Intelligence on Duty

Asset Performance Management for Reciprocating Compressors and Pumps

Intelligence on Duty
The path to successful products and services is always by way of intensive dialogue with potential buyers and customers. Only by exchanging experience on a continuous basis is it possible to gain the necessary knowledge of operator requirements which results in useful products. PROGNOST Systems defines Intelligence on Duty using this philosophy: through the permanent integration of new requirements and practical experience, state of the art technology is always available to users. This continuous development process leads to products and services which provide true benefits to our customers. The consistent adoption of this philosophy ensures that PROGNOST products and services will continue to meet the ever increasing expectations of our customers in future.

Highest productivity levels with automated machine condition diagnosis

Across the globe, businesses are under pressure to maximize the operating time of their machinery. Compressors and pumps are being operated up to and beyond their design limits, leading to the integration of stand by-machines into production processes, reduced inventories of replacement parts, and cutbacks in maintenance procedures. Consequently, the risks of damages and machine breakdown are increasing, while the resources needed to react quickly and efficiently to such incidents are dwindling. In this scenario, reliable online machine diagnosis is essential. Online diagnosis accurately identifies the most minute change in the condition of individual components and provides sound decision-making support to facilitate dependable, efficient, and safe machine operations.

Specialized technology
PROGNOST Systems were developed exclusively for reciprocating machinery. The operation and monitoring of these often process-critical machines is performed under the most diverse operating conditions around the world. With high-frequency data acquisition, automated real-time diagnosis, self-learning recognition of damage patterns, and other unique product features, PROGNOST fulfills industry requirements and is proven superior to non-specialized applications. As an Asset Performance Management system, PROGNOST links component-oriented condition data with their maintenance cycles, producing service-life information for more efficient maintenance planning. The design and architecture of the PROGNOST machine protection module is SIL certified and conforms to international standards for Functional Safety (IEC 61508).

The PROGNOST Difference: Information instead of data!

In many cases, complex machines are equipped with inadequate vibration protection, which is designed to trigger an alert or emergency shutdown of the machine. In case of an alert or shutdown, the operator receives no information about the location and cause of the problem. Only an extensive, manual search for the failure can reveal the contributing factors. PROGNOST-NT goes a step further by generating information such as: Damage Classification Rider Ring Wear, Cyl. 2, 100% Match. The automatic evaluation and interpretation of sensor data gives PROGNOST users a decisive advantage: clear diagnostic information as a basis for condition-based maintenance and safe machine operation. Data interpretation provides not only a diagnosis, but also valuable knowledge about failure causes. These causes may then be targeted and eliminated in order to achieve permanent, true improvements in reliability and safety.

PROGNOST is worth it
The advantage of a PROGNOST system is quantifiable. We will help you assess the profitability of a PROGNOST installation based on your own machine and operation data. In most cases, the purchase price is recovered within just a few months. We guarantee a realistic review, based on real-world data accumulated from more than 400 PROGNOST installations worldwide.

Photo: Courtesy of Emerson Process Management

PROGNOST-SILver

PROGNOST-NT
PROGNOST-NT Safety Protection is a powerful, SIL certified technology that reliably ensures the safety of people, the environment and the machine.

It is based on the continuous acquisition and analyses of machine vibrations, dynamic cylinder pressures, and piston rod or plunger vibrations. Vibrations at the crosshead are acquired with 25 kHz independently from the number of rpms, and subsequently divided into 36 segments of 10 crank angle. Each segment is monitored with its individual safety limit. This segmentation allows precise monitoring of specific changes in vibrations during one revolution, due to the working principle of a recip. It is exactly this segmentation that enables the PROGNOST -SILver is a PROGNOST -NT Safe- detailed analysis of individual machine functions ty Protection and SIL certified hardware solution during a crank revolution and avoids false alarms that provides operators with machine protection or false trips. analyses recognized and proven worldwide. PROGNOST-SILver is not a departure from previous PROGNOST Systems concepts for machine monitoring. Instead, it is a realization of proven analyses and parameters in an external 19 system. PROGNOST-SILver processes sensor data from up to eight reciprocating compressors, with a maximum of 68 sensors in one monitoring unit. An optional flameproof encapsulation, which can be installed in the field, reduces wiring costs dramatically and lowers overall installation costs. PROGNOST-SILver can be seamlessly integrated into PROGNOST-NT at any time as an expansion of existing systems or as a component of a new installation with field-supported monitoring. PROGNOST-SILver gives you a stand-alone safety protection system that can easily be expanded to the most powerful Asset Performance Management system currently available on the market.

