. There shall be no
junction between the sensors and these junction boxes. Where the junction boxes are not mounted
directly on the bearing housings they serve, the temperature sensors shall pass through flexible
conduit from the bearing housings to such junction boxes. The stainless steel sheaths shall be sealed
into the junction box or boxes using bulkhead-type compression fittings of an approved type.
When so specified, individual amplifiers shall be incorporated into the junction box or boxes to take
thermocouple outputs and convert them into standard 4-20 milliamp signals.
For electric motors and generators, the design of temperature detectors, connections, junction boxes,
etc. shall not bridge the bearing insulation that is fitted at both drive end and non-drive end bearings.

4 PERFORMANCE MONITORING - GAS TURBINES

4.1 General
Monitoring of change in performance can provide a means of diagnosing faults developing in the gas
turbine. The general procedure is to note the engine performance over the full range of normal loads
in the new ‘as installed' condition, and compare the actual readings with the ‘ideal' condition. To
ensure comparability, all readings are normalised to standard conditions. For effective results, all the
measurements detailed below are required, at the accuracy stated.
4.2 Temperature Measurement
All combustion gas turbines shall be provided with temperature sensors arranged to measure the
temperature of the hot gas stream downstream of the combustion chamber or chambers. These
sensors shall be located as close to the combustion zone as practicable with regard to the difficulty
and potential unreliability of measuring gas temperatures in the hottest part of the turbine. It is
accepted that this will generally mean locating the sensors after the high-pressure turbine in a two-
shaft machine, in the exhaust of a single-shaft machine or in the duct between the gas generator and
power turbine in an aircraft derivative type.
Where there are 8 or fewer fuel burner nozzles, there shall be at least as many sensors as there are
fuel burner nozzles with a minimum of four. Where there are more than 8 fuel burner nozzles there
shall be at least 8 thermocouples. The sensors shall be so located and distributed in the hot gas path
as to be able to detect significant differences in combustion from different burners.

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A minimum of two temperature sensors shall also be provided to monitor the compressor discharge
temperature. With a multi-shaft turbine, i.e. where different sections of the compressor are driven by
separate turbines at potentially different speeds, two sensors shall be provided to monitor the
temperature at the discharge of each compression section.
When the hot gas temperature sensors, required by `General', paragraph (1) to (3) inclusive above,
are fitted upstream of a final turbine stage (power turbine), a minimum of two additional sensors shall
be provided to monitor the temperature downstream of the final turbine stage.
The temperature sensors shall be replaceable without the need for significant disassembly of the
turbine or removal from its normal operating position.
Each temperature measuring element, unless otherwise agreed, shall be a chromel/alumel type K
thermocouple, stainless steel sheathed, mineral insulated with an insulated junction.
Where temperature measurement is used as a basis for the control of the turbine, independent
temperature elements for this purpose shall be provided.
Temperature sensors (minimum of 2) shall also be provided to monitor the ambient temperature at the
inlet to the gas turbine.
4.3 Pressure Measurement
All combustion gas turbines shall be provided with two independent instruments to measure the
pressure differential across the air intake filter/silencer assembly.
Pressure measuring instruments shall also be provided to monitor:
• the absolute pressure at the gas turbine inlet plenum;
• the pressure at the discharge of the compressor (or the discharge of each compressor section
in the case of a multi-shaft engine);
• the exhaust pressure at the inlet to any form of waste heat recovery system - if installed.
• the pressure between gas generator and power turbine where an aero derivative gas turbine is
used.
Each instrument shall comprise a pressure transmitter providing a 4-20 milliamp output signal. Air inlet
pressures shall be measured with absolute pressure transmitters.
4.4 Air Mass Flow Measurement
Pressure tappings shall be provided in the inlet `flare' of each combustion gas turbine in such locations
that measurement of the pressure differential between them provides an indication of the mass flow of
air through the turbine. Location of tapping points shall be such as to avoid contamination during crank
wash cycles.
The gas turbine vendor shall provide a calibration graph (Mass vs DP) for these tappings.
The pressure differential between these tappings shall be measured with a differential pressure
transmitter providing a 4-20 milli-amp output signal.
4.5 Speed Measurement
Instruments shall be provided to measure the speed of each compressor spool. These instruments
may be either separate from or part of the equipment provided to give overspeed trip protection. In the
latter instance, the provision of speed monitoring shall not affect the accuracy or effectiveness of
overspeed protection.
4.6 Output Power Measurement
Where the gas turbine is used to drive an electrical generator, output power measurement is to be
taken from instrumentation on the driven equipment, e.g. Wattmeter on generator switchgear. Where
the gas turbine is driving a pump or compressor, the method to be used for output power
measurement shall be determined by agreement between manufacturer and purchaser, depending on
the individual circumstances. Note shall be taken of the need for accurate and consistent
measurement.

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4.7 Fuel Flow Measurement

Provision shall be made to measure the flow of each fuel for which the turbine is designed.
Instrumentation shall be suitable for signal processing as defined in Instrumentation – Monitoring
Equipment.
4.8 Low Cycle Fatigue Life Monitoring
Where turbine components are identified that are subject to low cycle fatigue life limitations, an
automatic low cycle fatigue monitor shall be provided. This monitor should be provided as part of the
control system, but shall not compromise the integrity of control. It shall measure all parameters
affecting low cycle fatigue life and shall be capable of recording the life limit, the unique identifying
serial number of each life-limited component, and calculating and recording the actual life used.
Memory registers, which shall be electronic rather than mechanical, shall be re-settable to allow for
change-outs of life limited components. The memory shall be portable to allow the data to follow the
gas generator from berth to refurbisher and back to possibly a different berth on a different installation.
The security of the data shall be suitably protected against unauthorised alteration and accidental loss.
In addition, the facility for electronic data transfer to a separate data storage computer shall be
included.
Data transfer shall be in accordance with Instrumentation – Monitoring Equipment.
4.9 Accuracy/Repeatability
For effective operation of performance monitoring as a diagnostic tool, the accuracy and repeatability
of the readings, including any necessary signal processing, should be as follows:
Table 1 Accuracy of Performance Monitoring Readings

Parameter Required Accuracy

Intake Temperature 0.2%
Intake Pressure 0.2%
Pressure Drop across filter
Compressor Discharge Pressure 0.2%
Compressor Discharge Temperature 0.2%
Gas Generator Exhaust Pressure
Exhaust Cone Temperature 0.3%
Power Turbine Exhaust Temperature 1.4%
Output Power 0.5%
Compressor Speed 0.1%

4.10 Signal Processing

Indication of gas turbine performance requires calculations to be performed using some of the signal
outputs outlined in the preceding paragraphs. These outputs should be brought back to a suitable
central point for processing and display using SCADA or other appropriate system.
Signal transmission and processing shall be in accordance with Instrumentation – Monitoring
Equipment.

5 PERFORMANCE MONITORING - COMPRESSORS AND PUMPS

5.1 Compressors
(1) Instrumentation shall be provided to measure the pressure and temperature at all inlets and
discharges to and from all compressors, including suction gas scrubber and cooler, where used.
Suction flow shall also be measured. However, such instruments will normally be installed in the
connecting pipework and as such will not usually be within the compressor Vendor's scope of
supply.

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(2) Where compressor speed is variable, instrumentation shall be provided to measure compressor
speed.
(3) On all centrifugal or axial compressors fitted with a balance piston, instruments shall be
provided to monitor the pressure differential across the balance pipe through which gas leaking
past the balance piston labyrinth, passes back to a lower pressure section of the compressor.
The purpose of this measurement is to indicate significant deterioration of the balance piston
labyrinth seal.
(4) The performance calculation procedure used shall take account of possible variations in gas
properties.
5.2 Pumps
Monitoring of change in pump performance is justified only in special situations, on critical pumps
where major deterioration modes identified are characterised by loss of efficiency. For these pumps
either:
(1) Instrumentation shall be provided to measure the suction and discharge pressures of the pump,
flow through the pump and speed (if variable). This instrumentation will normally be installed in
the connecting pipework (between the pump and any non-return valve or control valve) and as
such will not usually be within the pump Vendor's scope of supply.
(2) Pump efficiency may also be monitored by the thermodynamic method. This requires
instrumentation to measure the suction and discharge pressures of the pump, and temperature
sensors located at the inlet and outlet pipework. These temperature sensors may either be in
thermowells in the pipework, or clamped to the outside of the pipework. If this method is used,
note that accuracy is dependent on the on-site measurement of very small temperature
differences with laboratory standards of precision. Great care is needed in the selection and
siting of sensors and connections to the monitoring equipment. It is also important to eliminate
external influences (e.g. weather). This equipment is also installed in connecting pipework and
is not usually within the pump Vendor's scope of supply.

