march 31st and april 1st, 2009mile high industrial and automation conference using virtualization...

March 31st and April 1st, 2009 Mile High Industrial and Automation Conference

Using Virtualization and XMLto Maximize your HMI

Investments

Dallas West

Jim Craib


Agenda

Introductions Is It Time To Upgrade or Prolong Life? Why, and How Much Will it Cost? Industry Changing Technologies What is Virtualization? Advantages of Virtualization? Case Study What Does the Future Hold? Conclusions Questions & Answers


Introductions

Jim Craib President, Orion Automation and Controls

Engineering 25 Years of Automation and Controls

Experience 16 Years of PLC/HMI Experience 10 Years of Experience Managing Automation

Projects BBA Degree from Golden Gate University ISA Member since 1988


Introductions

Dallas West BS. Biotechnology Hons. (1999) BS. Chemical Engineering (2001) Joined Genentech SSF Automation 2004 Current Role:

Cell Culture Automation Manager DCS & PLC Batch Operations

Currently Reading www.digg.com Globaleconomicanalysis.blogspot.com Blink by Malcolm Gladwell


Is the Time Right?

Has the vendor released a major revision?Is the vendor planning to end support?Does the system often crash or have

performance issues?Can operations staff perform their jobs

effectively and efficiently?


What Will it Cost?

Engineering Design and Documentation $1,000 to $25,000

Screen and Database Conversion $0 to $5,000 per screen or database tag

Hardware (COTS PC or Industrial PC) $400 to $20,000


What Will it Cost?

Software (OS and Vendor HMI Package) $1,000 to $50,000

Commissioning and Qualification $0 to $5,000 per screen

Validation $5,000 to $100,000


How Long Will It Take?

Conceptual/Preliminary/Detailed Design 1 to 3 months

Development/Build/Testing 1 to 6 months

Deployment/Training 1 to 3 months


Industry Changing Technology


Napsters Impact on the Music Industry

Global music sales dropped from: $38 Billion in 1999 $32 Billion in 2003

Stan J. Liebowitz argues in a series of papers (2005, 2006) that file sharing had a significant negative impact on record sales.


Then Came Apple


So What?

Music Industryis to the

Automation Industry

is to the


What is Virtualization?

Virtualization provides a means to run multiple instances of varying operating systems simultaneously on the same computer.


Guest OS

Host OS


Types of Virtualization

Server VirtualizationDesktop VirtualizationPresentation VirtualizationApplication Virtualization


How does it work?


How does this relate to HMIs?

The story of Jimmy


Slide from a 2008 Automation Vendor Conference

1987 – Product Life Cycle for an average HMI Console: 20 Years

2007 – Product Life Cycle for an average HMI Console: 5 - 7 Years

"Modern Technology has changed the Process Control Industry!"


Case Study

WinView HMI

BATT

PROC

FORCE

COMM

A B

A B

AB PLC 5/80EControlling a

ChromatographySkid

Ethernet


System Highlights

Mature HMI No changes made in year prior to project

Existing HMI met all current user requirements

Problem HMI PC would crash unexpectedly HMI PC hardware was failing causing unplanned

downtime

Question How can we extend the useful life of the existing system

while minimizing our investment costs?


Case Study Solution

Windows 95 Virtual Machine was created in a VMWare ACE Environment

HMI software was loaded and configured within the Virtual Machine. Virtual Machine package was installed on a new Corporate

Standard PC.


Case Study Demo


Case Study Outcome

Total invested cost = $2,000 Virtualization Software: $80 Corporate IT issued desktop computer: $750 Engineering Time:

Rebuilding New Image: 2 hrs x $200 per hr HMI Application Configuration: 4 hrs x $200 per hr

Time to deploy preconfigured Virtual Machine: 15 minutes

Cost savings on a 5-7 year basis: Ranges from $38,000 to $123,000!


Case Study Outcome

Based upon this success, other production systems were virtualized, including: Windows 95 Systems Windows NT Systems Windows 2003 Server Systems

Quote from Operations Staff “I never knew Windows 95 could run so fast!”


Advantages for End Users

Increases the longevity of a HMI Application Decreases downtime in the event of a failed HMI

PC Breaks the dependency between HMI Software

and Hardware.

Bottom Line It’s easier to do than a full HMI Upgrade! It’s going to save you downtime and money!


Attention all Vendors!!!

Who’s going to be the next Apple? Who’s going to be the first to sell a prepackaged

Virtual Machine? Think iTunes for Automation Software!

How many calls do your Call Centers get for Software Configuration issues? Potential Call Center call volume reduction

Competitive Advantage for whoever gets there first! My HMI will run indefinitely, Vendor Y’s is only good

for 5-7 years.


Limitations

Not all I/O is easily virtualized Rockwell: DH+ connections Foxboro: Nodebus connections

Non x86 machines cannot currently be virtualized to run on a x86 machine. ie.) Sun SPARC Workstations cannot be virtualized to run on

Windows Machine.

Licensing Disclaimer Read your EULA to determine what impact virtualization might

have on any licensing agreements you have.


What’s Does the Future Hold?

Seamless Software Upgrades At some point your going to want to upgrade

Take advantage of new features Take advantage of increased support

How will you do it in the most cost effective means? XML & XSLT!


Google Translate


What the XML is XSLT?

XML - eXtensible Markup Language.• Provides an means to expose data within an application

file.• Once the data is visable we can do something to it!

XSLT - eXtensible Stylesheet Language Transformation• XML-based language used for

doing some sort of action to an XML document or file.


XSLT Translation Process

OutputData

OutputData

InputData

InputData

MagicBlackBox

XML Input XSLT


XSLT Translation Process

Microsoft WordManufacturing Formula

Microsoft WordManufacturing Formula

Microsoft ExcelInput

Microsoft ExcelInput

RSBatchRecipe Output

RSBatchRecipe Output

MagicBlackBox

XML Input XSLT


XSLT Demo


Black Box Revealed


Unlock the possibilities!!!

HMI Rev NewOutput

HMI Rev NewOutput

HMI Rev OldInput

HMI Rev OldInput

MagicBlackBox

XML Input XSLT


Unlock the possibilities!!!

Vendor BCode

Vendor BCode

Vendor ACode

Vendor ACode

MagicBlackBox

XML Input XSLT


Attention all Vendors!!!

Who’s going to be the first to offer XSLTs that… Transform design docs to code/HMI? Transform design docs to commissioning test

scripts? Transform a competitors code/HMI to yours? Validate your XSLT’s for the regulated

industries?


Conclusion

When your ready to upgrade Explore how you can use XSLT translations to

make your next upgrade more cost effective!

Don’t be a victim of Microsoft! Use Virtualization to maximize your HMI

investments!



Questions and Comments?


Appendix


What is Virtualization?

"Virtualization is a framework or methodology of dividing the resources of a computer into multiple execution environments, by applying one or more concepts or technologies such as hardware and software partitioning, time-sharing, partial or complete machine simulation, emulation, quality of service, and many others."

march 31st and april 1st, 2009mile high industrial and automation conference using virtualization...

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