PROGNOST ®-SILver

SIL certif ied safety for people, the environment and machinery

Content

Intelligence on Duty .................................................................................................................................4

................................................................6

Overview of PROGNOST®-SILver machine analyses................................................................................8

Safety loop from sensor to safety controller ...........................................................................................10

Technical description of the input cards .................................................................................................12

Recommended signal analyses for different machine types ...................................................................13

Housing and assembly variations...........................................................................................................14

...............................................................................................................................16

PROGNOST Systems at a glance..........................................................................................................18

Our customers ......................................................................................................................................19

4

Intelligence on Du

The path to successful products and services is al-

ways by way of intensive dialogue with potential buy-

ers and customers. Only by exchanging experience

on a continuous basis is it possible to gain the neces-

sary knowledge of operator requirements which fuels

the development to useful products. PROGNOST

-

losophy: through the continuous integration of new

requirements and practical experiences, state of the

art technology is always available to users. This per-

manent development process leads to products and

-

tomers. The consistent adoption of this philosophy

ensures that PROGNOST products and services will

continue to meet the ever increasing expectations of

our customers in the future.

Intelligence on Duty

5

6

Intelligence on Du

PROGNOST®-NT has protected the investments

of rotating equipment operators for decades. The

vital role of a machinery protection system to miti-

gate the risk of serious damages is covered by the

proven its effectiveness and reliability on a daily

basis, worldwide in hundreds of installations. The

reliable avoidance of consequential damages has

been documented in many case studies, customer

reports and payback calculations.

PROGNOST®-SILver is a hardware implementation

of the former PROGNOST®

With its innovative design users can now install SIL

and effective protection analyses and shutdown pa-

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.

-

7

Intelligence on Du

tion (360°) are divided into 36 segments

segments is assigned its own safety limit and analyzed individually. This segmenta-tion allows precise vibration monitoring of critical components within the motion works assembly. Reciprocating machinery has

tion peaks during valve opening and closing, which are taken into consideration to avoid false alerts.

®

Temperature monitoring allows early detection of developing failures, for example, to bearings, valves, or packings.

Analysis of the maximum pressure difference per revolu-tion in the compression chamber enables detection of valve clogging and increased stress to pistons due to

1 4 0 0

1 6 0 0

1 8 0 0

2 0 0 0

2 2 0 0

2 4 0 0

2 6 0 0

2 8 0 0

3 0 0 0

3 2 0 0

3 4 0 0

3 6 0 0

3 8 0 0

4 0 0 0

4 2 0 0

4 4 0 0

4 6 0 0

4 8 0 0

5 0 0 0

5 2 0 0

5 3 8 6

p si a

0 2 0 4 0 6 0 8 0 1 0 0 1 2 0 1 4 0 1 6 0 1 8 0 2 0 0 2 2 0 2 4 0 2 6 0 2 8 0 3 0 0 3 2 0 3 4 0 3 6 0degree crank angle

T DC B DC T DC

Safety Limit

Peak-to-Peakdifferential pressure

-20

-10

0

10

20g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

T D C B D C T D C

0

5

10

15g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

crosshead guide Cyl.1 , R M S valu es via 36 S eg. .. 10 d egrees

degree crank angle

degree crank angle

Below: Segmentation with individually adjustable safety limits per segment.

Displacement signals providing piston rod

crank angle each for every revolution to detect critical mechanical conditions of the piston rod. The illustration shows two piston rod position signals:

to liquids inside the compression chamber

For high-pressure hyper compressors,the peak-to-peak levels of the verticaland horizontal plunger position for onerevolution are monitored and analyzed todetect erratic packing conditions thatcould lead to plunger fractures or breaks.

