PROGNOST速-SenSim
Contents
Enhance Safety Proof Test Intervals (PTI) .................................................................................................................................... 4 One device for all testing routines ............................................................................................................................................... 5 Simulation instead of stimulation ................................................................................................................................................ 6 PROGNOST速-SenSim Generator ................................................................................................................................................. 10 PROGNOST速-SenSim Handheld ................................................................................................................................................... 12 PROGNOST速-SenSim Starter Kit .................................................................................................................................................. 13 It all adds up to PROGNOST速-SenSim .......................................................................................................................................... 14
Enhance Safety Proof Test Intervals (PTI) Safety Instrumented Systems (SIS) perform specified functions to achieve a safe state of process when dangerous conditions occur. It is their aim to mitigate consequential events. Safety loops of Safety Instrumented Systems consist of: • Sensors • Logic solvers (processing the sensor signal and giving outputs) • Final elements (taking action to bring the process to a safe state, e.g. safety shutdown) Regulatory requirements According to the IEC 61511 Lifecycle Concept, many SISspecific monitoring and test activities are required to maintain the desired level of safety integrity, i.e. Safety Integrity Level (SIL). This validation is called Proof Test Interval (PTI) and has to be carried out on a regular basis. Proof tests must be conducted as defined procedures that ensure tests are done correctly and systematically. Failed devices must be repaired or exchanged to achieve completely reliable process safety.
Monitoring rotating equipment The population of rotating equipment in the process industry is huge. Pumps, compressors and auxiliary systems are integral parts of the production process. Many of these are rated as “critical” and call for a reliable and adequate safety protection systems. The most commonly used method for condition monitoring and safety protection of rotating machines is vibration analysis with proximity, velocity and acceleration sensors. PROGNOST®-SenSim is the first and only product available that is able to simulate sensors, including their elec- trical behavior to produce realistic static and dynamic signals.
One device for all testing routines
PROGNOST®-SenSim is a portable device for the simulation of sensors that are used for machine monitoring. It simulates sensors with static and dynamic signals for safety protection systems (Safety Instrumented Systems) and measuring loop test routines.
Realistic testing of safety functions and algorithms
protection
•
200X voting
•
Plausibility check
•
Counting of consecutive revolutions of safety limit violation (phase referenced signal)
Sensor simulation capabilities • Realistic simulation of sensors with separate setting of static and dynamic signal components • Simulation of full sensor measuring range. PROGNOST®-SenSim following signal types: • 4 _ 20 mA • ICP/IEPE • Eddy Current • Voltage • Trigger • Pulse • Strain Gauge
simulates
sensors
with
Eliminates risk of sensor damage Testing procedures of safety protection systems can be carried out without touching sensors. This eliminates all associated risks, such as sensor damage or recalibration issues.
the Adjustable to any desired frequency and amplitude The defined and precise violation of real safety limitsettings makes the execution of PTI (Proof Test Interval) compliant to IEC regulatory requirements (no manipulation of safety limits to initiate Alert / Shutdown / Unsafe conditions).
Simulation instead of stimulation ICP/IEPE Simulation of dynamic ICP/Vibration signals is mandatory for testing safety limits and to activate the final actor. The signal is phase-referenced, i.e. simulated per revolution over 360o crank angle. PROGNOST速-SenSim simulates sensors of all major brands such as Bently Nevada, IMI, CTC, Monitran and others.
Eddy Current Overlaying static signals with dynamic signals allows to simulate the dynamic rod position of a reciprocating compressor and other rotating equipment. PROGNOST速-SenSim is capable of producing different signals concurrently for the two output channels. This unique feature allows the simulation of x/y shaft vibration sensors (Orbit analyses). PROGNOST速-SenSim simulates sensors of all major brands such as Bently Nevada, Epro, Shinkawa, Metrix and others.
4 ... 20 mA
Voltage
The 4…20 mA sensor type simulates many transmitters used in the process and automation industry, such as pressure, temperature, flow, level etc. PROGNOST®-SenSim offers a customized selection of individual signal range, frequencies and units.
+/- 10 V voltage from norm signals in the field of measurement and control technologies.
Trigger (NAMUR & Eddy Current)
Lube Oil
Rotation speed simulation, the signal phase reference.
