Enhance Safety Proof Test Intervals (PTI) One device for all testing routines Simulation instead of stimulation... 6

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Reginald Eaton
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1 PROGNOST -SenSim

3 Contents Enhance Safety Proof Test Intervals (PTI)... 4 One device for all testing routines... 5 Simulation instead of stimulation... 6 PROGNOST -SenSim Generator PROGNOST -SenSim Handheld PROGNOST -SenSim Starter Kit It all adds up to PROGNOST -SenSim

Enhance Safety Proof Test Intervals (PTI) Safety Instrumented Systems (SIS) perform specified functions to achieve a safe state of process when dangerous conditions occur.

4 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) 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 electrical behavior to produce realistic static and dynamic signals. Regulatory requirements According to the IEC 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. 4

One device for all testing routines PROGNOST -SenSim is

for safety protection systems (Safety Instrumented

Sensor simulation capabilities of static and dynamic

with the following signal types: Realistic testing of

violation (phase referenced signal) Eliminates risk of

systems can be carried out without touching sensors.

defined and precise violation of real safety

5 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. Sensor simulation capabilities of static and dynamic signal components PROGNOST -SenSim simulates sensors with the following signal types: Realistic testing of safety protection functions and algorithms safety limit violation (phase referenced signal) 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. Adjustable to any desired frequency and amplitude The defined and precise violation of real safety limit-settings makes the execution of PTI (Proof Test Interval) compliant to IEC regulatory requirements (no manipulation of safety limits 5

Simulation instead of stimulation ICP/IEPE testing safety limits and to activate the final actor.

PROGNOST -SenSim simulates sensors of all major brands such as Bently Nevada, IMI, CTC, Monitran and

Eddy Current Overlaying static signals with dynamic signals allows to simulate the dynamic rod position of

6 Simulation instead of stimulation ICP/IEPE testing safety limits and to activate the final actor. The signal is angle. PROGNOST -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 -SenSim is capable of producing different signals concurrently for the two output channels. This unique feature analyses). PROGNOST -SenSim simulates sensors of all major brands such as Bently Nevada, Epro, Shinkawa, Metrix and others. 6

4... 20 ma in the process and automation industry, such as

PROGNOST -SenSim offers a customized selection of individual

7 ma 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. Voltage and control technologies. Trigger (NAMUR & Eddy Current) Rotation speed simulation, the signal phase reference. Lube Oil PROGNOST -SenSim simulates major brands of lubrication Strain Gauge Strain Gauges are used for indirect pressure measurement of high pressure compressors (Hyper), amongst others. 7

Channel 1 ICP 4... 20 ma Eddy Current Voltage Channel 2 ICP 4.

8 Channel 1 ICP ma Eddy Current Voltage Channel 2 ICP ma Eddy Current Voltage Example of phase referenced signal combinations of Channel 1 and Channel 2 2ooX voting logic 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). Signal shaping PROGNOST -SenSim provides unmatched signal shaping option: 8

9 9

10 PROGNOST -SenSim Generator Technical data Battery Environmental conditions Operating Temperature Storage Temperature Relative Humidity Protection Class charging time 3 hrs. 5 % to 95 % non-condensing

11 Technical data per channel Minimum Standard Maximum Unit ICP/IEPE Signal Range Frequency Range khz ma Resolution Bit Linearity Error (full range) % ma Signal Range 4 ma Frequency Range khz Output Impedance Ohm Resolution Bit Linearity Error (full range) % Eddy Current Signal Range Frequency Range khz Output Impedance Ohm Supply Current 7 9 ma Resolution Bit Linearity Error (full range) % Voltage Signal Range Frequency Range khz Output Impedance Ohm Resolution Bit Linearity Error (full range) % Trigger Namur Metal detected ma Metal not detected ma Switching Frequency Hz Trigger Eddy Current Metal detected -7 Metal not detected -13 Switching Frequency Hz Supply Current 7 9 ma Strain Gauge Signal Range 1 5 Frequency Range khz Bridge Resistance Ohm Resolution Bit Linearity Error (full range) % Lube Oil Pulses per Minute Hz Output Current ma 11

12 PROGNOST -SenSim Handheld Technical data Processor RAM Battery Environmental conditions Operating Temperature Storage Temperature Relative Humidity Protection Class Sunlight readable display IP65

13 PROGNOST -SenSim Starter Kit Hardware Cable Go online for additional cable options and individual product configuration: 13

It all adds up to PROGNOST -SenSim 1 Configuration PROGNOST -SenSim PROGNOST -SenSim 2 Proof Test SILver SILver 3 Verification ALERT SHUTDOWN UNSAFE Time savings and flexibility One device for the

14 It all adds up to PROGNOST -SenSim 1 Configuration PROGNOST -SenSim PROGNOST -SenSim 2 Proof Test SILver SILver 3 Verification ALERT SHUTDOWN UNSAFE Time savings and flexibility One device for the realistic simulation of all types of sensors, e.g. Damage simulation conditions. Reliable and user friendly configure the PROGNOST -SenSim Generator for simulating signals. After configuration, data is applied to the Generator which is then ready to be used independently from the Handheld. 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. 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 real safety limits and check of safety algorithms, e.g. voting, consecutive revolutions. 14

15 PROGNOST -SenSim Starter Kit Item number 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 Single items, spare parts, additional cable options Item number PROGNOST -SenSim, Case 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 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

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

Enhance Safety Proof Test Intervals (PTI)

PROGNOST -SenSim 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