SETPOINT® CMS powered by OSIsoft PI® is a comprehensive online condition monitoring software solution that connects directly to the VC-8000 machinery protection system without the need for any additional intervening hardware. It provides powerful visualization tools such as timebase, orbit, full- and half-spectrum, bode, polar, air gap, shaft centerline, multi-variable trend, and other plot types specific to rotating and reciprocating machinery, allowing online condition monitoring analysis and machinery diagnostics.
The VC-8000 rack is an API 670-compliant machinery protection system that uses two basic module types to continuously monitor machinery data: Universal Monitoring Modules (UMMs) and Temperature Monitoring Modules (TMMs). The fundamental task for these modules is to continuously monitor the signals from connected sensors, condition the signals into multiple measurement parameters for each sensor, and compare these measurements against alarm setpoints. The real time data collected by these modules is streamed down the rack’s backplane to the System Access Module (SAM) where the digitized, encoded data is available at the CMS port via a Gigabit Ethernet port. The protocol used for this interface is open. An engineered interface exists allowing it to directly communicate with OSISoft’s PI software. Communication with other systems is also available by anyone wishing to write an interface supporting our protocol.
The VC-6000 rack communicates directly with server software running on a host computer. This computer is normally a server-grade rack-mount machine running Microsoft Windows, PI Server Software, PI AF Server Software, and Microsoft SQL Server software. These software packages work in concert to collect and historize the real time data supplied by the VC-8000 rack. The data is then available to other PI servers and clients throughout the organization using local and wide area networks. Remote access is also available using the internet and standard, secure VPN (Virtual Private Networking) technology.
Client software provides the data visualization tools needed to view historized and real time vibration and process data in the OSIsoft PI® sever. Two tightly integrated client software packages are used in tandem to view data: An OSIsoft visualization client (PI® Vision or PI® ProcessBook) and SETPOINT® CMS.
The OSisoft visualization client allows you to navigate to points of interest using highly intuitive, highly customized plant overview and machine train mimic diagrams. Once one or more points of interest have been selected in the OSIsoft visualization client, you can view trends, statuses, currently values, and other data, just as from any other point in a PI process historian implementation. From there, you can drill down even deeper into the data than standard PI® visualization tools allow by means of our SETPOINT® CMS Display client. It is used specifically used for viewing vibration waveforms via plot types that are not availale in OSIsoft visualization tools. SETPOINT® CMS software can also operate independently of any OSIsoft visualization tools if desired, providing full functionality for navigating to points of interest and displaying trend information, alarms, and vibration waveforms, allowing powerful analysis capabilities.
- Open Interface
The SETPOINT® system is the first to offer an open interface for communication of all data, including waveforms, rather than just overall values and statuses. This fully open protocol affords more flexibility for users.
SETPOINT® CMS software has been designed for unmatched ease-of-use. Its simple “toggle pushbutton” user interface allows you to easily see which plot types have been selected, which points have been selected, which parameters have been selected, and to easily select/de-select attributes without navigating complex menu structures that may normally be hidden.
An innovative playback feature allows historical data to be played back like a video, making it easy to watch how a plot has changed over time and pause at points of interest. The playback feature is implemented on both static and dynamic plot types to see how a waveform, trend or other data changes over time. It is even implemented on machine train diagrams to easily see current values and statuses at a particular moment in time and then how it changed over the selected time period. It is like an instant replay that can be speeded up, paused, rewound, fast forwarded, and used just like your computer’s music player to quickly navigate through data and play it back.
- Near-Lossless Data Compression
The SETPOINT® CMS system takes advantage of a powerful firmware capability within the SETPOINT® machinery protection system that automatically characterizes complex waveform data based on how much it has changed from prior samples. Data is characterized in multiple ways – not just overall amplitude, changing speed (delta rpm), and whether in alarm or not. It can characterize data by changes in vibration phase, frequency content, and many other parameters. This allows both waveform and static data to be collected and characterized dozens of times each second, yet stored only when a new sample sufficiently differs from a prior sample. This pioneering technology gives users the best of both worlds: it collects all of the data, all of the time, but only stores it when a sufficiently large difference exists between a new sample and prior samples, providing highly effective and near-lossless data compression that does not discard valuable information.
