SIL certified safety for people, the environment and machinery Overview of PROGNOST -SILver safety analyses... 6

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1 PROGNOST -SILver

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

4 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 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. 4

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6 Overview of PROGNOST -SILver safety analyses 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. 6

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8 Signal Acquisition Analog signals from machine mounted sensors (for example vibration ) are transmitted hard-wired to the signal input of PROGNOST -SILver. 1 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

9 2 3 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. 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. 4 5 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. Fieldbus Profibus DP (FB1) The FB1 card transfers the status message (ALERT SHUTDOWN UNSAFE) via the Profibus DP/PROFIsafe interface to the Safety Controller. 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). 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 con figure 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. 9

10 Technical description of the input cards Description Measurement parameters / signals Input parameters AI1 ICP AI ma AI3 Eddy Current AI4 Voltage TI1 Trigger Vibration (Acceleration) Vibration (Velocity) Indicated cylinder pressure Suction/Discharge pressures Temperatures Dynamic position (Displacement) Indirect pressure measurement Phase reference General technical data of the analog input cards AI1 to AI4 and the TI1 card - 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 - Ambient without air flow: -20 to +60 C (-4 to +140 F), with air flow: -20 to +70 C (-4 to +158 F) 10

11 Recommended signal analyses for reciprocating machines Signal Piston Compressor Hyper Compressor Plunger Pump Vibration Crosshead (Acceleration) Housing Bearing (Acceleration) Position (Displacement) Piston rod position 36 Segments 36 Segments Peak-to-Peak 8 Segments Plunger position - Dynamic pressures Indicated pressure Suction & discharge pressures Temperatures Peak-to-Peak Peak-to-Peak 36 Segments 36 Segments 36 Segments 36 Segments - - Peak-to-Peak Peak-to-Peak Bearing Average Average Average Recommended signal analyses for centrifugal machines Shaft vibration Axial thrust Peak-to-Peak Average 11

12 Housing and assembly options 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 12

13 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. 13

14 Benefits at a glance SIL 2 certified Machine Protection for all signal types (vibration, displacement, temperature, pressure, phase reference, voltage... ) for reciprocating compressors / pumps and hyper compressors eliminate false alerts and shutdowns possible including field mounting certified and safe fieldbus technology for Asset Performance Management 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 PROG- NOST Systems are the world-leading techno logy for the safe, reliable and economical operation of reciprocating machinery. PROGNOST systems are Made in Germany. 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 14

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16 PROGNOST Systems GmbH Daimlerstraße Rheine Germany +49 (0) (0) info@prognost.com PROGNOST Systems, Inc Bay Area Blvd. Suite 105 Houston, TX, USA infousa@prognost.com