COMPARISON OF OVERALL CONDITION RATING SINCE IMPLEMENTATION OF PDM PROGRAM

OVERALL CONDITION MONTORING COMPARISON

BELOW ALARM EXCEEDING ALARM
SURVEY
GOOD (A) FAIR (B) ALARM 3 (C<30%) ALARM 2 (C>30%)
DATE
Feb-18
Mar-18
Apr-18 0% 60% 29% 8%

GRAPH BAR OVERALL CONDITION MONITORING COMPARISON

0.7

0.6

0.5

0.4

0.3
Apr-18
Mar-18
0.2 Feb-18

0.1

0
) ) %) %) )
(A (B 0 0 (D ED
IR <3 1 IR
OD FA (C (C>3 M Q U
GO 3 2 LAR RE
M M A N
AR AR TIO
AL AL AC
G ALARM
ALARM 1 (D) ACTION
REQUIRED

3% 40%

Apr-18
Mar-18
Feb-18
OVERALL CONDITION RATING REPORT
MACHINE NOT IN ALARM
MACHINE LOCATION
GOOD (A) FAIR (B)

GATHERING STATION 01 DB 13
DB 14
DB 15
DB 16
DB 17
DB 18
SB 11
SB 12
SB 14
SB 16

GATHERING STATION 02 IR 21
SB 21
SB 22
SB 23
SB 24
DB 21
DB 23

GATHERING STATION 03 UCP 32

UCP 33
UCP 34
UCP 35
DB 31
DB 32
SB 33
SB 34

GATHERING STATION 04 BJU 41

SB 41
SB 42
SB 43
DB 45

GATHERING STATION 05 DB 51
DB 53
DB 54
 BJU 51
BJU 52
SB 51
SB 53
SB 54

GATHERING STATION 06 SB 61
SB 64
SB 67
SB 68
IR 62

GATHERING STATION KOTA BATAK DB 12A

DB 12B
DB 12C
DB 12D
DB 12F
DB 12G
Total Summary 0 49
Percent Summary 0% 63%
 DATE: Apr-18

MACHINE WITH DETECTED PROBLEM (IN ALARM)

Schedule Repair at Maintenance Required
Trend Problem Only
Covenience ASAP
ALARM 3 (C<30%)
ALARM 3 (C>=30%) ALARM 1 (D)
BJU 11 SB 15
DB 11
DB 12
SB 13

BJU 21
DB 22

SB 32 SB 31 UCP 31

SB 44 DB 44 DB 43
DB 41
DB 42

DB 55 DB 56
DB 52 DB 58
DB 57
SB 52

SB 62
SB 65
SB 63
SB 66

DB 9A IR 11B
DB 9B
IR11A

21 6 2
27% 8% 3%
GS 01
GS 01
GS 01
GS 01
GS

SB 13
SB 15

DB 11
BJU 11
TAG
MACHINE NAME

X
UNBALANCE
MISALIGMENT/SOFT FOOT
BENT SHAFT
LUBRICANT PROBLEM

X
BEARING PROBLEM

X
X MECH. LOOSENESS
RESONANCE PROBLEM

X
VANE PASSING PROBLEM
CAVITATION
MOTOR ELECTRICAL
OIL WHIRL/WHIP
X

LOOSE FOUNDATION
MACHINE INDICATED PROBLEM(S)