Above: Online vibration signal for one crank revolution Below: Segmentation with individually adjustable safety limits per segment. In segments 12 and 30, the safety limit was violated.

Safety risks are identified in less than one second, examined for plausibility, confirmed, and optionally controlled by a machine shutdown. The plausibility check of incoming signals is a unique feature that reliably prevents false alarms or unwarranted machine shutdowns.

PROGNOST-NT

As an Asset Performance Management system, PROGNOST links component-oriented condition data with maintenance cycles, producing service-life information for more efficient maintenance planning. PROGNOST-NT consists of several modules that PROGNOST Systems were developed exclusive- can be used in various combinations for contily for reciprocating machines. With gapless, high nuous diagnosis of all vital functions of a reciprofrequent data acquisition, automated real-time di- cating machine. agnosis, self-learning recognition of damage patterns, and other unique product characteristics, Vibration-based Early Failure Detection identiPROGNOST fulfills industry requirements and is fies damage developments in their initial stages. Should thresholds, which are dependent on opproven superior to non-specialized applications. erating conditions, be exceeded, the module delivers plain-text messages to the operator. These messages serve as procedural recommendations for maintenance teams.
PROGNOST -SILver
Data Acquisition

PROGNOST-NT
Condition and Performance Monitoring

Safety Protection

Safety Analyses Early Failure Detection Performance Optimization Wear Monitoring

Visualization

Process Data Analyses Lubrication Monitoring Component Tracking

Wear Monitoring is provided by continuously PROGNOST -NT PROGNOST-SILver updated trends,Machine Protection as well as threshold monitoring. Condition and Performance Monitoring Data Acquisition The development of non-critical wear up to the level of impending damage is clear at all times Visu and the remaining life of individual components SIL Certified NT Server Client is quantifiable.
12,8 g TDC BDC TDC 10,5 9,0 7,5 6,0 4,5 3,0 1,5 0 -1,5 -3,0 -4,5 -6,0 -7,5 -9,0 -10,5 -12,0 0 20 40 60 80 100 120 140 160 180 CA 200 220 240 260 280 300 320 340 360

Vibration

2250 m 2025 1800 1575 1350 11 25 900 675 450 225 0

Safety Protection

Safety Analyses

Temperature Displacement Pressure

Early Failure Detection Performance Optimization

Process Data Analyses Lubrication Monitoring Component Tracking

PROGNOST system overview

Wear Other Wear development of a rider ring as a long-term trend Monitoring

The module for bi-directional communication between PROGNOST and the process control system is referred to as Process Data Analyses. This module offers interfaces to all popular control systems. It enables the integration of process operation data into the machine

Component Tracking expands condition monitoring by creating a protocol of maintenance procedures and the actual operating time of components. Condition-based and preventive measures can be combined to form an efficient maintenance strategy based on information about each individual component lifecycle.

diagnosis and provides information about irregular condition developments directly to the control room and machine operator. Blockage in lubrication lines, leaks, and uneven or over-lubricated cylinders and packings are identified through the Lubrication Monitoring module before damage occurs. The illustration of gas dynamics in the online p-Vdiagram and its automatic analysis form the basis of the Performance Optimization module. Changes in monitored parameters allow identification of defective components and enable optimization of machine efficiency. The acquisition and analysis of indicated pressures is also possible with hyper compressors. Systems for load control (for example, unloaders or cylinder clearance regulation) are automatically detected by this module and taken into consideration for monitoring purposes. Safety-relevant functions and parameters, such as piston rod load, rod load reversal, and maximum pressure ratios, are also monitored continuously.

