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Intelligence on Duty

PROGNOST速-SILver


Content

SIL certified safety for people, the environment and machinery ........................................................................................................................ 4 Overview of PROGNOST速-SILver safety analyses ........................................................................................................................................................... 6 Safety loop from sensor to safety controller..................................................................................................................................................................... 8 Technical description of the input cards.......................................................................................................................................................................... 10 Recommended signal analyses for different machine types...............................................................................................................................11 Housing and assembly options..............................................................................................................................................................................................12 Benefits at a glance ....................................................................................................................................................................................................................... 14 PROGNOST Systems company profile .............................................................................................................................................................................. 14

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SIL certified safety for people, the environment and machinery

PROGNOST® has protected the investments of rotating equipment operators for twenty years. The vital role of a machinery protection system to mitigate the risk of serious damages is covered by PROGNOST®-SILver. This technology has proven its effectiveness and reliability on a daily basis. The reliable avoidance of consequential damages has been documented in many case studies, customer reports and payback calculations. PROGNOST®-SILver is a certified SIL 2 hardware that provides operators with machine protection analyses that are recognized and proven worldwide. It processes sensor data from up to eight machines, with a maximum of 68 sensors in one monitoring unit. With its innovative design, users can install IEC 61508 certified data acquisition and protection hardware directly in the field. The benefits are obvious: proven and effective protection analyses and shutdown parameters with SIL certification as well as the lowest possible wiring costs through the use of certified bus technology and local installations. For those who want a full Asset Performance Management system, PROGNOST®-SILver can be upgraded to a PROGNOST®-NT at any time.

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Overview of PROGNOST®-SILver safety analyses

RMS value of crosshead vibrations Crosshead vibrations of every crank revolution (360°) are divided into 36 segments each with 10° crank angle. Each of these segments is assigned its own safety limit and analyzed individually. This segmentation allows precise vibration monitoring of critical components within the motion works assembly. Reciprocating machinery has specific vibration characteristics, e.g., rod load reversals, which are taken into consideration to avoid false alerts.

Peak-to-Peak analysis of the piston rod and plunger position (operational run out) Displacement signals providing piston rod position are divided into 8 segments of 45° crank angle each for every revolution to detect critical mechanical conditions of the piston rod. For high-pressure hyper compressors, the peak-to-peak levels of the vertical and horizontal plunger position for one revolution are monitored and analyzed to detect erratic packing conditions that could lead to plunger fractures or breaks.

Temperatures Temperature monitoring may be used for early detection of developing failures, for example, on bearings, valves or packings.

Peak-to-Peak pressure (differential pressure) Analysis of the maximum differential pressure per revolution in the compression chamber enables detection of valve clogging and increased stress to pistons due to higher load. Furthermore, flow restrictions or piping issues, e.g. pulsations, can be identified.

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Signal Acquisition Analog signals from machine mounted sensors (for example “vibration”) are transmitted hard-wired to the signal input of PROGNOST®-SILver.

Signal Input Sensor cables are attached to signal input clamps on the front or back side of the backplane. The signal input clamps are installed on the rack backplane to allow input card replacements without touching the wiring.

Safety loop from sensor to safety controller

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Data Input Analog input (AIx) Up to 68 intrinsically safe inputs are assigned to 17 individual cards; each processing four channels of one signaltype. Signals are acquired with 25 kHz and digitized. The function of the connected measuring loop and signal integrity are subject to continuous monitoring.

Safety Protection Machine Protection (MP1) The MP1 card analyzes the signals for up to 8 machines. The resulting status messages (ALERT – SHUTDOWN – UNSAFE) are transferred as Profibus DP/PROFIsafe telegram to the FB1 card and displayed on the LEDs. In parallel, the status messages are send to the DC1 card, the connection between PROGNOST®-SILver and PROGNOST®-NT. The plausibility of the safety analyses is permanently monitored.