X
VIB. MONITOR PROBLEM
SORTED FIRST BY PROBLEM PRIORITY, THEN BY PROBLEM SEVERITY WITHIN PRIORITY

INSTRUMENT PROBLEM
SEAL/ROTOR RUB
SUMMARY OF RESULT AND RECOMMENDATION FOR MACHINES FOUND TO HAVE PROBLEM

X
PUMP LOW PERFORMANCE
OTHER REMARKS

C
C
C
C

MACHINE STATUS

PRIORITY OF PROBLEM
P3
P3
P3
P2
GS 01 DB 12 X X X C P3

GS 01 BJU 12 X X P4

GS 01 DB 13 X X P4

GS 01 DB 14 X X P4

GS 01 DB 15 P4

GS 01 DB 16 X X P4

GS 01 DB 17 P4
GS 01 DB 18 X X P4

GS 01 SB 11 X X P4

GS 01 SB 12 X X X P4

GS 01 SB 14 X X P4

GS 01 SB 16 X X P4
GS 01 IR 11
GS 01 IR 12
GS 02 IR 21 X X P4

GS 02 SB 21 X X P4

GS 02 SB 22 X P4

GS 02 SB 23 X P4

GS 02 SB 24 X P4

GS 02 DB 21 X X P4

GS 02 DB 23 X X P4

GS 02 BJU 21 X C P3

GS 02 DB 22 X C P3
GS 03 UCP 31 X D P1

GS 03 UCP 32 X B P4

GS 03 UCP 33 X X B P4

GS 03 UCP 34 P4
GS 03 UCP 35 P4

GS 03 DB 31 P4
GS 03 DB 32 X P4

GS 03 SB 31 X P2

GS 03 SB 32 X P3

GS 03 SB 33 P4
GS 03 SB 34 X P4

GS 04 DB 43 X X D P1
GS 04 DB 44 X X C P2

GS 04 SB 44 X X C P3

GS 04 DB 41 X X C P3

GS 04 DB 42 X X C P3

GS 04 BJU 41 X B P4

GS 04 SB 41 X B P4

GS 04 SB 42 B P4
GS 04 SB 43 X X B P4
GS 04 DB 45 X B P4

GS 05 DB 56 X X C P2

GS 05 DB 58 X X C P2

GS 05 DB 55 X X C P3
GS 05 DB 52 X X C P3

GS 05 DB 57 X C P3

GS 05 SB 52 X C P3

GS 05 DB 51 P4
GS 05 DB 53 X X P4

GS 05 DB 54 X X P4

GS 05 BJU 51 X X P4
GS 05 BJU 52 X X P4
GS 05 SB 51 X P4

GS 05 SB 53 X P4

GS 05 SB 54 X P4
GS 06 SB 62 X X C P3

GS 06 SB 65 X C P3

GS 06 SB 63 X X C P3
GS 06 SB 66 X C P3

GS 06 SB 61 X X P4

GS 06 SB 64 X X P4
GS 06 SB 67 X P4
GS 06 SB 68 P4
GS 06 IR 62 P4

40

35

30 17 16 0 1 8 3 2 36 3 0 0 2 2 1 5 1

25

20

15

10

0
CE T FT M M SS M M N AL HI
P N M
AN FOO HA BLE BLE
ENE BLE BLE TIO RIC W TIO BLE
L S O O S O O A CT L/ A O
BA FT T PR PR PR PR VI
T
ND PR
UN /SO BEN T G LOO E G CA ELE HIR U R
N . C IN R W O
EN
T
ICA A RI
N
ECH AN SS TO IL SEF NITO M
R N A O
IL G
M
U B BE M SO E P M
O
O O
M
O
TRU
L RE L S
ISA
N B. IN
M VA VI
 % ALARM

6%
12%
20%
40%
% CHANGE FROM PREV

POSITION
CASING

LEVEL (mm/s)

-
-

6.9
7.5
POSITION
SHAFT

LEVEL (mils)

2.727
2.926
0
0
3% 0.9 0.064

0% 3.0 1

0% 0.7 0.627

0% - 0

0% - 0

0% - 0

0% - 0
0% - 0

0% - 0

0% - 0

0% - 0

0% -
OK

OK

OK

OK

OK

OK

OK

21%

17%
481% 48% P1V 8.3 PIY 6.67

0% 43% P1V 5.4 PIX 1.176

0% #DIV/0! 4.6 P1V 1.634

0%
0%

0%
0%

57%

22%

0%
0%

141% #DIV/0! MIH 6.5 MIY 4.286

54% 151% MIV 11.5 MIX 2.468

5% 44% PIH 6.9 PIY 2.236

5% 38% P1H 6.8 POX 1.887

1% 51% P1H 6.4 PIX 1.43

0% 54% P1V 5.4 MOY 2.61

0% 29% MOV 4.7 POX 1.798

0% 68% PIV 3.3 POY 0.912

0% 98% P1V 4.6 MIY 1.343
0% 87% PIA 5.9 MIX 2.284

38%

30%

24%
7%

4%

1%

0%
0%

0%

0%
0%
0%

0%

0%
22%

18%

18%
 12%

0%

0%
0%

Row 83

P N B E
HI TIO LE
M
LE
M
RU NC
/W A O B O B R A
IRL ND PR PR OT
O
OR
M
H O U R T R F
EF ITO EN L/ PE
R
S N U M S EA
O O W
LO M TR LO
IB. INS P
V M
PU
DATE : April 2018

RECOMMENDATIONS AND REMARKS

For structural looseness/grouting minor damage issue.

