NI InsightCM™ Enterprise for Condition Monitoring

ni.com/insightcm

NI InsightCM™ Enterprise Product Overview

NI InsightCM™ Enterprise is a software solution for online condition monitoring that acquires and

analyzes sensory information, generates alarms, allows maintenance specialists to visualize and

manage data, and simplifies deployment of large numbers of monitoring sytems. It provides insight

into the health of both critical rotating machinery and auxiliary rotating equipment to optimize

machine performance, maximize uptime, reduce maintenance costs, and increase safety.

The software suite consists of two main components:

NI InsightCM™ Data Explorer

Application for remotely analyzing raw time-series data

and results, drawing comparisons and viewing historical

trends with support for standard vibration plots

NI InsightCM™ Server

Server software with comprehensive analytic and data

management capabilities with a thin client for

configuring and viewing health of acquisition devices

The software suite also offers compatible out-of-the-box hardware options, the CompactRIO-based

NI Condition Monitoring Systems, that acquire data from a range of sensors, including proximity

probes, accelerometers, pressure sensors, voltage and current sensors, thermocouples, and RTDs.

NI InsightCM™ Enterprise Architecture & Features With the InsightCM™ Enterprise solution, data is automatically acquired using CompactRIO-based NI

Condition Monitoring Systems, and transmitted to the server where it is stored. The NI InsightCM™ Server

software calculates condition indicators and also manages the CompactRIO-based systems. The data is then

avaialable for remote viewing and analysis using the NI InsightCM™ Data Explorer client application. Data is

also exportable as tags to third-party software packages running at the enterprise IT level.

This solution enables users, including line operators, maintenance specialists and IT professionals, to:

Acquire Dynamic & Static Sensor Data

Embedded data acquisition nodes built on the rugged,

reconfigurable NI CompactRIO platform acquires data from a

multitude of sensor types at periodic and user-defined

intervals, and also streams data from critical assets during

transient events such as start-ups and coast-downs.

Analyze Waveform Data

The NI InsightCM™ Sever delivers a comprehensive set of

algorithms for analyzing dynamic waveform data, and

calculates key features and condition indicators for tracking

and determining equipment health.

Visualize Raw Data & Results

Maintenance Specialists can remotely view industry-

standard plots, track historical trends, correlate data to

events, and compare current data sets with previously

recorded ones with the NI InsightCM ™ Data Explorer.

Generate & Manage Alarms

Users can configure alarm conditions based on rotating

speed and other calculated results. Alarm configurations are

downloaded to acquisition systems for real-time alarm

detection, and automated e-mail notifications can be

configured to immediately alert specialists.

Manage Data

This software suite leverages the open TDMS file format

and proven technology for mining large engineering data

sets. The suite uses industry-standard data hierarchies to

correlate channels and devices to sensors and equipment,

and ages data to efficiently use disk space.!

Configure & Monitor Systems

The NI InsightCM™ Server simplifies firmware deployment

and device configuration as well as monitors the status of

acquisition systems to ensure reliability of the monitoring

solution.

Authenticate Users & Devices

The NI InsightCM™ Enterprise software suite ensures that

data is received only from authorized acquisition devices,

and supports user permissions to allow access to view and

change system data and parameters.

Integrate Into IT Infrastructure

The interoperability and open software architecture enables

integration with popular database historians and existing IT

software, while systems management functionality allows

IT professionals to monitor acquisition device connectivity

and network bandwidth.

NI InsightCM™ Data Explorer

The NI InsightCM™ Data Explorer provides in-depth, interactive visualization and analysis of real-time and

historical offline data to maintenance and equipment specialists. This application is designed to run on a

desktop or laptop and allows for convenient, remote access to data and results stored on the server.

Maintenance specialists can explore a variety of industry-standard vibration plots, including:

The NI InsightCM™ Data Explorer provides two modes: one for viewing periodically acquired data and one for viewing

previously captured transient events, such as start-ups and coast-downs.

The software package allows Maintenance Specialists to perform in-depth comparative analytics and detailed data mining

to diagnose equipment health. Specialists can:

• Select a server location, and navigate the equipment hierarchy

• View multiple channels or features together

• Correlate data to faults and events, and save notes to easily recall diagnoses

• Take snapshots to compare current data to previously recorded data on the same machine

• Compare suspect health issues on one machine to previous fault signatures from other machines

• Track historical trends

• Determine whether harmonics or sidebands are present, and calculate their frequency

• Listen to time series data which was recorded

Maintenance and equipment specialists can detect imbalances, bent shafts, misalignments, bearing defects, and other

faults in rotating machinery based on the visualization and analysis capabilities offered in this application, and determine

actions that need to be taken as part of the diagnosis and maintenance procedure

NI InsightCM™ Server

The NI InsightCM™ Sever delivers in-motion analytics coupled with management of CompactRIO systems,

data, and alarms. The server software manages reliable, loss-less communication across the entire

architecture and includes a thin-client application called NI InsightCM™ Systems Manager to configure, view

and manage the remote acquisition systems and server parameters. The optional InsightCM™ Enterprise

Gateway add-on allows exporting tags and feature calculations to external software packages.

