best practices to modernize and simplify your industrial ......virtualization & continuous...
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© 2016 Stratus Technologies. All Rights Reserved. 1
®
Best Practices to Modernize and Simplify Your Industrial Control Systems
John Fryer, Senior Director of Industry Solutions, Stratus
© 2016 Stratus Technologies. All Rights Reserved. 2
Agenda
• Typical challenges with Industrial Control Systems
• The impact of new technologies
• Modernizing an ICS with best practices
– Virtualization
– Enabling new applications that simplify operation
– Protecting your virtualized environment
• Modern solutions are more than just technology
• Key considerations
• Why Stratus?
• Case studies
• Next steps
© 2016 Stratus Technologies. All Rights Reserved. 3
Typical comments we hear about ICS’s
“Our systems are so oldand fragile we dare not change anything in case
it breaks”
“We are adding more and more complexity to our systems making
them more breakable”
“IT does a great job ofscheduling planned downtime, but the
bigger issue isbreak/fix ”
“I can’t even count the number of
devices we have to manage these days”
“We do not have technical IT skills tofix system issues atremote locations”
“When applications stopworking we don’t even
know until other issues arise”
© 2016 Stratus Technologies. All Rights Reserved. 4
Tomorrow’s advancements will create more complexity and risk
Business goals
• Increase output
• Improve quality
• Be more agile
Challenges
• More fire drills
• Increased complexity
• Additional (IT) support
Technology drivers
• Virtualization
• Industrial Internet of
Things (IIoT)
• Cloud/Big data analytics
• Plant interconnectivity
• Cyber-security
© 2016 Stratus Technologies. All Rights Reserved. 5
Poll question 1
• What do you see as the biggest challenge with your current
ICS?
– Keeping aging applications running
– Keeping aging platforms running
– Getting IT support when something goes wrong
– Complexity of managing the overall ICS environment
– Adding new functionality without disrupting operations
© 2016 Stratus Technologies. All Rights Reserved. 6
Primary
ICS
serverThick clients
Backup
ICS
server
PLCs and Automation devices
Historian
server
Disruption in Industrial Automation – Current state
ICS isolated to secure plant floor devices
Mixed O/S environments with security
holes
Each system individually managed
Local workstation required to access
information
Complex redundancy where most
critical
Break/fix or constant
monitoring
Reactive ComplexIT
“heavy”
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Rely less on ITBe more proactive Reduce complexity
What do best practices look like?
• Detect issues before they become
bigger problems
• Protect your entire IA technology stack
• Always keep your ICS apps running
(Historian, HMI, MES and MOM running
etc)
• Easily take advantage of new
technologies
• Consolidate 5+ servers into a single
system
• Get built-in hardware redundancy with
that single system
• Purchase and manage fewer software
licenses
• Use a single system view for all your OT
and IT applications
• Get proactive notification of potential
problems
• Automate hardware remediation
• Easily swap hardware components by
yourself
• Get instant access to IT specialists with
IA expertise
© 2016 Stratus Technologies. All Rights Reserved. 8
Modernizing IA eliminates disruption
Secure connectivity to the plant floor
devices
Secure advanced data
historian & analysis
Centralized management
and thin clients
Access to your information
anytime, anywhere
Simplified virtualization &
continuous availability
Optimize with tasks &
analytics
Go To Market Partners
Proactive remediation &
on demand support
Thick, Managed thin, Mobile, and Web clients
PLCs and Smart automation devices
leveraging OPC
Microsoft
Proactive Simple IT “lite”
© 2016 Stratus Technologies. All Rights Reserved. 9
Poll question 2
• When are you planning to update your ICS and move to
virtualization?
– Already virtualized
– In the next 12 months
– 1-3 years
– No current plans
– Need to learn more about virtualization first
© 2016 Stratus Technologies. All Rights Reserved. 10
Protecting virtualized environments
Standard
Servers
• Single Points of failures
cause downtime and data
loss
Virtualization HA
OS
APP
OS
APP
OS
APP
OS
APP
OS
APP
OS
APP
• Not optimized for availability
• Very similar to a cluster
External LAN
LAN 1 LAN
2
Heartbeat 1
Heartbeat 2
Clusters
• Management complexity adds
risk and expense
1-4 Hour Service
Response to fix
Days of outage in
remote locationsFAILURE RECOVERY
NOT FAILUREPREVENTION
FAILURE RECOVERY
NOT FAILUREPREVENTION
Scripts must be executed •Still experience failover•Cannot move apps from a failed server
Fault tolerance is the preferred solution
Integrated Redundant
& Fault-tolerant
Solution
No downtime or data loss
Simple integrated
solution
Easy to service
FAILURE PREVENTION
• No single points of failure
• Optimized for IA applications
© 2016 Stratus Technologies. All Rights Reserved. 11
Key considerations for modernizing an ICS
What is my tolerance for
unplanned downtime?
What hardware/application
protection do you need ?
Would an increased level of “9’s” generate savings
and/or increased productivity?
How do you restore normal application processing
and how does this affect your ROA?
How important is your (in-
flight) data?
Is there a seamless migration
path?
Are specialized skillsets
required?
Is the solution future-ready
with the best ROI?
Does data loss present risks for asset management
& IIoT analytics and/or regulatory requirements?