6 LUBRICATING OIL ANALYSIS

Lubricating oil analysis may be used for several reasons:
• to indicate contamination by water, product or combustion products;
• to indicate the loss of oil properties, and hence the need to change oil;
• to detect equipment faults by the presence of wear products or debris.
Facilities provided for oil sampling shall take account of the reasons for sampling in particular
instances.
(1) Sampling Value
Sampling valves shall be sited such that the reason for sampling is not negated by the
presence of other parts of the lubrication system, for example:
(a) If wear debris is looked for then sampling should be upstream of any filters in the system.
(b) If contamination by-product is expected then the sample point should be before any
settling tanks etc.
It shall be possible to obtain samples safely with the machine in operation under normal
operating conditions. The valve design shall minimise the risk of contamination of the sample
through metal to metal contact, and shall be sited to minimise the amount of oil necessary to
purge the sample line in which it is installed. Sample valves to be secured so that they will not
vibrate open.
(2) Wear Debris Detector
Where magnetic plugs for wear debris detection are fitted the Vendor shall supply an adapter
that will fit into the magnetic plug housing, in accordance with Wear Debris Detection.
This adapter is also to fit onto a sample bottle, to allow samples of oil to be drawn off for
analysis. The adapter design should allow oil samples to be taken with minimum spillage.

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7 WEAR DEBRIS DETECTION

(1) Provision shall be made in all oil drain lines from bearings and gear cases for the fitting of
magnetic plugs for the collection of ferritic wear debris.
(2) In the case of major machines such as aero derivative gas turbines, with rolling element
bearings, the probes shall be an electronic type capable of counting the rate of wear-particle
collection and of differentiating between large and small particles. The actual location,
arrangement and type of detection shall be discussed with Shell Expro.
(3) Permanent magnet type probes shall be designed and arranged so that they can be removed
and replaced without significant oil spillage. Where specified by the purchaser this shall be with
the machine in service.

8 TORQUE MEASUREMENT
(1) When specified in the order (or enquiry), machines, driven by any prime mover other than an
electric motor, shall be fitted with continuous torque measuring equipment. The torque
measuring system shall be discussed and agreed with Shell Expro.
(2) Torque measuring systems shall be based on one of the following two types.
(a) Measurement of the torsional strain in the driving coupling spacer with resistance strain
gauges and transmitting the signal through a rotating transformer.
(b) Measurement of the twist between toothed flanges forming part of a spacer type coupling.
(3) The arrangement shall be such as to minimise the effect on normal maintenance operations.

9 CURRENT SPECTRUM MONITORING

(1) This method of monitoring involves analysing the current drawn by an electric motor into its
spectral components. It is applicable to both High Voltage and Low Voltage motors, irrespective
of power rating. The work necessary to allow monitoring will not involve any modification to the
motor itself, so is outside the scope of the motor Vendor's supply, but will involve work in the
switchgear. The intention to use Current Spectrum Monitoring must therefore be communicated
to the switchgear Vendor at an early stage of development of a new project.
(2) To permit Current Spectrum Monitoring, access is required to the output from the ammeter
current transformer in the switchgear. It shall be possible to obtain this access at any time while
the motor is in operation, without any need to go near live power circuits or control circuits that
are live at greater than 110V ac. There must also be no risk of causing inadvertent operation of
control circuit components operating at this voltage or lower, or of inadvertently open-circuiting a
current transformer secondary circuit.
(3) The signal for Current Spectrum Monitoring is normally sampled periodically. The signal for
sampling should be obtained using one of the following methods:
(a) Current transformer clipped around a secondary circuit lead from the ammeter current
transformer.
(b) Leads from a resistor in the ammeter circuit taken to a plug on the cubicle front.

10 DISCHARGE DETECTION
Winding discharge detection is applied only to high voltage electric motors and generators operating at
a voltage of 6.6kV and above.
(1) Discharge detection coils shall be of the 'Rogowski Coil' type.
(2) One coil shall be fitted on each of three phases. These coils shall be fitted either within the
terminal box or inside the machine adjacent to the bushings through the machine housing into
the terminal box. Where connections of the 'Bi-mold' type are used, the coils shall be clamped to
the outside of the connector.

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Co-axial cable connections from the Rogowski Coils shall be brought out to a separate junction
box, on the frame of the motor or generator. If the motor or generator is situated in a Hazardous
area, connections shall then be routed to a nearby non-Hazardous area, for connection to
measuring instrumentation.
(3) Where a motor or generator is installed in a Hazardous area, the Rogowski Coil installation shall
be fully certified within the hazardous area certification of the motor.

11 INSTRUMENTATION - MONITORING EQUIPMENT

11.1 General
The functional, equipment, communication and installation requirements of the Condition Monitoring
System are indicated in this section of the Specification.
Although Condition Monitoring performs a maintenance function it may also form part of the
information structure for facility Control or Operation. To ensure that Condition Monitoring Systems
comply with Corporate requirements, system functionality should be consistent with Shell Expro
Operating Philosophy, 0191-001Appendix 12.
Also, in addition to the requirements of Functional Requirements.
The system architectural and data communications structure requirements are indicated for facilities
with and without coupled DCS/SCADA systems. Where coupled DCS/SCADA systems exist or are
planned then the following structure should be applied, as required by EA/073 Strategy for Control and
Safety Systems for Large Size Offshore Installations.
As developments in the functionality of DCS/SCADA are very rapid, reference must be made to
Functional Engineering Department in the preparation of system specifications to ensure that
duplication of functionality and data transfer requirements are minimised.
Utilisation of existing data and signal sources is permissible from other installed systems such as
SCADA/DCS and Machine Protection Systems subject to the retention of the integrity and functionality
of the source systems.
It may be necessary to transfer data collected and generated by the Condition Monitoring system to
the SCADA/DCS for reporting and incident analysis purposes or for hand-off to higher level systems
e.g. IMIS. Data for process or machine monitoring and control should be obtained directly from
installed instrumentation by the DCS, and not via the Condition Monitoring system.
The proliferation of network usage and dedicated terminals should be minimised in line with functional
networking strategy.
The system architecture and functionality specified in this document is configured around industry
standard equipment and the need for special development work is not anticipated to meet these
requirements.
Although protection requirements for rotating machines are indicated within this document, it is not
intended that this Specification is utilised for the specification and procurement of protection systems.
For this purpose the following reference should be utilised: EA/002 - Instrumented Protective
Functions (Emergency Shutdown and Emergency Trip Systems).
11.2 Functional Requirements
11.2.1 General
This section of the specification is primarily concerned with the functions of equipment needed to
display and analyse the parameters measured for condition monitoring purposes. Detailed
requirements for the sensors are included elsewhere in this specification.
The principal functions of the equipment will be:
• To collect the data needed for condition monitoring purposes, either from on-line or off-line
measurements.
• To display the data collected, as needed in specific situations.
• To carry out any analysis of the data collected necessary to determine machine condition.
• To store for future use any of the data collected, and provide facilities to recall that data.

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• To provide an interface with other platform data management systems as needed for
maintenance purposes.
The functionality of the Condition Monitoring System should avoid duplication with installed or
projected facility SCADA systems.
11.2.2 Data Collection
An On-line Condition Monitoring System shall be designed so that data is collected from all
measurement points at fixed periods not exceeding 0.5 sec. Facilities should be provided to validate
readings (e.g. a 4-20 mA signal must not lie outside these values).
To avoid data overload on these systems, the collected data may be reduced by using signal deviation
controlled storage techniques, provided that the significant characteristics of the signal are retained.
Averaging over time shall not be allowed.
Where data entry is from portable data collectors, all data shall be stored.
11.2.3 Calculations
It must be recognised that some of the measured variables may change according to the operating
mode of the machine, as well as with the machine condition. The system must therefore be able to
calculate normalised parameters from the incoming raw data to eliminate the effects of change in duty.
It shall be possible to calculate machine performance, either directly or in terms of normalised
parameters, in either on-line or off-line modes of operation.
Where required, vibration signals shall be analysed into spectra using Fast Fourier Transform
calculation methods, with a zoom facility to improve the clarity over the parts of the spectrum of
interest.
The system shall carry out any calculations needed to show trends or rates of change of either
measured or display parameters.
The system shall carry out any specific calculations needed for the monitoring of reciprocating
machinery, as identified in Appendix - Equipment: Reciprocating Compressors.
11.2.4 Maintenance Alarms
For any measured variable or display parameter, the following indications shall be available:

‘Alert' warning of a significant drift in value from the normal.