Safe PLC Safety Controller (SC1) The Safety Controller assigns the status message (ALERT – SHUTDOWN – UNSAFE) to its safe relay outputs. Status messages are transferred either via relay outputs or as digital signals (PROFIsafe) to the DCS or ESD (Emergency Shutdown Device).

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Data Transfer Data control (DC1) All 17 input cards send the digitized signals to the DC1 card. The DC1 card has two output interfaces and sends the data stream to the MP1 card via internal backplane bus and/or in parallel to PROGNOST®-NT via Ethernet.

Fieldbus Profibus DP (FB1) The FB1 card transfers the status message (ALERT – SHUTDOWN – UNSAFE) via the Profibus DP/PROFIsafe interface to the Safety Controller.

Ethernet/FO-Converter (MC1) The Ethernet/FO-Converter establishes a connection to PROGNOST®-SILver via a fiber optic cable. This converter can be used to configure PROGNOST®-SILver via PROGNOST®-ADMINsafe or create a connection to PROGNOST®-DataCenter or PROGNOST®-NT.

DCS connection (PROGNOST®-DataCenter) PROGNOST®-DataCenter and PROGNOST®SILver are connected via Ethernet. For the transfer of analyses results, status information and safety limits, the interfaces MODBUS (RS484/RS232) and TCP/IP are provided. Optionally, the connection can be realized by OPC.

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Technical description of the input cards Description

Measurement parameters / signals

Input parameters • Anti-aliasing filter • 16-bit resolution

AI1 ICP

Vibration (Acceleration) • Crosshead • Cylinder • Bearing • Frame (crankcase) Vibration (Velocity) • Frame • Bearing • Piping

• Bessel low pass filter • 8 adjustable cut-off frequencies • 16-bit resolution

AI2 4-20 mA

Indicated cylinder pressure • Compression chamber Suction/Discharge pressures • Piping Temperatures • Bearing • Gas • Valve • etc.

AI3 Eddy Current

Dynamic position (Displacement) • Piston rod position • Plunger position • Shaft vibration • Axial thrust

• Anti-aliasing filter • 16-bit resolution

AI4 Voltage

Indirect pressure measurement • Cylinder tie rod • Strain gauge • etc.

• Input voltage range +/-10, +/-5, +/-2, +/-1 Volt • Anti-aliasing filter • 16-bit resolution

TI1 Trigger

Phase reference

• NAMUR input according EN 60947-5-6 • Detection of Trigger cam or hole

General technical data of the analog input cards AI1 to AI4 and the TI1 card • • • • • • •

Four intrinsically safe inputs Ex ia IIC T4, Class 1, Zone 1, according to ATEX, c CSA us, Kosha, GOST-R Galvanic separation of each input channel 2 A/D converters per channel (redundancy) Sampling rate = 25 kHz per channel DSP and FPGA technology Card self test Continuous signal integrity check: - Failure detection open circuit - Failure detection short circuit - Failure detection by redundant signal processing - Failure detection voltage supply

Technical data of DCS-interface PROGNOST®-DataCenter • Power Requirements: 9 V ~ 36 V DC • Dimensions: W: 195 mm (7.7“), D: 200 mm (7.9“), H: 65 mm (2.6“) • Environment: Temperatures (According to: IEC60068-2-1, IEC60068-2-2, IEC60068-2-14) - Ambient without air flow: -20 to +60 °C (-4 to +140 °F), with air flow: -20 to +70 °C (-4 to +158 °F) • Certifications: CE approval, FCC Class A

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Recommended signal analyses for reciprocating machines Signal

Piston Compressor

Hyper Compressor

Plunger Pump

Crosshead (Acceleration)

RMS 36 Segments

RMS 36 Segments

RMS 36 Segments

Housing (Velocity)

RMS 1 Revolution

RMS 1 Revolution

RMS 1 Revolution

Bearing (Acceleration)

RMS 36 Segments

RMS 36 Segments

RMS 36 Segments

Peak-to-Peak 8 Segments

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Peak-to-Peak 1 Revolution

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Indicated pressure

Peak-to-Peak 1 Revolution

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Suction & discharge pressures