How much impact will an upgrade transition have to
your operations?
Does extensive (and costly) training have to be
factored in?
Will the system support new applications, such as
IIoT, does to have a 5-7+ year lifespan?
© 2016 Stratus Technologies. All Rights Reserved. 12
Stratus customer
The Stratus solution
Active
service
network
• Automatic
re-synchronization
• Hot swap replacement
• Overnight delivery
• Automatic replacement part
ordering and shipment
• Automatic hardware
problem detection
• OPC
• Application monitoring
and re-start
• Continuous operation during failures
• Automatic Uptime Layer
• Integrated redundancy
On demand
Support
services
• Proactive
recommendations to
address problems
• Proactive notification of potential
problems (failure or performance)
• Constant monitoring of ftServer
generated notifications
• 24x7x365 access to IA IT experts
ftServer
© 2016 Stratus Technologies. All Rights Reserved. 13
Textiles
Fabricated metals
Machinery
Material handling
Printing
Automotive
Food and beverage
Pharmaceuticals
Cement
Metals and mining
Water and waste
Pulp and paper
Chemical
Oil and gas
Power generation
Refining
Petrochemicals
Industry classificationDiscrete vs. Continuous automation
Discrete
Continuous
Source: Morgan Stanley research
Serving customers in every IA segment
© 2016 Stratus Technologies. All Rights Reserved. 14
The continuous application availability market leader
• Protecting lives, assets and revenues since 1980
• Over 40 hardware and software availability patents
Corporate headquarters
Maynard, Massachusetts USA
Systems installed
20,000+ worldwide
Global presence ~500 people
Americas – EMEA – APJ
Robust financial profile
Stable revenues, cash and profit
Key Industrial Automation and technology partnerships
© 2016 Stratus Technologies. All Rights Reserved. 15
Case study – Pinellas County Utilities
Initial situation• Upgrade outdated automation systems
• Decreasing tax base
• Increased regulations
• Reduced resources
ResultsIncreased efficiency• Fault-tolerant virtualized platform eliminates
unplanned downtime
• Simple to operate and service - no IT expertise
needed for maintenance
• Data always available for regulatory scrutiny
Reduced costs• Single virtualized platform at each location
• Automated support model reduces equipment
monitoring saving manpower
• Single copy of s/w required controlling costs
Key issues• Multiple remote control rooms
• Cost effective solution to limit
server costs
• Prevent control room
“blindness” through unplanned
downtime
• No data loss to meet new EPA
regulations
• Integration into new IT
infrastructure
• Maximize efficiency
Workload managed• 71 million gals clear water
• 30 million gals waste water
• 4.2 million residents
• 24 communities
• 2,000 miles of pipe
• 13 field wells
• 5 surface water sources
• 3 wastewater facilities
• 350 lift stations
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Dependable Gas Transmission
Requirements
Meet new Control Room Management (CRM) regulations
Operational simplicity
Real-time analytics without data loss
Several catastrophic incidents led the company to examine their 15,000 miles of pipeline, spread across 16 states, which transports over 1 trillion cubic feet of natural gas per year
Chosen solution
Stratus® ftServer® platform
Operationally simple system to run virtualized applications remotely without
IT expertise and real-time analytics for complete operational visibility
Business impact
100% operational continuity
Zero downtime
Zero data loss
Solutions considered
Multiple servers at each compressor station
Virtualization solution with manual specialized maintenance
“We can get a lot more flexibility by adding applications in the compressor stations without the need for IT expertise.”
Lead Automation Electrical Engineer
© 2016 Stratus Technologies. All Rights Reserved. 17
Dairy Farmers of America
Requirements
Requirements
24x7 monitoring of entire stack
Total hardware redundancy
Enough capacity to run all VMs on one server
No defined life expectancy
Simple implementation
Producer of milk, ice cream and other dairy products, sports drinks and salsa for well-known brands
Chosen solution
Stratus ftServer 6410 system
ACP ThinManager running 15 virtual machines supporting:
• PlantPAx, HMI, FactoryTalk, EWS, Histortian, and more
Upgrade server architecture to standardize, ensure absolute availability and improve operation speed of Portales plant without interrupting operation
Business impact
Eliminated downtime
Improved efficiency of overall system
Lowered implementation cost
Widened IT infrastructure
Solutions considered
‘High-end’ Dell/IBM/HP server farm
Rockwell Automation’s server offerings
Low-end solutions such as “Why don’t we just go down to Walmart and buy some servers?”
“Hours and perhaps days of downtime have been eliminated by removing the unsupported PCs and replacing them.”
Eric Miller, Engineering Manager
Dairy Farmers of America
© 2016 Stratus Technologies. All Rights Reserved. 18
Next steps / Where to get more information
• Next Steps
• Conduct an assessment of your business objectives
• For more information or to schedule a live demo, contact Greg Paden at [email protected] or call (978) 461-7579
• Connect, follow, consume and have a conversation with us!
• Blog: www.stratus.com/stratus-blog/
• LinkedIn: www.linkedin.com/company/stratus-technologies
• Twitter: www.twitter.com/StratusAlwaysOn
• YouTube: www.youtube.com/user/StratusTech
© 2016 Stratus Technologies. All Rights Reserved. 19
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Questions?