Virtualized System Reduces Client s Capital and Maintenance Costs

Transcription

1 Virtualized System Reduces Client s Capital and Maintenance Costs Insert Photo Here Steve Malyszko, P. E. President Steve Schneebeli Lead Systems Engineer Rockwell Automation Process Solutions User Group (PSUG) November 14-15, 2011 Chicago, IL McCormick Place West

2 Agenda Who is Malisko Engineering? Project overview and expectations System requirements and project design Virtualization and Terminal Services Cost benefits realized Control system overview Benefits and results Questions?

3 Who is Malisko Engineering? Experts in manufacturing automation and validation Founded in 1994 Headquartered in St. Louis, Missouri USA Historic Laclede s Landing on the Mississippi Riverfront Regional Office in Denver, Colorado USA Serving the Rocky Mountain Region and the West Rockwell Solution Partner for Control, Process, and Information Systems. CSIA Certified Member Historic Laclede s Landing St. Louis, MO Denver, CO Malisko Western Regional Office

4 Project Overview and Expectations Customer: The project was justified by the need to produce a new generation of flavor enhancer products. Implemented by creating three separate work centers to eliminate process bottlenecks. Project Requirements: To replace aging hardware and software and improve operations visibility with Data Historian Provide an upgrade path for future integration into VantagePoint and Batch DairiConcepts needed an integrator knowledgeable with PlantPAx and experienced to implement a virtualized system Standardization on Rockwell Automation products at all sites Copyright Rockwell Automation, Inc. All rights reserved.

5 System Requirements System Requirements: Upgrade virtually undocumented legacy PLC and HMI system while providing better automated sequencing Reuse all 1771 I/O currently in place and supplement with new Remote ControlLogix I/O racks Deploy a virtualized PlantPAx system with thin client HMIs utilizing Terminal Services Provide redundancy at the HMI and Domain controller level Utilize HMI screen layout and functionality developed at a sister plant to maintain consistency across plants Provide remote system access through a VPN connection Archive process data to FactoryTalk Historian SE Store alarms and events to a SQL server

6 Control System Overview Virtualized PlantPAx system Provides cost savings by reducing server count from 7 to 3 Redundant HMI / Data Servers Primary and Backup Active Directory Domain Controllers Terminal Services used for HMI Thin Clients Thin Client hardware utilized low cost Dell Optiplex small form factor pc s running Windows OS, and utilizing Remote Desktop connections (RDP) to the Terminal Server KEPServer, FactoryTalk Gateway, and WIN911 provide alarm notification Data Historian and SQL Server resides on a non-virtualized machine Allows for future expansion Cisco ASA VPN security appliance allows remote support and provides framework for connection to a multi-plant VantagePoint system

7 Control System Overview

8 Project Design Project Design Requirements: Utilize KEPServer to poll data from A-B UPS s and provide server and network diagnostic data to WIN911 Control Platform is Rockwell Automation ControlLogix Programmable Automation Controllers (PACs) with A-B IntelliCENTER MCCs and Stand-Alone A-B VFDs All Remote rack, MCC, and Drive communications utilizes Ethernet/IP protocol Upgrade existing A-B IntelliCENTER MCC (motor starters and VFDs) to Ethernet/IP Interface to Emerson Wireless HART Transmitter gateway via Prosoft in-rack Modbus TCP adapter DairiConcepts provided a high-level architecture requirement and Malisko was tasked to detail and implement the system

9 Project Design Functional Description document was generated based off of current system functionality along with enhanced automated procedures. DairiConcepts graphics library was the baseline for HMI design Malisko-provided device control faceplates along with AOIs Generous use of add-on instructions and user-defined data types within the PAC; Efficiencies in cost and schedule relating to configuration Quicker maintenance and troubleshooting Utilized controller-based Phase Manager to execute phase logic Structured for future FactoryTalk Batch upgrade

10 Virtualization Technology Overview What is Virtualization? Traditional Servers vs. Virtualized Servers Levels of Virtualization Benefits

11 What is Virtualization? Wikipedia defines Virtualization, with regards to computing, as the creation of a virtual (rather than actual) version of something, such as a hardware platform. Hardware Virtualization was utilized in this project to reduce the physical number of servers required.