‘Alarm' indicating that a condition exists that may require maintenance action.

‘Rate of Change' to indicate if a variable is increasing or decreasing at a greater rate than normal.

This indication should be based on the calculated trend for the variable and should operate if the
variable is over the ‘Alert' level.
For vibration (or other) spectra, it shall be possible to set the Alert and Alarm levels to different values
at different frequencies, depending on the levels expected in a particular application. The Rate of
Change alarm shall operate at any discrete frequency.
11.2.5 Displays and Analysis Facilities
The facilities listed in this section are based on an On-line system. Wherever possible, these shall also
be available for Off-line measurements.
Display of:
• Current value of any measured variable or display parameter;
• Any stored value of any measured variable;
• Status messages;
• Alerts or Alarms;
• Trend displays incorporating features as defined: User selectable and Predefined Time Periods.

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Up to 6 trends displayed for frequency components and process derived points;

Short, medium and long term trends;
Facility to `zoom in' to part of trend to examine in greater detail;
Facility to use regression techniques to establish underlying trends;
Transient trends, including pre-trip, for several machine run-up or run-down sequences.
Display and analysis facilities for:
• Timebase waveform;
• Frequency envelope spectrum;
• Nyquist diagrams;
• Comparisons between frequency spectra;
• Waterfall and cascade spectra;
• Orbit diagrams;
• Automatic baseline comparison checks for Frequency spectrum, Orbit data, Performance data;
• Cepstrum analysis facilities;
• Cyclic analysis facilities (reciprocating machines);
• Automatic capture of spectrum or orbit on alarm occurrence.
11.2.6 Storage and Reporting
The system shall have the capability to store all data needed for assessment of the condition of the
machines monitored, covering at least the period between major overhauls. This shall include facilities
for archiving data for long term storage and subsequent retrieval. Suitable buffering shall be provided
to prevent data loss if the archive medium is filled.
Events, (alarms and status changes) shall be time-tagged before storage. It is anticipated that storage
of at least 2000 events will be needed.
Data required for baselines shall also be stored, with adequate security to ensure that it is not
inadvertently overwritten.
Comments entered free-hand from a portable data collector shall also be stored.
The manufacturer shall identify how these storage requirements will be achieved, which storage
functions will be automatic and which will require operator intervention.
Reports shall be available to identify first-up alarms (for on-line systems) and to show latest and
previous measurements for pre-selected sets of points. The system shall also generate User-definable
summary reports and hours-run reports.
11.2.7 Interface with Other Systems
It is expected that in the future condition monitoring system will have to interface with IMIS (for
maintenance action data) and an Expert System used as an aid to fault diagnosis. The configuration
shall be such as to facilitate these future interfaces.
11.2.8 System Configuration
The functionality noted above, communication and data acquisition control and graphics building shall
be configurable in the off-line mode. Configuration shall be simple and shall not involve the generation
of software. Initial configuration and major changes to configuration shall normally be carried out on a
separate development machine and loaded by disc to the system processor. Minor changes shall be
possible from the system keyboard.
A security system shall be provided to prevent unauthorised access to the configuration control
system.

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11.3 System Architecture

The system architecture should comply generally with EA/073 Strategy for Control and Safety
Systems for Large Size Offshore Installations.
Where coupled DCS/SCADA Systems do not exist then data should be exchanged with installed
SCADA Systems e.g. CAPO System.
The Condition Monitoring System shall be constructed from computer and instrument industry
standard equipment utilising a standard operating system and selected from the Shell Expro Preferred
Vendors List.
System architecture shall be generally as indicated in Figure Condition Monitoring – System
Integration.
This comprises data acquisition equipment, a communications unit, processing unit, main operator
station, system printer and a remote operator station.
Provisions shall be made for keypad data entry and manual loading data from portable electronic
logging equipment. Facilities for archiving, reloading and displaying archived data shall be provided.
11.4 Data Acquisition
The data required by the Condition Monitoring system shall be obtained automatically from
instrumented systems, by the manual entry of data obtained from equipment logs or downloaded on
demand from portable electronic logging systems, to perform the functionality stated in Functional
Requirements.
Signals available from installed instrument systems shall be utilised as far as is reasonably practical
while ensuring that the integrity of the source systems is not compromised. Such systems include any
installed SCADA and Rotating Machine Protection System. The integrity of the latter system is of
particular importance and should not be downgraded to satisfy Condition Monitoring requirements (i.e.
faults on auxiliary output or data circuits used for Condition Monitoring purposes must not affect the
operation of the machine protection system).
Where continuous and automatic measurement inputs are required and where the appropriate
instrumentation is not installed or where integrity requirements and data scan rate limitations dictate
that installed instrumentation cannot be utilised, then additional dedicated instrumentation shall be
provided.
Where signals are subjected to fast processing techniques e.g. Fast Fourier Transforms, they shall be
raw unfiltered time domain analogues of the measured value and shall be directly applied to the
Condition Monitoring input condition system prior to digitisation and processing within the Condition
Monitoring Processor. These may be obtained from dedicated instrumentation or from unfiltered
buffered outputs of installed signal conditioning equipment.
Installed SCADA systems shall be utilised only as a source of measurement data and shall not be
utilised for data processing or storage for Condition Monitoring purposes. This avoids unnecessary
loading of the SCADA data highways and utilisation of limited SCADA system data storage and
retrieval facilities. Data obtained from the SCADA system shall be checked for consistency of
engineering units and that it can be polled at rates consistent with the functional requirements of the
application software. It should be noted that such data will already be filtered and processed and is
unsuitable as inputs to high speed data processing applications.

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REMOTE
OPERATOR
TERMINAL

DATA
COLLECTOR

RS232

OPEN
HOST NETWORK
COMPUTER PRINTER
MANAGEMENT
LINE DATA
INTERFACE

PROCESS
DATA
DCS/SCADA
DATA
ACQUISITION

(OPERATING DATA)
ANALOGUES EVENTS

PROCESS
MACHINE PROTECTION MEASUREMENT
AND STATUS

MEASUREMENT SHUTDOWN
COMMANDS

MACHINE TRAIN

(illu5580182)

Figure 2 Condition Monitoring - System Integration

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11.5 Data Processing

11.5.1 Processor Performance
The processing capability of the system shall be consistent with the application requirements of
Functional Requirements.
As a general guide to mean response times, simple displays should be started in 1 second and
complete within a further 2 seconds. More complex displays should be started in 1 second and
complete within a further 4 seconds. No displays should have a response time of more than 7
seconds.
11.5.2 Scan Rates
Continuously scanned measurement points shall be scanned at rates consistent with processing
software requirements. For Performance Monitoring purposes, the necessary data shall be captured
within a 10 second period.
11.5.3 Analogue Signal Processing
In order to retain signal intelligence, signals shall, in general, be averaged over periods not greater
than one second prior to processing. Where Fast Fourier Transforms operation is required, anti-
aliasing filtering shall be applied appropriate to the sampling frequency applied.
11.5.4 Data Compression
The application of data compression techniques for data transmission and storage purposes shall not
degrade the data intelligence and any utilised technique shall be reviewed for possible degradation
especially under signal transient conditions. To capture an acceptable quality of transient data while
minimising on data transfer and storage loadings, techniques such as signal deviation controlled data
storage should be considered.
11.6 Open System Data Hand-Off
An Open Network Port shall be provided which shall provide access to the Condition Monitoring
System data and configuration bases including all live, processed and calculated values and
associated engineering units attributes.
It is anticipated that in the future, open systems will replace the need for dedicated terminals on
Condition Monitoring systems. Reference should be made to Functional Engineering and Information
Technology departments to assist in determining the detailed architectural and data transfer
strategies.
11.7 External Data Communications (Existing and Future)
Data communications between the Condition Monitoring system and external systems shall be as
follows:
(1) Honeywell DCS to CM system: Modbus Protocol; asynchronous RS232 electrical interface.
(2) CAPO (Ferranti Argus) to CM system: Modbus or Kermit protocol; asynchronous RS232
electrical interface.
(3) Other SCADA systems to CM system: To be agreed with Functional Engineering.
(4) Portable Electronic Logging Systems to CM system: The Host Condition Monitoring Computer
shall accommodate the protocol and electrical interface required. A minimum data transfer rate
of 9600 Baud is suggested.
(5) Open Network to CM system: The communication standards for open systems are not complete
when preparing this Code of Practice and Project Groups are required to consult their
appropriate Information Technology and Functional Communications Departments for advice.
However it can be stated that Bridged Ethernet technology is likely to be utilised in offshore and
onshore applications. In offshore applications, protocols shall be robust and be suitable for
satellite time delay.
(6) CM processor to Remote CM Operator Station: Satellite robust protocol for offshore
applications; probable bridged ethernet electrical interface as (5) above.