- The Power of PI®
OSISoft’s PI System is the world’s most widely used platform for storage and visualization of real time data. It enjoys over 1400 installations globally in the power generation, hydrocarbon processing, pharmaceutical, food & beverage, forest products, and dozens of other process industries. This extremely large installed base means that PI has proven itself for decades as a robust real time database suitable for the most critical applications – including nuclear power – with outstanding security models that work seamlessly across firewalls and satisfy even the most demanding IT criteria. SETPOINT® is proud to base the core of our condition monitoring offering on the proven PI System platform, using it as the repository for our condition monitoring data and its powerful Asset Framework (AF) features for organizing measurement points across assets, plants, and enterprises.
- IT Compatibility
Asking your IT department to endorse yet another application with different server requirements, different remote access requirements, and different security models can be daunting. Because the PI System is so widely used, chances are that your company is already using PI. Thus, you can simply extend your existing PI System rather than qualifying and deploying a different system. For those customers not already using PI, the SETPOINT® CMS solution can function as a stand-alone package that is minimally intrusive to existing systems and infrastructures while able to satisfy even the most stringent IT requirements.
Because the PI System features thousands of engineered software interfaces, it can communicate with virtually every commercially available process control and automation system through an enormous library of PI Interface software available from OSISoft. This means that users can easily import and export data in real time from the SETPOINT® CMS system so that data from disparate systems can be visualized and analyzed at the same time.
SETPOINT® CMS software is refreshingly affordable and many installations will see savings exceeding 40% compared to competing systems. Each SETPOINT® machinery protection system incurs a modest per-monitoring-module adder to turn on the rack’s CMS communications port. Appropriate server software is then installed on the host computer(s), much of which may already be available at sites that are already using PI. Data visualization is provided through PI ProcessBook® software, and through the SETPOINT® CMS display client (freely available from our website at no charge). SETPOINT® CMS software extends the basic data visualization capabilities in PI ProcessBook to encompass the rich suite of plot types pertinent to rotating and reciprocating machinery vibration analysis and condition monitoring.
While SETPOINT® CMS software can also be used with machinery protection systems from other suppliers. Simply use the SETPOINT® hardware as a data acquisition interface by connecting to the buffered outputs of the other system. When it is time to upgrade the underlying machinery protection system, the SETPOINT® system can be left in place and connected directly to the existing transducers, then configured to perform both machinery protection and condition monitoring functions.
The PI architecture is highly scalable, allowing additional points to be added easily. These new points can come from additional SETPOINT® racks, process points originating elsewhere in the plant, or simply the insertion of additional modules into an existing SETPOINT® rack for new channels. A single server can typically provide adequate storage capacity and data streaming/archiving speeds to address 500 monitoring channels or more.
SETPOINT® CMS Software delivers a rich suite of plot types, ensuring that rotating machinery engineers and vibration specialists can properly analyze data and diagnose problems. Available plot types include:
- Machine overview diagrams (fully customizable in PI ProcessBook and PI Vision)
- Hierarchical dashboards (fully customizable in PI ProcessBook and PI Vision)
- Enterprise Overview (see below)
- Plant Overview
- Multi-Machine Overview (see below)
- Individual Machine Overview (see below)
- Filtered timebase
- Unfiltered timebase
- Filtered orbit (see below)
- Unfiltered orbit (see below)
- Full spectrum
- Half spectrum (see below)
- Multivariable trends (see below)
- Polar (see below)
- Bode (see below)
- Air Gap
- Shaft Centerline
- Reciprocating Compressor Plots
- Acceleration vs. Crank Angle
- Rod Load vs. Crank Angle
- Cylinder Pressure vs. Crank Angle
- Cylinder Pressure vs. Displaced Volume (with and without adiabatic curve)
- Rod Drop / Rod Position