4,0

4,2

4,4

4,6

4,8mil

0 20 40 60 80 100 120 140 160 180 200 220 240 260 280° CA

TDC BDC

0

0,4

0,8

1,2mil

0 30 60 90 120 150 180 210 240 270

1

300

300

0

15

30

45

60

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

T D C B D C T D C

0

10

20

30

40

m il

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8

R D S tage 1, P eak-P eak over 8 S eg. .. 45 d egrees

degree crank angle

degree crank angle

m il

6 |

In the case of impending damage, the FB

bus DP/PROFIsafe interface to the safety controller.

5 |

All safety analyses for up to 8 machines are conducted in the MP card. The resulting sta-

telegram to the FB card and displayed on the

is permanently monitored.

2 |Sensor cables are attached to signalinput clamps on the front or back sideof the backplane. The signal input clamps are installed on the rack back-plane to allow input card replacements without touching the wiring.

Analog signals from machine mounted

transmitted via hard-wired cable to the signal input of PROGNOST®-SILver.

2

456

The safety controller assigns the status message

outputs. Status messages are transferred via these

down Device).

Two connectors, 24 V input voltage each, are available for redundant power supply to PROGNOST®-SILver.

4 |

All 17 input cards relay the digitized signals

interfaces and sends the data stream to the MP card via internal backplane bus and/or in parallel to PROGNOST®

lishes a connection to PROGNOST®-

This converter can be used to con-®-SILver via

to PROGNOST®-NT.

|

signed to 17 individual cards; each process-ing four channels of one signal-type. These cards digitize the signals. The function of the connected measuring loop and signal integ-rity are subject to continuous monitoring.

12

Intelligence on Du

Order no. Vibration (acceleration)

Vibration (velocity)

Order no. 3 000 007

Dynamic pressures

Suction/Discharge pressures

Temperatures

etc.

th order

Order no. 3 000 009

Dynamic position (Displacement)

Order no. 3 000 011

Indirect pressure measurement

Order no. 3 000 002

Phase reference

Failure detection open circuit Failure detection short circuit Failure detection by redundant signal processing Failure detection voltage supply

13

Plunger

(Acceleration)RMS

36 SegmentsRMS

36 SegmentsRMS

36 Segments

Housing(Velocity)

RMS1 Revolution

RMS1 Revolution

RMS1 Revolution

Bearing(Acceleration)

RMS36 Segments

RMS36 Segments

RMS36 Segments

Piston rod position Peak-to-Peak8 Segments

- -

Plunger position - Peak-to-Peak1 Revolution

-

Shaft vibration Peak-to-Peak1 Revolution

Peak-to-Peak1 Revolution

-

Axial thrust Average Average -

Indicated pressure Peak-to-Peak1 Revolution

- -

Suction & discharge pressures

Peak-to-Peak1 Revolution

- Peak-to-Peak1 Revolution

Bearing Average Average Average

14

Intelligence on Du

Minimum requirement of housing

Minimum requirement of housing

15

Minimum requirement of housing

Housing is applicable in zone 1 and 2

The internal temperature of the Ex d housing may not exceed 65 °C (149 °F)! The internal tem-perature 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.

Ex d

Ex e

16

Intelligence on Du

compressors / pumps and hyper compressors

of PROGNOST®

eliminate false alerts and shutdowns

®-NT

for Asset Performance Management

PROGNOST®-NT installations

Functional Safety (SIL). PROGNOST®

17

18

Intelligence on Du

The systems and services of PROGNOST Systems

are based upon many years of technical experience

and competence in the acquisition, automated evalu-

ation, and interpretation of condition data for recipro-

cating machinery.

Asset Performance Management systems from

PROGNOST Systems are the world-leading techno-

logy for the safe, reliable and economical operation of

reciprocating machinery.

Design and production of our systems takes place in

Rheine, Germany.

responsive and reliable on-site support.

19

from the oil, gas, chemical, and petrochemical in-

dustry on over 400 PROGNOST installations con-

tribute 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.

Birkenallee 177

48432 Rheine

Germany

1020 Bay Area Blvd. Suite 118

Phone: +1 - 281 480 93.00

Fax: +1 - 281 480 93.02

TI_F

lyer

SIL

ver

A4_

02_E

N