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Sensor simulation from Prognost

Hydrocarbon Engineering,

The population of rotating equipment in the process industry is huge. Compressors, pumps, turbines and auxiliary equipment are integral components of the production process. Many of these are rated as critical and call for a reliable and ample machine protection system. These protection systems are available in a variety of designs. They span from eutectic devices to SIL certified online equipment with diagnostic capabilities. The regular integrity validation of the necessary measuring loops is a nightmare for instrumentation engineers. The number of sensors with different electrical behaviours (acceleration, velocity, pressure, displacement, etc.), maybe located inside the machine, as well as protection logics, such as voting schemes, require a widespread knowledge and lots of working hours. Until today, outdated and inaccurate test procedures with shakers for vibration sensors or a micrometer to make out a displacement signal are in use to check the loops of highly priced and complex machine protection systems. PROGNOST´s answer to this unsatisfying situation is ‘sensor simulation’ instead of ‘sensor stimulation’. The PROGNOST sensor simulator, short PROGNOST®-SenSim, is a portable device for the simulation of sensors with static and dynamic signals that are used for machinery monitoring. The PROGNOST®-SenSim has two components: the handheld with a touchscreen that runs the configuration software for the signal generator. The generator processes the configuration and produces the requested signal. Both components are connected via USB. After the configuration, the generator can be disconnected from the handheld and be used as a single piece of equipment for the test routine. With the PROGNOST®-SenSim it is possible to produce all kinds of sensors with their electrical behaviour, i.e. users can simulate the full measuring range and are not limited to the shaker, or other tools, capabilities. Furthermore, all signals can be produced in parallel with a phase reference (Trigger) signal.


What can it simulate?

The list of sensors the generator can simulate comprises:

  • Trigger/phase reference (machine speed).
  • 4-20 mA (pressure).
  • ICP/IEPE (vibration).
  • Eddy Current (displacement).
  • Voltage.
  • Pulse (lube oil).
  • Strain Gauge.

The built in library of common sensor types and brands is helpful and convenient. The testing of safety protection systems can be carried out without disassembly and reassembly of the sensors. This eliminates all associated risks, such as sensor damage or calibration issues.

Technology parameters

PROGNOST®-SenSim enables instrumentation engineers to test complex protection logics such as:

  • 2 out of X voting (3 dynamic signals in parallel).
  • Plausibility checks.
  • Signal for a specific number of consecutive revolutions.

Users are now able to simulate machine damages with freely shapeable amplitudes and frequencies of the sensor signals. PROGNOST®-SenSim is the ultimate device for the realistic 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. This device is most helpful for: instrumentation engineers, diagnostic services groups, machine vendors and OEMs.

Simulation of dynamic vibration signals is mandatory for testing safety limits. The signal is phase referenced, i.e. simulated per revolution. PROGNOST®-SenSim simulates vibration sensors of all major brands.

Edited by Claira Lloyd.

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