1. Plan to repair grouting/foundation before vibration getting worse and damage other component at motor.
2. See attach schematic for repair planning. Photo will be updated soon.
3. Forecasting vibration at motor casing will be reach Danger status on Early February 2019 (see plot MOH)

For early bearing defect at pump inboard.

1. Trend data to know if evidence still increase or not

1. Trend vibration data, if vibration going better gradually, it can be assumed seal/wear ring has fitted
properly.
2. Try exercise of control valve open due to hydraulic unbalance issue. Evaluate operating condition to pump
Best efficiency point (BEP). Run pump as possible near BEP to reduce high radial force vibration and achieve
optimum efficiency.
3. Trend orbit data at pump DE and NDE due to early bearing scratch issue (bearing clearance issue at pump
NDE)

1. Swap card modul Bently on pump inboard and outboard, if vibration decrease and normal value after swap
card modul Bently then replace with a new one.
2. Equipment is in good condition. Trend vibration data.

1. Based on finding data, pump was low performance since flow rate only 24199 BPD (around 30% from
normal value).
2. Sideband at vane pass frequency may indicate vane problem or clearance bearing problem. To verify this
analysis then check bearing clearance.
3. Spectrum and orbit at pump inboard indicated instabilities and may due to shaft instabilities or bearing
clearance.
4. Both clearance problem at bearing or wear ring and vane problem (maybe had been degraded) may affect
pump performance.
5. Since high vibration at inboard (suction vane), restriction at suction may affect pump flow rate.
1. Trend sideband 1xTS around vane pass frequency which may indicated impeller vane problem.
2. Check sleeve bearing degradation on pump DE by perform oil analysis
3. On next window opportunity check sleeve bearing clearance (lift play) and thrust bearing clearance (end
play).

1. Trend vibration data 5xTS at point PIV and P1V

2. Trend orbit plot at pump NDE due to slight rub; compared to oil analysis result.
1. Trend frequency 7xTS at point PIV. Change of amplitude and pattern may indicated process change or
process problem.
2. Trend data on sleeve bearing inboard due to slight rub.

Since vibration still normal value please trend and close monitoring on:
1. Motor axial direction 3xTS due to resonance issue which may be excited from harmonics of 1xTS.
2. Pump sub harmonic frequency which indicate early thrust bearing defect balance piston instability due to
process flow.
3. Trend vane pass frequency especially on point PIH P1V.

Since vibration still normal value please trend and close monitoring on:
1. Motor axial direction 3xTS due to resonance issue which may be excited from harmonics of 1xTS.
2. Trend vane pass frequency especially on point PIV PIA.

Since vibration still normal value please trend and close monitoring on:
1. Trend vane pass frequency especially on point PIV PIA.
2. Trend unbalance issue on pump inboard and motor inboard.
Unit OFF

Since vibration still normal value please trend and close monitoring on:
1. Trend vane pass frequency especially on point PIV and its sideband due to impeller problem.
2. Trend flow rate at same CV open to monitoring effect of 1xTS sideband of VPF
3. Trend orbit pattern which indicate slight misalignment. On next PM window, please check alignment figure
of this unit.

1. On next PM replace RTD4 and proximity sensor at inboard X motor.

2. On next PM please check cable, probe, card module at pump inboard due to instrument error.
3. Trend vane pass frequency. Changing in pattern and amplitude may indicated problem on process or
clearance issue.

To know the root cause of evidence high impacting on outboard bearing please do this step:
1. Check alignment figure, adjust if needed.
2. Check bearing clearance on pump DE and NDE due to bearing loose fit issue.
3. Replace lube oil on NDE pump due to high contamination and high ferrous.
4. Check shaft centerline by performing vibration analysis when pump start to load to know eccentricity issue.