The software includes a comprehensive set of algorithms for processing dynamic waveform data, including:

• RMS, Peak-Peak, True Peak, Derived Peak,

• DC Gap, Crest Factor

• Spectral Bands

• 1x Magnitude/Phase

• 2x Magnitude/Phase

• High Frequency (1kHz!FMAX)

• Subsynchronous (.2!.8 orders)

• Custom, useful for defining bearing, gear and

other fault frequencies (BPFO, BPFI, etc.)

• Integration/Differentiation

• English and Metric unit support

To manage access to data and server parameters, the InsightCM™ Server lets users setup custom roles for specific

levels of access within the software. These roles can be mapped to existing corporate LDAP/Active Directory groups for

centralized role management. The server also uses Secure Remote Password (SRP) & Credentialing to ensure secure

connections to CompactRIO acquisition systems, and SSL encryption to browser thin-clients.

NI InsightCM™ Systems Manager

This thin-client is accessible via any web browser, providing

a portal to access, view and configure a number of server

capabilities, such as:

• Web-based CompactRIO configuration

• Automatic module discovery

• Template based configuration of channels,

analytics, alarms

• Remote updates of firmware & settings

• Web-based test panels for commissioning systems

• Equipment layout definition

• IT system console with error and message logs

• Alarm & notification management

• Aging of data to automatically reduce data

NI InsightCM™ Enterprise Gateway (optional)

Integration with third-party data historian, SCADA, CMMS,

and other enterprise software packages is offered via the NI

InsightCM™ Enterprise Gateway. With this add-on option,

calculated results can be communicated via tags using the

OPC UA protocol to a large number of software packages,

or directly to the OSIsoft® PI System server, a database

historian commonly used in the Energy & Oil & Gas

industries. Aggregation of key calculated features from the

NI InsightCM™ Enterprise software suite with other

measurements and business data allows for additional

trending and alarming possibilities and also consolidation

with decisions related to budgeting, downtime scheduling,

spare parts and maintenance personnel.

NI Condition Monitoring Systems

!The CompactRIO-based NI Condition Monitoring Systems are available in two main configurations to

differentiate between machines requiring only periodic monitoring, and those producing important transient

events. The CompactRIO platform provides a flexible range of analog and digital sensor input options, and

allows companies to cost-effectively deploy online monitoring systems to a greater percentage of fleet assets.

The systems are capable of on-board analysis to detect alarm conditions in real-time. NI InsightCM™

Enterprise provides application firmware, enabling the systems to acquire, buffer, and forward data to the NI

InsightCM™ Server. For an easy, out-of-the-box experience, the systems ship with all C-Series modules

installed, needing only to be provisioned and commissioned for authenticated communication with the server.

Periodic & Event Recorder (CMS-9068)

• Logging based on configurable time intervals, measurements, and user triggers • Support for wide range of dynamic waveform and static measurement sensors • Accounts for 75-80% of measurements in a predictive maintenance program,

suitable for replacing traditional, manual diagnostic rounds • 4 supported configurations of NI C-Series measurement modules:

• Dynamic measurements only (up to 8 NI 9232 modules, 24 channels) • Up to 6 NI 9232 and 2 static measurement modules • Up to 2 NI 9232 and 6 static measurement modules • Static measurements only (up to 8 modules)

CMS-9068 Controller Specifications: • 667 MHz dual-core processor

• 1 GB nonvolatile storage

• 512 MB system memory

• -40 to 70 C˚ operating temp range • 50g shock, 5g continuous • 10/100/1000 Ethernet

Supported Dynamic Modules: • NI 9232 (3 Channel DSA +/-30V) • 24-bit Dynamic Signal Acquisition

• IEPE signal conditioning

Supported Static Scan-Engine Modules (up to 1Hz sampling rate) • NI 9205 (16 differential +/- 10V voltage)

• NI 9207 (8 differential +/- 10V and 8 +/- 21.5 mA)

• NI 9239 (4 differential and isolated +/- 10V voltage)

• NI 9229 (4 differential and isolated +/- 60V voltage)

• NI 9208 (16 +/- 21.5 mA current)