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11.8 Equipment Standards

11.8.1 System Hardware
The system hardware shall be industry standard computer and instrumentation equipment. Where
PCs are employed Information Technology Department preferred types should be utilised subject to
technical and environmental considerations.
Panel instrumentation shall be the manufacturers standard equipment and meet the requirements of
DEP 32.30.10.30 Gen System Cabinets.
Sensors, signal conditioning and monitoring equipment shall be selected from the Preferred Vendors
List, and shall where relevant, meet the requirements of:
DEP 32.31.00.32Instruments for Measurement and Control
API Standard 670: 1976Non-contacting Vibration and Axial Position Monitoring System
API Standard 678: 1981 Accelerometer-Based Vibration Monitoring System
Where possible these shall be obtained form a single Vendor. The use of non-preferred equipment
shall be sanctioned by Functional Engineering.
11.8.2 System Software
The computer Operating System shall be a recognised industry standard system and preferably be
machine portable. e.g. UNIX.
The system software shall have been developed using recognised Quality Control procedures and its
functionality should have been proven either by 3rd party testing or by previous successful field
utilisation, and certified under BS 5750 Part 1 - Specification for design/development, production,
installation and servicing.
A functional and calibration check on the software shall be carried out prior to placing a supply
contract.
11.8.3 Radio-Frequency Interference (Ref. IEC801-3)
The system shall be subjected to an interference test at radio frequencies, by operating a portable
transmitter/receiver at a distance of one metre from the cabinet with the doors open and any
maintenance extender circuit card(s) installed.
The electric field strength measured at the cabinet shall not exceed 10V/m.
The test shall be carried out at frequencies of 70-170 MHz, 460 MHz and the frequency of any
portable transmitters used at the site of destination. During the test the computer equipment shall
remain unaffected, digital signals shall not change status and analogue signals shall not change by
more than 0.5% of span.
11.8.4 Field Equipment
Bearing temperature sensors shall be Platinum resistance temperature detectors or stainless steel
sheathed Chromel/Alumel type thermocouples generally to the requirements of EM/019 Guidelines
For Field Mounted Instrumentation: Offshore Installations.
(Thermocouple sheaths should be 2mm diameter).
Sensors shall meet the requirements of:
API Standard 670: 1976 Non-contacting Vibration and Axial Position Monitoring System
API Standard 678: 1981Accelerometer-Based Vibration Monitoring System
Transducers with current outputs are acceptable subject to environmental and dynamic response
considerations.
The system shall comply with the requirements of: EM/019 Guidelines For Field Mounted
Instrumentation: Offshore Installations.
For hazardous area installations, Intrinsically Safe Ex `i' equipment shall be used where possible.

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The withstand voltage of the signal conditioning equipment and associated cabling shall be consistent
with the maximum voltage which can be impressed upon it under fault conditions from the machinery
electrical power supply taking into account any voltage suppression provisions.
Consideration shall be given to the performance of sensors or transducers located in environmentally
hostile locations with special reference to performance and reliability in response to dynamic
temperature conditions.
11.9 Installation Requirements
The installation shall meet the requirements of:
EM/016 Electrical Facilities Offshore Installations
Instrumentation
EM/019Guidelines For Field Mounted Instrumentation: Offshore Installations
API Standard 670: 1976 Non-contacting Vibration and Axial Position Monitoring System
API Standard 678: 1981Accelerometer-Based Vibration Monitoring System
This is in relation to earthing and shielding which shall be consistent with the RFI requirements of:
Radio-Frequency Interference (Ref. IEC801-3).
Field cabling shall in addition be in accordance with the requirements of:
API Standard 670: 1976Non-contacting Vibration and Axial Position Monitoring System
API Standard 678: 1981 Accelerometer-Based Vibration Monitoring System
As modified by the Amendments in Amendments to API 670:1986 and API 678: 1981.
In process areas where deluge and sprinkler systems are installed, particular attention is to given to
the exclusion in the long term of moisture from the cabling and junction box installation. Field mounted
materials and components shall be resistant to humid, saliferous and corrosive atmosphere. The
limitations of API 670 and 678 with respect to environmental requirements should be appreciated and
reflected in the specification. Refer to:
API Standard 670: 1976Non-contacting Vibration and Axial Position Monitoring System
API Standard 678: 1981 Accelerometer-Based Vibration Monitoring System
Where bearing insulation is installed for protection against circulating currents (e.g. on electric motor
and generator bearings), the design of the sensor installation shall ensure that the integrity of the
bearing isolation and the shielding and earthing requirements are maintained (e.g. by the appropriate
use of insulated glands).
11.10 Maintenance Requirements
Calibration. The system design shall provide calibration and signal injection facilities and test points to
permit ease of calibration and testing of all system inputs from field element to operator terminal.
These shall be integral within the system and the need for the use of field calibration equipment shall
be minimised.
Maintainability. Particular attention shall be paid to the maintainability of the system in terms of ease of
repair, fault diagnostic and fault monitoring provisions, ease of computer back-up and rebooting. It
shall be ascertained that first line maintenance (including preventive maintenance) of the system is
uncomplicated and can be carried out by a competent plant or platform Operations Technician without
the need for technical backup. The maintainability of the system shall be demonstrated by the Vendor
to satisfy the above maintainability and calibration requirements.
Spares. Spares for first line maintenance purposes shall be procured and retained at the user site.
The long term availability of maintenance spares shall be assured. Spares may be purchased or
leased from the Vendor via a maintenance support agreement.
Vendor Support. Vendor support for the computer system shall be assured with particular reference to
the repair of faulty equipment, spares and parts replacement, spares testing, corrective maintenance
support, software support including problem fixing and corrective and functional upgrades and
documentation revisions.

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Documentation. Adequate documentation shall be provided for the installation, maintenance, repair,
modification and operational requirements of the system. Corrective maintenance and preventive
maintenance procedures shall be clear and concise.
Maintenance Scheduling and Reporting. Preventive maintenance routines for the Condition Monitoring
system including end elements shall be entered into the IMIS system. Where existing end elements
are utilised, the adequacy of the prevailing preventative maintenance routine frequency shall be
reviewed.