Overview page of the Component Tracking module for a reciprocating compressor

PROGNOST-NT Swift
This mobile diagnostic system is a complete PROGNOST-NT product, with all performance capabilities of long-term machine monitoring. The system can be installed quickly and used on short notice, for example, to detect potentially damaging operation conditions. PROGNOST-NT Swift is also ideal for temporary applications, such as initial machine start-ups or re-starts after extensive maintenance or modification measures.

p-V diagram of head end and crank end cylinders

PROGNOST-NT Swift

PROGNOST-Genuit
This system reliably diagnoses leaks at piston rings, valves, and stuffing box packings in lesscritical compressors. PROGNOST-Genuit works with a specially developed, model-based technology that distinguishes it from monitoring systems. Only data from the process control system is evaluated for condition diagnosis. In most cases, additional costs for sensors or wiring is not necessary. This compact system is the first to enable efficient monitoring of machine lines, which in the past were not sufficiently process-critical to justify an investment in online condition monitoring.
75,12 % 72,50 70,00 67,50 65,00 62,50 60,00

PROGNOST-Pump
PROGNOST-Pump is the online application for process-critical plunger and diaphragm pumps. It is based on PROGNOST-NT and contains all the necessary performance capabilities required for reliable operation of oscillating displacement pumps. PROGNOST-Pump contains the proven analyses and parameters of the PROGNOST-NT Safety Protection, Early Failure Detection and Performance Optimization modules.

57,50 55,00 52,50 50,00 47,50 45,00 14.08.2006 10:07:00 14.08.2006 18:00:00 15.08.2006 02:00:00 15.08.2006 10:00:00 15.08.2006 18:00:00 16.08.2006 02:00:00 16.08.2006 10:07:00 PROGNOST Systems GmbH

Temperature trends (above) and residuum distribution with maximum and minimum thresholds (below)

The operating method of PROGNOST-Genuit clearly differs from conventional monitoring systems. Instead of temperature or pressure monitoring with absolute thresholds, a comparison is made between measured actual values and reference values, which are continuously calculated in a theoretical compressor model based on operating conditions. The difference between both values is controlled by individually adjustable thresholds. Should the threshold be exceeded, a plain-text diagnostic message is issued. This message informs the control room about the damage probability percentage and the severity of leakage to suction and/or pressure valves, stuffing box packings, piston gaskets and gas coolers.

The vibration acceleration signal (lower curve) shows clear peaks caused by opening the pressure valve of a triplex-pump. The dynamic discharge pressure (top curves), measured in the pressure vessel, shows pressure peaks, which correspond to the valve openings.

Sound customer satisfaction through service and support

Customers who are satisfied in the long term that is why we give our very best. Our comprehensive service range will meet your unique requirements and regular software updates will keep all your systems current with the latest developments.

Applicable knowledge through instruction and training

Reciprocating machines are complex. The interaction between components, gases/liquids, high pressures and material stressing, as well as a number of relevant physical values, make reliable machine diagnosis a true challenge. To help your personnel meet that challenge, PROGNOST Another advantage is the exchange of damage Systems offers a variety of on-site courses, such classes for pattern recognition between custom- as advance training of personnel for their new reers, which enables all PROGNOST users to bene- sponsibilities. User Forums are another benefit, as fit from the experiences of others. customers meet customers to share experiences and take advantage of additional training to optiPROGNOST support ranges from an annual sys- mize the use of their PROGNOST systems. tem evaluation based on machine diagnosis reports in varying cycles (half-year, quarterly) to round-theclock telephone support (10/5 or 24/7).

PROGNOST Systems at a glance

The systems and services of PROGNOST Systems are based upon many years of technical experience and competence in the acquisition, automated evaluation, and interpretation of condition data for reciprocating machinery. Asset Performance Management systems from PROGNOST Systems are the world-leading technology for the safe, reliable and economical operation of reciprocating machinery. Design, production, and maintenance of our systems takes place in Rheine, Germany. PROGNOST Systems locations in Europe and USA, along with our worldwide partners, guarantee responsive and reliable on-site support.

Our Customers
Continuous dialogue with more than 100 enterprises from the oil, gas, chemical, and petrochemical industry and over 400 PROGNOST installations contribute to the onging optimization of our product and services. Our customers reward this focused approach with high marks for satisfaction and long-standing loyalty.

PROGNOST Systems GmbH Birkenallee 177 48432 Rheine Germany Telefon: +49 (0)59 71 - 8 08 19.0 Fax: +49 (0)59 71 - 8 08 19.42 E-Mail: info@prognost.com

PROGNOST Systems, Inc. 1020 Bay Area Blvd. Suite 118 Houston, TX, 77058 USA Telefon: +1 - 281 480 93.00 Fax: +1 - 281 480 93.02 E-Mail: infousa@prognost.com

www.prognost.com