12 Traditional Server Architecture Traditional Servers are based on one operating system per physical server.

13 Hardware Virtualized Servers Hardware virtualized servers remove the dependency of the hardware from the operating system, and allow multiple separate operating systems to share common hardware.

14 Hardware Virtualized Servers Interfacing between operating systems and the physical server hardware is handled through the Hypervisor, in this case, VMWare ESXi.

15 Benefits of Virtualization Traditional servers running a single operating system never fully utilize the available resources (both CPU and RAM). Costs are reduced by requiring less hardware and reducing overall energy requirements. Remove reliance of a system backup on specific hardware. VMWare ESXi images are easy to transfer between servers. Allows for easy hardware upgrades without the need for re-installation of the operating system and application files. Decrease the downtime incurred during a hardware failure Virtual system image is stored as a file. New hardware only requires installation of the hypervisor and copying system images.

16 Terminal Services Overview Microsoft Windows Terminal Services provides the ability to host multiple, simultaneous client sessions on Microsoft Windows Server 2003 or later. Starting with Windows Server 2008 R2 and Windows 7, Terminal Services name changed to Remote Desktop Services. Provides centralized deployment and management of FT View SE Client software. FT View SE Client is loaded on the Terminal Server, along with applicable licenses. Physical Client HMI stations require very little configuration The Terminal Server is configured to only launch FT View SE whenever a Remote Desktop Connection is initiated. Remote Desktop Protocol (RDP) connection is used.

17 Terminal Services Architecture FT View SE Client Windows Server 2008 RDP Desktop PC s running Windows XP and Vista

18 Virtualization & Thin Client Cost Savings A traditional installation for this system would require seven servers, and five thick clients with FT View SE installed on each client. Using Virtualization, server count was reduced to three servers Server cost savings: 60% Terminal Services allowed the use of smaller, lower speed desktop PCs Desktop PC cost savings: 33% Reducing the number of servers and lower power client PC s realizes a power savings of approximately 55%

19 HMI Layout Top Banner Main Screen Bottom Banner

20 Device Control Pop-ups Device control is performed by clicking on the device, to open up it s associated faceplate Single Speed Motor Control Valve Control VFD Motor Control PID Control

21 Phase Detail Pop-up Phase Details are displayed on a dynamic Phase Detail prompt.

22 CIP Control Pop-up CIP Line Circuit Selection and Setup

23 ControlLogix Phase Manager

24 Remote Alarm Notification Specter Instruments WIN-911 is used for Alarm Notification via messaging FactoryTalk Alarms and Events manages HMI alarms and interfaces with WIN-911 Kepware s Kepserver gathers UPS, switch, and server health using Simple Network Management Protocol (SNMP), and alarmed through WIN-911

25 Historical Data Collection 225 tags are archived on the Historian Ad-hoc data can be evaluated using the DataLink Excel add-in Engineering and Production utilize reports created in Excel Allows monitoring of critical process parameters Currently in process of implementing a multi-plant VantagePoint System Connection to remove VantagePoint server via VPN Tunnel.

26 Project Benefits and Results Provided upgrade path for VantagePoint and FactoryTalk Batch Virtualization realized a server hardware cost savings of approximately 60% Thin Client technology provided a savings of 33% on Client Hardware Power usage for the servers reduced by approximately 55% Maintenance time required to replace a Client PC has dropped by 2 hours Ability to store server images and restore to upgraded hardware without rebuilding the software installation Increased capacity and on-line time improvement due to process changes and automated control functions.

27 Questions Steve Malyszko, P. E. President Steve Schneebeli Lead Systems Engineer