12 AMENDMENTS TO API 670:1986 AND API 678: 1981

API Standard 670: 1976Non-contacting Vibration and Axial Position Monitoring System
API Standard 678: 1981 Accelerometer-Based Vibration Monitoring System
NOTE: It is expected that during the currency of this specification, a Third Edition of API 670 will
be published. This will include the content of API 670:1986 and API 678:1981 and will be
modified to allow metric dimensions, threads, etc. It also allows for recent developments
in process control and display technology, and specifies technical requirements rather
than methods of implementation of requirements.
The Third Edition of API 670 shall be used, when published. It is not anticipated that major changes to
the technical content of this section will be needed on publication of the new standard.
12.1 Amendments to API 670:1986
The amendments fall into the following categories:
‘Modification' where the API paragraph has been modified: only the modified portions are detailed
in this Standard;
‘Addition’ where additions are made to the API paragraph.
In this section the paragraph numbers in parentheses are the numbers of the API Standard 670
paragraphs to which they refer.
Equipment supplied in accordance with this Standard shall comply with API Standard 670: 1986,
except as amended below.
12.1.1 API SECTION 1 – General
(1.3) REFERENCED PUBLICATIONS – Modifications
The references to NEMA Standards shall be replaced by the following.
BS5420 Degrees of Protection of Enclosures of Switchgear and Control gear for voltages up
to and including 1000V ac and 1200V d.c.
Shell Expro Specification
ER/034 Specification for Electric Cables - Offshore Installations
The reference to NFPA 496 shall be replaced by:
BS5501 Electrical Apparatus for Potentially Explosive Atmospheres Pt.3 : Pressurised
Apparatus
12.1.2 API SECTION 2 - General Design Specifications
(2.1) ACCURACY REQUIREMENTS - Addition:
(3) The Vendor may be required to demonstrate that the equipment supplied complies with the
requirements of this API clause and of API clause (2.3).
12.1.3 API SECTION 3 - Conventional Hardware
(3.2.1) SENSORS – Modification
The standard temperature sensor shall be a Chromel/Alumel (Type K) thermocouple.
Where specified, the standard optional temperature sensor shall be a 100 ohm platinum, resistance
temperature detector.

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Temperature sensors shall comply with the requirements of EM/019 Guidelines For Field Mounted
Instrumentation: Offshore Installations.
(3.3) POWER SUPPLY AND SYSTEMS-OUTPUT RELAYS – Modification
(3.4) MONITORS – Modification
The monitoring hardware and data handling requirements shall be as specified in Instrumentation –
Monitoring Equipment.
(3.5) WIRING and CONDUITS – Modification
(3.6) GROUNDING – Modification
The installation and earthing of all cabling required for condition monitoring shall be carried out in
accordance with EM/016 Electrical Facilities – Offshore Installations.
12.1.4 API APPENDIX B - CABLES - Modification
The construction and arrangement of all cables shall be in accordance with Shell Expro Specification
ER/034 Specification for Electric Cables - Offshore Installations.
12.2 Amendments to API 678:1981
The amendments fall into the following categories:

‘Substitute' where the paragraph has been substituted for the complete API paragraph;

‘Modification' where the API paragraph has been modified: only the modified portions are detailed
in this Standard;

‘Addition' where additions are made to the API paragraph.

In this section the paragraph numbers in parentheses are those of the API Standard 678:1981
paragraphs to which they refer.
Equipment supplied in accordance with this Standard shall comply with API Standard 678: 1981,
except as amended below.
12.2.1 API SECTION 1 - General
(1.5.1) REFERENCED PUBLICATIONS – Modifications
The reference to IPCEA S-61-402 shall be replaced by:
Shell Specification

ER/034 Specification for Electric Cables - Offshore Installations

The reference to NFPA 496 shall be replaced by reference to:

BS5501 Electrical Apparatus for Potentially Explosive Atmospheres, Pt.3: Pressurised

Apparatus

The reference to NEMA ICS 1-110 shall be replaced by:

BS5420 Degrees of Protection of Enclosure of Switchgear and Control Gear for voltages up
to and including 1000V ac and 1200V d.c.

12.2.2 API SECTION 2 - General Design Specifications

(2.1) LINEARITY REQUIREMENTS - Addition:
The Vendor may be required to demonstrate that the equipment supplied complies with the
requirements of this API clause and of API clause (2.3).
12.2.3 API SECTION 3 - Conventional Hardware
(3.5) POWER SUPPLY AND SYSTEMS OUTPUT RELAYS – Substitution

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(3.6) VIBRATION MONITOR – Substitution

(3.7) FILTERS – Substitution
(3.8) MONITOR OPTIONS – Substitution
The monitoring hardware and data handling arrangements shall be as specified in Instrumentation –
Monitoring Equipment.
(3.9) WIRING AND CONDUIT- Substitution
All electric cables shall be in accordance with ER/034 Specification for Electric Cables - Offshore
Installations.
Installation and earthing of all cabling required for condition monitoring shall be carried out in
accordance with EM/016 Electrical Facilities - Offshore Installations.
12.2.4 API SECTION 4 - Transducer Arrangement
(4.1) LOCATION - Substitute:
The number and location of transducers shall be as specified in the Shell Expro Standard ES/077.
(4.3) CHARGE AMPLIFIED MOUNTING - Addition:
Particularly on large machines, the preferred arrangement is to have two junction boxes in which the
charge amplifiers are mounted, one at each end of the machine.
12.2.5 APPENDICES A and B – Substitution
The appropriate specifications shall be used for the cable types outlined, from ER/034 Specification for
Electric Cables - Offshore Installations.

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APPENDIX 1 CONDITION MONITORING GUIDELINES

(1) INTERPRETATION OF GUIDELINES
(2) GUIDELINES FOR EQUIPMENT TYPES
(a) 2.1 Centrifugal Compressors
(b) 2.2 Reciprocating Compressors
(c) 2.3 Auxiliary Equipment - Lubrication Systems
(d) 2.4 Electric Motors
(e) 2.5 Electrical Generators
(f) 2.6 Centrifugal Pumps
(g) 2.7 Gas Turbines
(h) 2.8 Gearboxes

1 INTERPRETATION OF GUIDELINES
The tables in this Appendix have been produced as a result of studies into failure modes on the
different equipment types considered. The work carried out consisted of a systematic assessment of
the following, for each equipment type considered.
• deterioration/failure mode and symptom analysis
• ranking and selection of deterioration modes
• subsequent identification of relevant parameters
• identification, selection and specification of suitable monitoring techniques.
Failure mechanisms related to specific design deficiencies are not considered and should receive
special attention by the user.
The tables in the following sections of this appendix give the recommended methods of condition
monitoring for machines to which the following applies:
(1) Machine is identified as critical from Maintenance Strategy Review.
(2) The machine does not have an installed 'spare'.
(3) The machine is large and of high value.
(4) Condition monitoring is likely to detect the failure modes anticipated as most likely.
It is appreciated that all these factors may not apply in many cases, and that as a result, application of
all the techniques listed would be inappropriate and excessive. It is therefore important that a review is
carried out to identify the machines for which Maintenance on condition is an appropriate strategy, and
the level of criticality of the machines considered. This background information will allow engineering
judgement to be exercised effectively in determining which of the techniques listed are appropriate in a
given situation.
1.1 Guidelines For Equipment Types
1.1.1 Section 2.1
CONDITION MONITORING GUIDELINES
EQUIPMENT: CENTRIFUGAL COMPRESSORS

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8a 7a 8b 7b

3 LUBE OIL SUPPLY TEMP

9 LUBE AND SEAL OIL QUALITY
1
2, 4
2, 4
(il u5580183)

Figure 1 Condition Monitoring for Centrifugal Compressors

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Table 1 Primary Condition Monitoring - Centrifugal Compressors

Ref No. Monitoring Location Sensor and Minimum No. Monitoring

on Parameter Instrument of Sensors Equipment
Figure Type Analysis and
other
Requirements
1 Temperature of Thrust bearing Resistance As: Tilting Pad Continuous
metal adjacent to temperature Type Thrust monitoring for
bearing surfaces detector (RTD) Bearings bearing
or Fixed- temperature
Thermocouple Geometry rise (metal
(TC) Hydrodynamic minus lube oil
Thrust supply
Bearings temperature)
2 Temperature of Radial bearing RTD or TC In accordance Alarm and trip
metal adjacent to with API 670 functions when
bearing surfaces Non maximum
Contacting permissible
Vibration and temperature is
Axial Position exceeded
Monitoring
Scheme
3 Temperature of Supply line RTD or TC One
lube oil
4 Vibration Adjacent to Eddy current Two per Continuous
(Compressor rotor bearing proximity bearing vibration
displacement) journals probes displacement
monitoring in
accordance
with API 670
Non Contacting
Vibration and
Axial Position
Monitoring
Scheme
5 Rotor unbalance Rotor, forward Magnetic One per rotor Access to
(key phaser) or aft sensor or Eddy sensor and
current balance
proximity holes/planes to
probe be provided
6 Axial shaft Thrust bearing Eddy current In accordance Trend axial
displacement proximity with API 670 shaft position at
probes Non common
Contacting operating
Vibration and modes,
Axial Position periodically
Monitoring
Scheme

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Table 1 Primary Condition Monitoring - Centrifugal Compressors (continued)

Ref No. on Monitoring Location Sensor and Minimum Monitoring

Figure Parameter Instrument No. of Equipment
Type Sensors Analysis and
other
Requirements
7 Gas Pressure (a) Pressure (a) Two Plot operating
Compressor transducers or point and
inlet ports for compressor
portable test efficiency on
the compressor
base line
characteristics
to check for
performance
degradation
(b) (b) Two
Compressor
discharge
8 Gas Temperature (a) RTD to TC (a) Two
Compressor RTD or TC
inlet
(b) (b) Two
Compressor
discharge
9 Lubricating and Lube and seal Oil sampling Oil deterioration
seal oil quality oil discharges kit analysis
applied and
trended
periodically for
problem
diagnosis and
oil change
scheduling.