All parameter still at acceptable level. Please trend data on:

1. Orbit plot pattern change
2. Vane pass frequency on plot PIV and P1V

All parameter data still at acceptable value and normal condition. Please trend:
1. Process turbulence flow which may affect pump efficiency
2. Monitor slight rub and compare with oil analysis.
1. On next PM You should check for parallel and angular misalignment of the shaft center lines
2. Please recheck the process flow conditions or the internal dimensions of this unit. If pump was running out
BEP, then the problem was due to hydraulic issue rather than excessive clearance on bearing or wear ring.
Peak trending specifically on pump DE sleeve bearing.

1. Overall equipment in good condition.

2. Continue monitoring and trending.

Since vibration trend are stable and normal value, continue monitoring.

1. Continue monitoring.
2. Trending peak for 1x RPM and orbit plot motor DE NDE.
3. Check RTD instrumentation and replace if needed

Since vibration trend are stable and low level value, keep running on this condition.

1. Continue monitor for peak trending, specifically for thrust NDE pump.
2. Evaluate operating parameter and compared to BEP.

1. Keep monitoring to trend of especially on point PIV P1V

2. Repair BNC panel and replace RTD 6

1. Check end play and lift play thrust bearing.

2. Check lube oil condition by perform oil analysis
3. Plan to replace thrust bearing if trend still increasing

1. Please recheck the process flow conditions or the internal dimensions of this unit. If pump was running out
BEP, then the problem was due to hydraulic issue rather than excessive clearance on bearing or wear ring.
1. To ensure analysis, please check equipment history of pump between October 10, 2014 and February 4,
2015. Please provide data maintenance activity had been done at pump unit since October 10, 2014, for
detailed analysis.
2. Provide trending data vibration at monitor logging between October 10, 2014 and February 4, 2015 to
ensure the evidence of increasing at pump inboard.
3. Shutdown equipment and check shaft roundness or run-out using gap voltage of proximity probe (after
ensure the probe and cables are in good condition)
4. Further recommendation will be given after step recommended action done properly

Since vibration trend stable and normal condition, Please trend:

1. Vane pass frequency on P1V and its sideband
2. Stretch or glitch on shaft inboard pump
1. Close monitoring at trust bearing temperature and vibration due to early stage bearing failure.
2. Keep monitoring this equipment.
0

1. On next PM, verify shaft scratch at NDE motor by measure gap voltage at slow roll motion shaft.
2. Keep running on this condition.
3. On next vibration surveillance, take high resolution analysis on motor.

Since vibration trend is stable and normal value, continue monitoring.

1. On next PM please alignment on this unit
2. Keep monitoring on this condition.

1. Strongly recommended plan to cleaning and inspect rotor motor condition before it reach danger status.
High vibration on motor may reduce bearing life and high power consumptions. Do Balancing at workshop if
needed.
2. Reducing vibration on motor can saving cost from high power consumptions.

1. On next vibration surveillance, please inspect for loose bolt or loose foundation (weak base) by measuring
phase on base plate and visual inspection.
0
1. Trend unbalance issue on rotor motor
2. Continue monitoring

There 2 evidence which may interact and influenced together:

Electrical unbalance
1. Since high vibration is real and can damage other component, please manually shut down pump unit
immediately.
2. Take vibration data when unit manually shut off to verify electrical fault.
3. If current unbalance is suspected, high vibration at motor will disappear and decrease suddenly. Take
vibration transient will more useful.
4. But if vibration decreasing slowly, mechanical fault may be the main issue.

Coupling misalignment
5. After pump manually shut down
6. Uncouple motor and pump to eliminate other possibilities.
7. Check alignment figure and make sure still at acceptable level.
8. Solo run motor and check vibration to ensure source of high preload on motor.
On next surveillance please check, the source high preload by measuring:
1. Cross phase on coupling motor inboard and pump inboard.
2. Soft foot/loose bolt condition by measuring.
3. Visual inspection on base plate and foundation.

On next PM, please check and adjust if needed alignment of this unit.

Since vibration still at low level please trend:

1. Unbalance issue on rotor motor
2. Vane pass issue on pump and compare to operating condition.
1. Prepare to check thrust bearing on pump unit, replace If needed.
2. Continue monitoring on vane passing frequency and its operating parameter.

Since vibration is still low level, please trending and monitoring:

1. On next PM You should check for parallel and angular misalignment of the shaft center lines
2. Please recheck the process flow conditions or the internal dimensions of this unit. If pump was running out
BEP, then the problem was due to hydraulic issue rather than excessive clearance on bearing or wear ring.