PROGNOST®-SenSim simulates major brands of lubrication instrumentation, e.g. Loft 600, KIS and Kracht.
Strain Gauge Strain Gauges are used for indirect pressure measurement of high pressure compressors (Hyper), amongst others.
Channel 1
Channel 2
ICP
ICP
4 ... 20 mA
4 ... 20 mA
Eddy Current
Eddy Current
Voltage
Voltage
Example of phase referenced signal combinations of Channel 1 and Channel 2
2ooX voting logic
Signal shaping
Testing of voting routines such as 2ooX are supported by the 2-channel architecture of PROGNOST®-SenSim. 2ooX architectures with large X-values typically indicate applications where unacceptable process conditions can occur in multiple distinct locations. Proof testing this architecture requires two different signals of one kind in parallel. PROGNOST®-SenSim simulates concurrently the following sensors fully phase referenced (one channel each sensor).
PROGNOST®-SenSim provides unmatched signal shaping option: • Simulation of sensor physics (signal spread) • Definable amplitudes on every part of the revolution • Realistic simulation of static and dynamic sensors up to 10 kHz
•
ICP/IEPE
•
4 20 mA
•
Eddy Current
•
Voltage
Amplitude (+/–10 V)
Dynamic (up to 10 kHz)
PROGNOST速-SenSim Generator
Technical data Battery
Lithium Polymer battery pack (3.7V, 2600mAh, 9.7 Wh), up to 5 hrs. run time charging time 3 hrs.
Environmental conditions Operating Temperature Storage Temperature Relative Humidity
-20oC to +60 oC (-4 oF to + 140 oF) -20oC to +60 oC (-4 oF to + 140 oF) 5% to 95 % (Class 3K3) non-condensing
Protection Class Dimensions Weight
as per IEC 529 (EN60529) IP 50 135 mm x 125 mm x (5.31 inch x 4.92 inch x 1.49 inch) 60 gr (1.367 lbs)
Technical data per channel ICP/IEPE Signal Range Bias Voltage Frequency Range ICP/IEPE current Resolution Bit Linearity Error (full range) 4 ... 20 mA Signal Range Frequency Range Output Impedance Resolution Linearity Error (full range) Eddy Current Signal Range Frequency Range Output Impedance Supply Current Resolution Linearity Error (full range) Voltage Signal Range Frequency Range Output Impedance Resolution Linearity Error (full range) Trigger Namur Metal detected Metal not detected Switching Frequency Supply Current Trigger Eddy Current Metal detected Metal not detected Switching Frequency Supply Current Strain Gauge Signal Range Excitation Voltage Frequency Range Bridge Resistance Resolution Linearity Error (full range) Lube Oil Input Voltage Pulses per Minute Output Current
Minimum
Standard
6
Maximum 16
11 0 2
10 10 12 0.5
4 0
20 10 100 12 0.5
-19 0
-1 10 100 9
7 12
0.5 -10 0
10 10 100 12 0.5 1.2
2.1 0.5
50 10 -7 -13
0.5 7
50 9
-2 1 0
2 5 10
2.5
V V kHz mA Bit % mA kHz Ohm Bit % 7 kHz Ohm mA Bit % V kHz Ohm Bit % mA mA Hz V V V Hz mA
0.5
Mv/V V(AC/DC) kHz Ohm Bit %
600 20
V Hz mA
350 10
24 0.6
Unit
PROGNOST®-SenSim Handheld
Technical data Processor RAM Display . Battery Power (Charging Unit) Environmental conditions Operating Temperature Storage Temperature Relative Humidity Protection Class Dimensions Weight
Intel® Atom Processor N2600 (1.6 GHz) Dual Core, Passive cooling 2 GB DDR3 800 7” TFT LCD with resistive touchscreen and LED-backlights, 1024 x 600 Pixel Sunlight readable display 2x Lithium lon battery pack Up to 8 hrs. run time, hot-swappable, charging time around 3 hrs Input 100V – 240V, 50 Hz – 60 Hz -20oC to +65 oC (-4 oF to - 149 oF) -45oC to +60 oC (-49 oF to - 140 oF) 95% @ 60o C (140 oF) 5 x 48 hrs cycles IP65 225 mm x 145 mm x 39.8 mm (8.85 inch x 5.7 inch x 1.5 inch) 1.3 kg including 2 batteries (3 lbs including 2 batteries)
PROGNOST®-SenSim Starter Kit
Hardware • • • •
PROGNOST®-SenSim Generator PROGNOST®-SenSim Handheld Charger (Multi Country) Outdoor case with shoulder strap
Cable • • • • •
Cable Handheld/Generator Channel 1/Channel 2/Cable Open end NAMUR/Open and Trigger Short circuit Channel 1/ Channel 2 Short circuit Trigger (Namur and Eddy Current)
Go online for additional cable options and individual product configuration: www.prognostsensim.com
Time savings and flexibility
Reliable and user friendly
One device for the realistic simulation of all types of sensors, e.g. • Vibration • Position/displacement • Temperature • Level • Flow • Pressure
With PROGNOST®-SenSim Handheld, users are able to configure the PROGNOST®-SenSim Generator for simulating signals. After configuration, data is applied to the Genera- tor which is then ready to be used independently from the Handheld.