1.1.2 Section 2.2

CONDITION MONITORING GUIDELINES
EQUIPMENT: RECIPROCATING COMPRESSORS

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CYLINDER SEAL OIL CRANKCASE MAIN BEARING

PRESSURE PRESSURE VIBRATION TEMPERATURE
8 11 3 5
ROD DROP BIG-END BEARING
PROBE TEMPERATURE
4 7
1

CROSSHEAD SLIPPER
BEARING TEMPERATURE
PRESSURE PACKING 6
VENT GAS LOSSES
DISCHARGE 2 LUBE OIL
TEMPERATURE QUALITY
9 10

LUBE OIL
PRESSURE
12 (illu5580184)

Figure 2 Simplified Reciprocating Compressor Showing Components where Condition

Monitoring/Protection Techniques should be Applied

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Table 2 Primary Condition Monitoring - Reciprocating Compressors

Ref No. Monitoring Location Sensor and Minimum Monitoring

on Figure Parameter Instrument No. of Equipment
Type Sensors Analysis and
other
Requirements
2 Pressure packing Downstream of V-Cone One per Venturi type
vent gas losses packing on Flowmeter cylinder flowmeter with
horizontal pipe mechanical
run pressure gauge
giving constant
readout
3 Crankcase Where good Accelerometer Two per Primarily used for
vibration transmission of to API 678 crankcase protection, with
vibration Accelerometer- alarm and trip
occurs. Based levels set locally.
Dependant on Vibration May give more
machine Monitoring information in
design System association with
key phaser
4 Rod Drop Crankcase Displacement One per Trend rod to probe
distance piece probe to API piston rod clearance related
in vertical 670 Non to position of
plane Contacting piston (Use key
Vibration and phaser) Periodic
Axial Position measurements If
Monitoring used for protection,
Scheme set alarm and shut
down to 50% and
95% clearance.
5 Main bearing Main bearing Resistance In Trend temperature
temperature caps temperature accordanc related to required
detector or e with API power
thermocouple 670 Non
Contacting
Vibration
and Axial
Position
Monitoring
Scheme
6 Crosshead Lower RTD or One or two Used for protection
bearing crosshead Thermocouple per purposes. Alarm
temperature slipper bearing bearing and shutdown
guide levels set by
operator
experience
7 Big end bearing Big end AMOT Switch One per Used for protection
temperature bearing cap bearing only if potential
problems are
likely. (Reliability
not high)

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Table 2 Primary Condition Monitoring - Reciprocating Compressors (continued)

Ref No. Monitoring Location Sensor and Minimum Monitoring

on Figure Parameter Instrument No. of Equipment
Type Sensors Analysis and
other
Requirements
8 Cylinder Cylinder Pressure One per Take PV diagrams
Pressure tapping transducers location periodically using
portable
equipment.
Acceptable
performance
operator
dependant.
9 Gas discharge Discharge line RTD or One per Trend temperature
Temperature Thermocouple location related to required
power
10 Lube-oil quality Upstream of Oil sampling kit Analyse
filter periodically for
chemical analysis /
flash point / water
content/ additives /
viscosity /
corrosiveness
Lube-oil debris Analyse
periodically for
wear particles and
metals
11 Seal oil pressure Between Pressure One per Used for protection
lubricator and gauge or high only
compressor transducer pressure
line
12 Lube-oil pressure In lure-oil Pressure Two per Used for protection
supply line transducer system only. Alarm and
trip functions (dual
voting)

1.1.3 Section 2.3

CONDITION MONITORING GUIDELINES
EQUIPMENT: AUXILIARY EQUIPMENT
AUXILIARY EQUIPMENT
LUBRICATION SYSTEM
Monitoring of the lubricating oil, in addition to providing information on the state of the main machine
bearings, can also provide data on the condition of the lubrication system itself. To be used effectively
in this way, knowledge of the materials of the lubrication system is needed.
An indication of the faults detectable by monitoring of the lubrication system is given on the following
two pages.
PARAMETER LUBE-OIL PRESSURE
SENSOR PRESSURE TRANSDUCER
NUMBER TWO PER SYSTEM FOR REDUNDANCY
LOCATION IN LUBE-OIL SUPPLY LINE UPSTREAM OF MACHINE

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Table 3 Conditioning Monitoring - Auxiliary Equipment

REF. DEFECT/SYMPTOM PROTECTION MONITORING

NO REQUIREMENTS
REMARKS
LUBE-OIL SYSTEM Alarm Pressure Level Low Alarm Not used for C.M., for
LOSS OF INTEGRITY Pressure Level Low Shut down dual protection only
PIPING FOULING voting
PUMP WEAR Alarm Pressure Level Low Alarm Not used for C.M., for
CNTRL/DRIVE MALF. Pressure Level Low Shut down dual protection only
COOLER FOULING voting
PRESS. CNTRL. Alarm Pressure Level Low Alarm Not used for C.M., for
VALVE MALF. Pressure Level Low Shut down dual protection only
FOULING LUBE -OIL voting
VISCOSITY CH.

PARAMETER LUBE-OIL QUALITY AND DEBRIS

SENSOR OIL SAMPLES TAKEN FOR ANALYSIS
NUMBER ONE SAMPLE POSITION
LOCATION UPSTREAM OF FILTER
Table 4 Conditioning Monitoring - Auxiliary Equipment

REF. DEFECT/SYMPTOM PROTECTION MONITORING

NO REQUIREMENTS REMARKS
PUMP WEAR Alarm Pressure Low Level Monitor metal content of lube-oil
Effectiveness depends on layout
EROSION Alarm Pressure Level Low
of lubrication system and
CORROSION Shut down dual voting sample point. Change of
components can disturb trend
FATIGUE process

COOLER EROSION Alarm Pressure Level Low Monitor metal content of lube-oil
Effectiveness depends on layout
WEAR Alarm Pressure Level Low
of lubrication system and
CORROSION Shut down dual voting sample point. Change of
components can disturb trend
process
LUBE-OIL Alarm Pressure Level Low Sample location up-stream of
CONTAMINATION filter chemical analysis/flash
point, water content etc.,
CHEMICAL Alarm Pressure Level Low
additives / viscosity /
CHANGE corrosiveness
VISCOSITY Shut down dual voting

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1.1.4 Section 2.4

CONDITION MONITORING GUIDELINES
EQUIPMENT: ELECTRIC MOTORS

9
9

3
4 4
2

10

1 TERMINAL BOX
6 LUBE OIL DISCHARGE
7,8 SWITCHGEAR OR MCC (illu5580185)

Figure 3 Condition Monitoring for Electric Motors – CACW

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3
4 4

2
2

10

1 TERMINAL BOX
6 LUBE OIL DISCHARGE
7,8 SWITCHGEAR OR MCC (illu5580186)

Figure 4 Condition Monitoring for Electric Motors – CACA

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4,2

7.8 SWITCHGEAR OR MCC

1 TERMINAL BOX (illu5580187)

Figure 5 Condition Monitoring for Electric Motors – TEFC

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Table 5 Condition Monitoring - Electric Motors