• NI 9211 (4 channel thermocouple)

• NI 9213 (16 channel thermocouple)

• NI 9214 (16 channel thermocouple - high accuracy)

• NI 9217 (4 channel 100 Ohm RTD)

• NI 9425 (32 channel 24V digital input sinking)

• NI 9426 (32 channel 24V digital input sourcing)

• NI 9219 (4 channel universal module for voltage, current, resistance, digital input, and thermocouple & RTD temperature sensors)

Transient, Periodic & Event Recorder (CMS-9024)

• Logging based on configurable time intervals, measurements, and user triggers • Streaming of time waveform data during run-up and coast-down transient events

until steady state is maintained • Support for accelerometers, velocity meters, and proximity probes,

and up to 3 Keyphasor® sensors • Acquisition from Buffered Outputs on common third-party protection systems • Intended for monitoring of critical rotating machinery such as turbines

CMS-9024 Controller Specifications: • 800 MHz processor

• 4 GB nonvolatile storage

• 512 MB DDR2 memory • -40 to 70 C˚ operating temperature range • 50g shock, 5g continuous • 10/100 Ethernet

CMS-9024 Supported Modules (up to 8 modules): • NI 9232 (3 Channel +/-30V dynamic input module)

• 24-bit Dynamic Signal Acquisition (DSA)

• IEPE signal conditioning

• 41 kHz bandwidth

• 102.4 kS/s per channel maximum sampling rate

• Keyphasor® sensor support on module in slot 1

• Open/Short detection of sensors

Additional Specifications for Deployment

Recommended system configuration for NI InsightCM™ Server

Dedicated server with: • 8+ core processor with 3+ GHz CPUs

• 32+ GB RAM

• Windows Server 2008 R2 SP1 64-bit operating system

• 3 physical hard drives including:

o 1 hard drive for the OS & application (250-500+ GB)

o 1 hard drive for the NI DataFinder index (250+ GB SSD or high performance HDD)

o 1 hard drive for the data files (1+ TB high performance storage)

For running NI InsightCM™ Systems Manager: Supported browsers include Google Chrome, Microsoft Internet Explorer, and Mozilla Firefox.

For running NI InsightCM™ Enterprise Gateway: Connecting to the OSIsoft PI Server requires installation and configuration of the PI System Access License from OSIsoft on

the server hardware.

Recommended system for running NI InsightCM™ Data Explorer application

Laptop or PC with: • Windows 7 64-bit operating system

• 2+ Core processor with 2+ GHz CPUs

• 8+ GB RAM

• 4+ GB HD available for application

Recommended IT and network specifications

Supported network configurations include:

• 10/100 Ethernet (1000 Ethernet recommended)

• Wired or wireless network

• NI InsightCM™ Server machine and NI

InsightCM™ Data Explorer client machine must

be on the same Windows domain

• Open client-side communication ports (for NI

InsightCM™ Data Explorer)

• TCP Port 6342 (port number configurable)

• Must be on same domain to access shared

folder where TDMS data is stored

• Open server-side communication ports:

• To CompactRIO systems: o TCP Port 6342 (port number configurable) o Web service on port 8002 o mDNS port 5353 for device discovery

• To InsightCM™ Data Explorer clients o TCP Port 6342 (port number configurable) o Incoming UDP on port 2343 o Outgoing UDP on ports 2343, 6000-6010 o TCP Ports 2343, and 59100 - 59110

• To InsightCM™ Systems Manager o TCP Port 6342 (port number configurable) o TCP Port 80

Ordering Information The NI InsightCM™ Server software, along with its add-on options, can be purchased as a lifetime license or as a

renewable one-year license, and NI InsightCM™ Data Explorer clients are sold on a per user basis. Volume pricing is

available for CompactRIO systems, as are additional systems assurance and support options for hardware and software.

Contact your local sales engineer to discuss your application, and to configure and price a solution to meet your needs.

Visit http://www.ni.com/contact/ to get in touch with your local representative.

NI in Condition Monitoring

With hardware and software tools, NI has been a direct player in the condition monitoring market for

over 20 years, helping customers in a range of industries to solve complex maintenance challenges.

Visit ni.com/mcm to learn more about customer successes in condition monitoring.

About NI National Instruments is a technology pioneer and industry leader in measurement and automation, delivering today’s most

advanced technologies for monitoring and control. Since 1976, engineers and scientists in virtually every industry have used

flexible, high-performance NI products to create reliable, user-defined systems. With the graphical system design approach,

which combines graphical programming software and modular, open hardware, NI has redefined how engineers work

throughout the entire product design cycle, resulting in reduced time to market and lower development costs.