Damage simulation Realistic signals up to 10 kHz allow simulation of real-life conditions. Risk avoidance No calibration issues or damage of sensors due to disassembly, mechanical stimulation and reassembly. Eliminates the need of mechanical signal stimulation, e.g. shaker. Regulatory compliance Proof Test Interval of SIS/Safety Protection systems with real safety limits and check of safety algorithms, e.g. voting, consecutive revolutions.
After connecting the measuring loops, the Generator will produce the previously configured simulation values in order to check the measuring loop and safety protection systems.
PROGNOST®-SenSim Starter Kit Item number 3000062
PROGNOST®-SenSim Starter Kit PROGNOST®-SenSim Generator with power supply PROGNOST®-SenSim Handheld with power supply Connecting cable Generator - Handheld Sensor cable Trigger (Namur) Short circuit plug Trigger (Namur) Sensor cables Cut End, Channel 1 & Channel 2 (2 pcs. ) Short circuit plug Channel 1 & Channel 2 Outdoor case User manual
Configure your PROGNOST®-SenSim online www.prognost-sensim.com
Single items, spare parts, additional cable options Item number 1 002 053 3 000 060 3 000 061 3 000 062 3 000 063 3 000 064 3 000 065 3 000 070 3 000 071 3 000 072 3 000 073 3 000 074 3 000 075 3 000 076 3 000 077 3 000 078 3 000 079 3 000 080 3 000 081 3 000 082 3 000 083 3 000 084 3 000 087 3 000 088 3 000 089 3 000 120 3 000 121
PROGNOST®-SenSim, Case1 PROGNOST®-SenSim, GD1 Generator PROGNOST®-SenSim, HH1 Handheld PROGNOST®-SenSim, SK1 Starter Kit PROGNOST®-SenSim, PG1 Power Supply Generator PROGNOST®-SenSim, PH1 Power Supply Handheld PROGNOST®-SenSim, GD1-HH1 cable 2.0m PROGNOST®-SenSim, CH1/2-Cut End cable 2.5m PROGNOST®-SenSim, CH1/2-Vibration MIL cable 2.5m PROGNOST®-SenSim, CH1/2-Pressure M16 cable 2.5m PROGNOST®-SenSim, Ch1/Ch2-Short Circuit plug PROGNOST®-SenSim, TriggerNamur-Cut End cable 2.5m PROGNOST®-SenSim, TriggerNamur-M12 cable 2.5m PROGNOST®-SenSim, TriggerEddy-Cut End cable 2.5m PROGNOST®-SenSim, Trigger-Short Circuit plug PROGNOST®-SenSim, StrainGauge-Cut End cable 2.5m PROGNOST®-SenSim, StrainGauge-M8 cable 2.5m PROGNOST®-SenSim, LubeOil-Cut End cable 2.5m PROGNOST®-SenSim, LubeOil-Loft600 cable 2.5m PROGNOST®-SenSim, LubeOil-KIS2 cable 2.5m Power Cable, Type B (US, JP, CU, MX, CA, TH) Power Cable, Type G (GB, HK, KE, IE, MY, CY, LK, MT, SG, AE) Power Cable, Type F (DE, FR, BE, CZ, PL) Power Cable, Type I (AU, NZ, AR) Power Cable, Type J (CH, LI) PROGNOST®-SenSim, Manual English PROGNOST®-SenSim, Manual German