Ref No. Monitoring Location Sensor and Minimum Monitoring Equipment

on Parameter Instrument Type No. of Analysis and other
Figure Sensors Requirements
1 High frequency Motor Rogowski coil One per Monitor and trend average and
discharge Terminal phase (may peak repetitive discharge
box be portable if levels periodically. Specialist
required) examination needed for
diagnosis
2 Bearing shell Radial Thermocouple In C.M. - Trend temperature
temperature bearing (TC) or accordance protection- alarm and
(journal Resistance with API 670 shutdown levels
bearings) Temperature Non-
Detector (RTD) Contacting
Vibration and
Axial Position
Monitoring
System
or Bearing Radial RTD or TC One per C.M. - Trend temperature
temperature bearing bearing protection- alarm level only
(rolling element
bearings)
3 Stator winding Embedded RTD or TC Two per Continuous monitoring of
temperature between phase winding temperature alarm
coil sides levels only
in stator
slots
4 Bearing vibration Adjacent Eddy current Two per Continuous vibration
(Journal to bearing proximity probe bearing displacement monitoring in
bearings) journals accordance with API 670 Non-
Contacting Vibration and Axial
Position Monitoring System
Or Bearing vibration On bearing Accelerometer in As Shaft Continuous vibration
(Rolling element housing accordance with Vibration monitoring in accordance with
bearings) API 678 API 678 Accelerometer-Based
Accelerometer Vibration Monitoring System
Based Vibration
Monitoring System
5 Key phaser At Eddy current One Primary use for diagnostic
accessible proximity probe purposes
end of
rotor
6 Lube-oil quality Sample Oil sampling kit Effectiveness depends on
and debris point at layout of lubrication system
lube-oil and sample point
discharge
7 Stator current Switchgear Ammeter/C.T. One May be useful for driven
equipment performance
monitoring
8 Current Switchgear Current One Normal monitoring using
spectrum transformer (portable) portable equipment at 6 month
Analysis intervals

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Table 5 Condition Monitoring - Electric Motors (continued)

Ref No. Monitoring Location Sensor and Minimum Monitoring Equipment

on Parameter Instrument Type No. of Analysis and other
Figure Sensors Requirements
9 Water leakage Below Capacitive One per No routine monitoring.
(CACW motors cooler detector cooler Protection - alarm on
only) activation
10 Internal air In airflow RTD or TC Two Occasional monitoring
temperature before and needed. Protection - alarm
after only
cooler

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1.1.5 Section 2.5

CONDITION MONITORING GUIDELINES
EQUIPMENT: ELECTRICAL GENERATORS

8
8

1
3
2

4 TERMINAL BOX
5 LUBE OIL DISCHARGE
7 SWITCHGEAR OR MCC (illu5580188)

Figure 6 Condition Monitoring for Alternators

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Table 6 Condition Monitoring - Electrical Generators

Ref No. Monitoring Location Sensor and Minimum Monitoring Equipment

on Parameter Instrument Type No. of Analysis and other
Figure Sensors Requirements
1 Bearing Adjacent Eddy current Two per Continuous vibration
Vibration to bearing proximity probe bearing displacement monitoring in
(Journal journals accordance with API 670 Non-
bearings) Contacting Vibration and Axial
Position Monitoring System
or Bearing On bearing Accelerometer to As Shaft Continuous vibration
Vibration housing API 678 Vibration monitoring in accordance with
(Rolling element Accelerometer (Step 3) of API 678 Accelerometer-Based
bearings) Based Vibration this Spec. Vibration Monitoring System
Monitoring System
2 Bearing shell Radial Thermocouple In C.M. - Trend temperature
temperature bearing (TC) or accordance protection- Alarm and
(Journal Resistance with API 670 shutdown levels
bearings) Temperature Non-
Detector (RTD) Contacting
Vibration and
Axial Position
Monitoring
System
or Bearing Radial RTD or TC One per C.M. - Trend temperature
temperature bearing bearing protection- Alarm only
(Rolling element
bearings)
3 Stator winding Embedded RTD or TC Two per Continuous monitoring of
temperature between phase winding temperature. Alarm
coil sides levels only
in stator
slots
4 High frequency Generator Rogowski Coil One per Monitor and trend average and
discharge terminals phase (may peak repetitive discharge
be portable if levels periodically. Specialist
required) examination needed for
diagnosis
5 Lube-oil quality Sample Oil sampling kit Effectiveness depends on
and debris point in layout of lubrication system
return line and sample point
(before
filter)
6 Water leakage Below Capacitive One per No routine monitoring.
cooler detector cooler Protection - alarm on
activation
7 Electrical Switchgear Overcurrent / No routine monitoring. Trip on
protection Earth fault relay. activation
Differential
protection relay.
Impedance relay
8 Internal air In airflow RTD or TC Two Occasional monitoring
temperature before and needed. Protection - alarm
after only
cooler

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1.1.6 Section 2.6

CONDITION MONITORING GUIDELINES
EQUIPMENT: CENTRIFUGAL PUMPS

4 1,2 3 1,2 4

7 7

5c
5b
(illu5580189)

5a

5a 5b 5c

Figure 7 Condition Monitoring for Centrifugal Pumps

2 1 3 3 1 2

4 4

5c
5b
(illu5580190)

5a

5a 5b 5c

Figure 8 Condition Monitoring for Centrifugal Pumps (continued)

Table 7 Condition Monitoring - Centrifugal Pumps (Rolling Element Bearings)

Ref No. Monitoring Location Sensor and Minimum Monitoring Equipment

on Parameter Instrument Type No. of Analysis and other
Figure Sensors Requirements
1 Bearing Radial Thermocouple One per Protection - alarm level only.
temperature bearing (TC) or bearing C.M. - Trend Temperature
Resistance
Temperature
Detector (RTD)
2 Bearing vibration Radial Accelerometer in As Shaft Continuous vibration
bearing accordance with Vibration monitoring in accordance with
API 678 (Step 3) API 678 Accelerometer-Based
Accelerometer Vibration Monitoring System
Based Vibration
Monitoring System
3 Lubricating oil Supply line Pressure One Used for protection only
pressure transducer

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Table 7 Condition Monitoring - Centrifugal Pumps (Rolling Element Bearings) (continued)

Ref Monitoring Location Sensor and Minimum Monitoring Equipment

No. on Parameter Instrument Type No. of Analysis and other
Figure Sensors Requirements
4 Lubricating oil Lube-oil Oil sampling kit Oil deterioration analysis
quality discharge applied and trended
periodically for problem
diagnosis and oil change
scheduling
5 Pump (a) Inlet or (a) Orifice flow Ensure suction orifice is
performance discharge meter suitable for full flow (inc.
flow recirculation). Speed
measurement reqd. for
(b) Inlet and (b) RTDs or TCs variable speed pump
discharge
temperature
(c) Inlet and (c) Ports for
discharge portable test
pressures gauge or sensors
for permanent
system

Table 8 Condition Monitoring - Centrifugal Pumps (Journal Bearings)

Ref Monitoring Location Sensor and Minimum Monitoring Equipment

No. on Parameter Instrument Type No. of Analysis and other
Figure Sensors Requirements
1 Temperature of Thrust Thermocouple Two Continuous monitoring for
metal adjacent bearing (TC) or embedded in bearing temperature rise
to bearing Resistance each bearing (metal minus lube oil supply
surfaces Temperature temperature) per bearing
Detector (RTD)
2 Temperature of Journal Thermocouple Two Alarm and trip functions when
metal adjacent bearing (TC) or embedded in maximum permissible
to bearing Resistance each bearing temperature is exceeded
surfaces Temperature
Detector (RTD)
3 Axial shaft Thrust Proximity probes In Trend axial shaft position at
displacement bearing accordance common operating modes
with API 670 periodically
Non-
Contacting
Vibration and
Axial Position
Monitoring
System
4 Radial shaft Adjacent to Eddy current Two per Vibration displacement
displacement each proximity probe bearing (as monitoring in accordance with
bearing API 670 Non- API 670 Non-Contacting
journal Contacting Vibration and Axial Position
Vibration and Monitoring System
Axial Position
Monitoring
System

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Table 8 Condition Monitoring - Centrifugal Pumps (Journal Bearings) (continued)

Ref Monitoring Location Sensor and Minimum Monitoring Equipment

No. on Parameter Instrument Type No. of Analysis and other
Figure Sensors Requirements
5 Pump (a) Inlet or (a) Orifice flow Ensure suction orifice is
performance discharge meter (b) RTDs or suitable for full flow (inc
flow (b) TCs (c) Ports for recirculation). Speed
Inlet and portable test measurement reqd. for
discharge gauge or sensors variable speed pump
temperature for permanent
(c) Inlet and system
discharge
pressures
6 Lubricating oil Lube-oil Pressure Used for protection only
pressure supply line transducer
7 Lubricating oil Lube-oil Oil sampling kit Oil deterioration analysis
quality discharge applied and trended
periodically for problem
diagnosis and oil change
scheduling