Peak-to-Peak 1 Revolution

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Peak-to-Peak 1 Revolution

Average

Average

Average

Vibration

Position (Displacement) Piston rod position Plunger position Dynamic pressures

Temperatures Bearing

Recommended signal analyses for centrifugal machines Shaft vibration

Peak-to-Peak 1 Revolution

Axial thrust

Average 1 Revolution

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Housing and assembly options

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19“ rack assembly with clamps on front

Technical data Ambient temperature: -25 to +65 °C (-13 to +149 °F) Storage temperature: -40 to +85 °C (-40 to +185 °F) Relative humidity: < 95 %, non-condensing Minimum requirement of housing Protection type according to EN 60529: IP54

19" rack assembly with clamps on back

Technical data Ambient temperature: -25 to +65 °C (-13 to +149 °F) Storage temperature: -40 to +85 °C (-40 to +185 °F) Relative humidity: < 95 %, non-condensing Minimum requirement of housing Protection type according to EN 60529: IP54


Rear panel assembly with clamps on front

Technical data Ambient temperature: -25 to +65 °C (-13 to +149 °F) Storage temperature: -40 to +85 °C (-40 to +185 °F) Relative humidity: < 95 %, non-condensing Minimum requirement of housing Protection type according to EN 60529: IP54

Assembly in Ex d housing (Component CWF1 and Ex d housing)

Technical data Housing is applicable in zone 1 and 2 Explosion-proof housing Ex d IIB + H2 Junction box Ex e Ambient temperature: -20 to +50 °C (-4 to +122 °F) Storage temperature: -40 to +85 °C (-40 to +185 °F) Relative humidity: < 95 %, non-condensing Protection type according to EN 60529: IP66

The internal temperature of the Ex d housing may not exceed +65 °C (+149 °F)! The internal temperature is the ambient plus the internal excess temperature caused by the power dissipation of the built-in devices. Please contact PROGNOST Systems for further information.

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Benefits at a glance

• SIL 2 certified Machine Protection for all signal types (vibration, displacement, temperature, pressure, phase reference, voltage ... ) • Developed for rotating equipment, especially for reciprocating compressors / pumps and hyper compressors • Redundant signal processing • Continuous signal integrity check • Proven safety analyses plausibility check to eliminate false alerts and shutdowns

• Several housing and assembly variations possible – including field mounting • Significantly reduced wiring costs due to certified and safe fieldbus technology • Seamless integration with PROGNOST®-NT for Asset Performance Management • Easily added as SIL-protection system to existing PROGNOST®-NT installations

PROGNOST Systems company profile The systems and services of PROGNOST Systems are based upon 20 years of technical experience and competence in the acquisition, automated evaluation, and interpretation of condition data for rotating equipment. Asset Performance Management systems from PROGNOST Systems are the world-leading technology for the safe, reliable and economical operation of reciprocating machinery.

PROGNOST Systems office locations in Europe and USA, along with our worldwide partners, guarantee responsive and reliable on-site support. Continuous dialog with more than 100 enterprises from the oil, gas, chemical, and petrochemical industry with over 600 PROGNOST® installations contribute to the ongoing optimization of our product and service offerings. Our customers reward this focused approach with high marks for satisfaction and long-standing brand loyalty.

TI_PROGNOST®-SILver_0112_EN

PROGNOST® systems are Made in Germany.

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PROGNOST Systems GmbH Birkenallee 177 48432 Rheine Germany +49 (0)59 71 - 8 08 19 0 +49 (0)59 71 - 8 08 19 42 info@prognost.com

www.prognost.com

PROGNOST Systems, Inc. 1020 Bay Area Blvd. Suite 105 Houston, TX, 77058 USA +1 - 281 - 480 - 93 00 +1 - 281 - 480 - 93 02 infousa@prognost.com

PROGNOST ® -SILver  

PROGNOST - SILver SIL certified safety for people, the environment and machinery

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