Since vibration still normal level, please trend:

1. Internal motor preload due to different bearing stiffness (bearing life)
2. Trend suspected structural looseness on pump

1. Please recheck the process flow conditions or the internal dimensions of this unit. If pump was running out
BEP, then the problem was due to hydraulic issue rather than excessive clearance on bearing or wear ring.
2. Trend rotor unbalance on motor.

1. Vibration level both pump and motor are in good condition.

1. Keep monitoring pressure and flow rate for this pump.
1. Check and evaluate operating pressure and flow rate and compare to BEP.
2. Trending data pump flow rate as indication of flow passing through axial direction.
3. High vibration at axial direction also can reduce thrust bearing life.

1. For further analysis, try to exercise percent of control valve open to mapping BEP to reduce vibration
severity which caused by vane passing or hydraulic disturbance.
2. On next PM, please check alignment on this unit.

Try to reduce, high radial load from vane pass by:

1. Operate pump near BEP, adjust valve and monitoring vibration
2. On next PM, Check clearance configuration such as clearance wear ring, vane tip, also bearing without
disassembly part
3. Prepare to replace sleeve bearing pump inboard due to indication of out of clearance.
4. Ensure high bearing temperature on motor DE and NDE by perform IR thermograph

Keep monitoring trending vibration and temperature thrust bearing

1. For further analysis, try to exercise percent of control valve open to mapping BEP to reduce vibration
severity which caused by vane passing or hydraulic disturbance.
2. On next PM, please check end play thrust bearing due to bearing problem.
3. Plan to replace thrust bearing pump
1. For further analysis, try to exercise percent of control valve open to mapping BEP to reduce vibration
severity which caused by vane passing or hydraulic disturbance.
2. On next PM, please check alignment on this unit.

1. For further analysis, try to exercise percent of control valve open to mapping BEP to reduce vibration
severity which caused by vane passing or hydraulic disturbance.
2. To ensure high temperature at bearing motor, cross check temperature at bearing casing motor side with
thermal cam.
3. Since from baseline at Mar 2017, pump was running smoothly (low vibration), check all parameter related
to operating condition and make it as baseline operating condition.

1. If trending still increase, please prepare to cleaning unit on workshop and do balancing if required.

OFF
1. For further analysis, try to exercise percent of control valve open to mapping BEP to reduce vibration
severity which caused by vane passing or hydraulic disturbance.
2. On next PM, please check alignment on this unit.
3. On next PM, please check lift play on pump sleeve bearing inboard.

1. For further analysis, try to exercise percent of control valve open to mapping BEP to reduce vibration
severity which caused by vane passing or hydraulic disturbance.
2. Check multilink panel due to indication multilink panel error or broken
OFF
OFF
1. Plan to check lift play sleeve bearing NDE and DE pump
2. Check endplay thrust bearing pump
3. If bearing clearance already out of tolerances, replace bearing.
4. Check proximity cable on pump DE due to indication error.

1. Keep running on this condition.

2. Continue monitoring.
OFF DUE TO MAINENANCE

1. On next PM, please check and cleaning air filter motor due to suspected dust entering inside casing.
2. Trend 1xTS on motor, if trending increase gradually, then prepared to cleaning rotor.
3. Unbalance may cause short bearing lifetime.
4. For cavitation issue, make sure tank level has enough supply. Try to control flow rate to reduce cavitation
issue.

Since trend are stable and still at acceptable level please trend:
1. Vane pass issue at point P1V.
2. Close monitoring at 2xLine on motor

Since trend are stable and still at acceptable level please trend:
1. Vane pass issue at point P1V and PIV
2. Suspected unbalance at rotor motor.
 1. Trend vibration amplitude at vane pass frequency and compare to flow rate and discharge pressure.
2. Trend process flow turbulence suspected restriction presents on pump.
3. On Motor casing measurement, take high resolution data on next surveillance and take high frequency
related to rotor bar issue.

Since trend are stable and still at acceptable level please trend:
1. Vane pass issue at point P1V and PIV
2. Suspected unbalance at rotor motor.

OFF
OFF
off
off

Row 83

B CE
AN
M
FOR
R
PE
PDM MACHINE REPAIR LOG

MACHINE DATE
MAINTENANCE ACTION