1.1.7 Section 2.7

CONDITION MONITORING GUIDELINES
EQUIPMENT: GAS TURBINES
PREFERRED CONDITION MONITORING - GAS TURBINES
1.1.8 1 Introduction
The aim of this appendix is to give some guidance on the preferred methods of condition monitoring
for Gas Turbines. Information is given for both the gas generator and power turbine components. For
detailed notes on specific methods of monitoring refer to the section in the main document for the
technique concerned. The data given here is necessarily generalised, since the turbines used vary
considerably in design and construction. As a result, the sensors required, their positions, and the
access available for fitting them vary significantly. The construction may therefore limit the monitoring
possible.
This appendix is prepared on the basis of the following information:
(1) Thornton Research Centre report TNGR.94.011 - Deterioration mode analysis and standard
procedures for condition monitoring of gas turbines.
(2) PDO Asset Management Manuals, Ref. EP95-2902 to EP95-2908. These outline the monitoring
used, and the significant failure modes experienced with the gas turbines used in PDO.
(3) Avon and RB211 Condition Monitoring. Presentations by RRIMGT to Operators Conference,
October 1995.
The data in these reference documents is complementary, since the PDO data concentrates on the
gas turbine itself; the TRC document directs attention to the ancillary equipment (e.g. for fuel supply
and lubrication) in the turbine package, and the RR data covers performance monitoring of specific
gas turbine types. The information in these documents is supplemented and amended where
necessary by experience gathered from review of the maintenance work carried out in Shell Expro.

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1.1.9 2 Preferred Methods of Monitoring

When considering the monitoring of gas turbine units, two aspects need to be considered. Firstly, the
experience gained suggests that condition monitoring techniques may have more limitations for a gas
turbine than for some other equipment types. A significant proportion of the possible faults do not give
clear indications of their presence using techniques that can be applied with the turbine running. A
shutdown and inspection (e.g. by boroscope) is needed to detect these. Secondly, much of the
unplanned downtime comes from faults in auxiliaries such as the fuel supply, lubrication or control and
starting systems. Some characteristics of these (e.g. lube oil pressure) are measured to provide
protection functions. The relationship between variables in these systems is related to the operating
point of the gas turbine, so for critical systems it is recommended that the auxiliaries are also
monitored. Refer to Appendix 3 for data on the monitoring of lube oil systems.
With these points in mind, the suggested techniques are indicated on the following pages. In each
case it is necessary to refer to the Notes, below, for comment on the effectiveness and application of a
particular technique.
1.1.10 3 Notes
(1) Casing Vibration - 'Aero derivative' gas turbines on most 'aero derivative' gas turbines, access
to the rolling element bearings for fitting of monitoring devices is limited or impossible.
Measurement of vibration is therefore limited to casing accelerometers. The transmission paths
for vibration from the bearings to the casing may be long and indirect. While overall casing
vibration level is used as part of the machine protection, this limited access restricts the use that
can be made of vibration monitoring as a diagnostic tool. Each model of turbine should be
assessed individually, and monitoring points on the casing used (1) where specified by the
vendor for protection purposes, and (2) where otherwise safely accessible. One location
sometimes used is on auxiliary gearboxes, to monitor these components as well as the main
turbine.
(2) Shaft Displacement 'Industrial' gas turbines Most industrial gas turbines use sleeve bearings,
and in a number of designs there is sufficient access to these bearings to fit displacement
probes. In these instances standard monitoring procedures for sleeve bearings should be used.
(3) Bearing Temperature This applies mainly to industrial turbines with sleeve bearings, where
there may be access to fit thermocouples as well as vibration probes. This can give both
monitoring and protective functions.
(4) Lube-oil Quality The sampling location must be upstream of any filters in the oil system. This
technique is primarily useful for determining when the oil should be changed.
(5) Lube-oil Debris The detectors used are:
(a) Magnetic Plugs. These require shut-down of turbine for examination.
(b) Detectors monitoring presence of debris in oil flow. These must be placed upstream of
any filters, and are used for on-line monitoring.
(6) Performance Monitoring For meaningful gas generator performance monitoring a simple
trending procedure of a small number of basic performance parameters is generally what is
required. The preferred monitoring parameters are:
• Ambient pressure and temperature.
• Air inlet (filter) differential pressure.
• Gas generator and power turbine speeds.
• Compressor inlet and exit pressures.
• Compressor inlet and outlet temperatures.
• Exhaust temperatures and spread.
• Fuel flow and quality (calorific value etc).
• Variable Inlet Guide Vane Angle.

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A more limited assessment of performance can be made provided the following minimum of data is
available:
• Air intake temperature.
• Barometric Pressure.
• Gas generator speed.
• Exhaust gas temperature.
• Compressor delivery pressure.
• Variable Inlet Guide Vane Angle.
2 2B 2A 2

1 1 1

P1 VARIABLE INLET GUIDE VANE ANGLE P2 Wf P4

T1 T2 Wt T4 (ECT)

7 (See Notes on Ref. 6)

3 3 3
(illu5580192) Gas Generator Power Turbine

Figure 9 Condition Monitoring for 'Aero derivative' Gas Turbines

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2B 2 7 2 6 2 2B 2

GAS GENERATOR C.T. P.T.

3 3 2A 3 3 2A 3 3
(illu5580193)

Figure 10 Condition Monitoring for 'Industrial' Gas Turbines

1.1.11 Section 2.8
CONDITION MONITORING GUIDELINES
EQUIPMENT: GEARBOXES
NOTE: The gearbox shown in this drawing has journal bearings. On appropriate sizes/speeds of
gearbox rolling element bearings may be used.

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 ES/077
Rev 2 1996

INPUT

3 2 1 2 4 3 6 5 8

2 3 2 7 3 1

OUTPUT
Note: The gearbox shown in this drawing has journal bearings.
On appropriate sizes/speeds of gearbox rolling element
bearings may be used. (illu5580194)

Figure 11 Condition Monitoring for Main Gearboxes

Table 9 Preferred Condition Monitoring – Gearboxes

Ref Monitoring Location Sensor and Minimum Monitoring Equipment

No. Parameter Instrument Type No. of Analysis and other
Sensors Requirements
1 Temperature of Thrust RTD or 2 embedded Continuous monitoring for
metal adjacent Bearing Thermocouple in each bearing temperature rise.
to bearing bearing (1 Alarm/Trip function
surfaces spare)
2 Temperature of Journal RTD or 2 embedded Continuous monitoring for
metal adjacent Bearings Thermocouple in each bearing temperature rise.
to bearing bearing (1 Alarm/Trip function
surfaces spare)

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 ES/077
Rev 2 1996

Table 9 Preferred Condition Monitoring – Gearboxes (continued)

Ref Monitoring Location Sensor and Minimum No. of Monitoring Equipment

No. Parameter Instrument Type Sensors Analysis and other
Requirements
3 Radial shaft Gearbox Eddy Current Two per bearing Vibration displacement
Displacement bearing proximity probes (As API Standard monitoring in accordance
(Journal journals 670: 1976 Non- with API Standard 670:
Bearings) contacting 1976 Non-contacting
Vibration and Vibration and Axial Position
Axial Position Monitoring System
Monitoring
System
3A Bearing Bearings Accelerometer in As API Spec. Vibration monitoring in
Vibration accordance with accordance with API
(Rolling API Standard Standard 678: 1981
Element Brgs.) 678: 1981 Accelerometer-Based
Accelerometer Vibration Monitoring System
Based Vibration
Monitoring
System
4 Casing Gearbox Accelerometer Two. In axial and
Vibration casing (Ensure response vertical/horizontal
covers gear mesh planes
harmonics)
5 Lubricating Oil Lube-oil Oil sampling kit Oil deterioration analysis
Quality discharge applied and trended
periodically for problem
diagnosis and oil change
scheduling
6 Lube-oil Supply line RTD or One
temperature Thermocouple
7 Key Phasor Output Proximity probe One Where suitable, key phasor
shaft from driven equipment may
be used
Optional Monitoring
8 Oil Debris Gearbox Magnetic plug or Periodic analysis based on
Analysis Oil Drain Oil Sampling Kit equipment criticality

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