rockwell introductiontovirtualizationforcontrolsystems
DESCRIPTION
rockwell automationTRANSCRIPT
Experience the Difference!
Electrical • Lighting • Automation • DataComm
Virtualization for Manufacturing Industries
-PRESENTED BY
Mike Murphy – Schaedler Yesco Tim McCain – Rockwell Automation
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2
Agenda
Virtualization & Rockwell
Virtualization for Production
Virtualization for Engineers
Overview & Drivers
Additional Options
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
30%
36%
36%
44%
46%
48%
50%
53%
61%
71%
20%
20%
21%
41%
30%
23%
11%
22%
8%
12%
30%
16%
21%
11%
15%
19%
25%
12%
20%
8%
20%
28%
21%
4%
9%
10%
14%
14%
11%
8%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Transportation/Logistics (N=20)Retail/Wholesale (N=25)
Government (Federal, N=28)Communications & Media (N=27)
Financial (N=79)Government (State & Local, N=48)
Professional Services (N=36)Health Care (N=51)
Manufacturing (N=74)Education (N=59)
Server virtualization adoption, by industry. (Percent of respondents)
Using server virtualization in a production environmentUsing server virtualization, but in a test environment onlyHave not yet deployed server virtualization, but plan toHave not deployed and have no current plans to
Virtualization Adoption, by Industry
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Virtual Machine Deployment Projection
4
Source: IDC
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Operating System Application Application Application
Traditionally the OS and its applications were tightly coupled to the hardware they were installed on
Virtualization breaks the link between operating system and physical hardware
This allows the ability to change hardware without replacing the OS or applications
Additionally multiple instances of an OS with independent applications can now run on the same hardware
Hypervisor
What is Virtualization?
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
HW 8 HW 8 HW 8
VMware ESX 5.x+3 VMware ESX 5.x VMware ESXi 5.x+1 VMware ESX 5.x+2
HW10 HW10 HW10 OS APP
OS APP
OS APP
Typical computer refresh cycle is 3-5 years Typical Industrial control system refresh is15 to 20
years Computer replacements typically require software
upgrades which are expensive and difficult Virtual hardware exposed to the guest OS does not
change when physical hardware is replaced Each virtual hardware version is supported for three
major releases of vSphere
Increased Application Longevity
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
• Many physical servers - Under utilized - Requiring maintenance - Generating heat - Consuming energy
• Fewer physical servers – More efficiently utilized – Easier to maintain – Generating less heat – Consuming less energy
Server Consolidation
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 8
Agenda
Virtualization & Rockwell
Virtualization for Production
Virtualization for Engineers
Overview & Drivers
Additional Options
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Hosted (aka Desktop) Virtualization
Host Operating System
Application
Hypervisor
OS
App
OS
App
Hosted or “Desktop” Hypervisor runs as an application on another OS such as Linux or Windows Advantages: • Low cost • Self administered • Independent of IT management and
controls
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
VMware Player Overview
Free solution built on the same hypervisor technology as VMware Workstation
Allows basic creation, modification and use of one or more virtual machines
Similar in functionality to Windows Virtual PC and WindowsXP mode for Windows 7
Aimed at end users that need multiple OS or software versions with limited IT support.
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
VMware Workstation Overview
Easily and quickly build and run multiple VM’s Snapshot capabilities to allow rapid recovery from
botched upgrades or destructive tests Basic server functions, for sharing VM’s with a team
of engineers Integration with VMware vSphere
Aimed at developers and engineers that need to build a multi tiered application in a test environment, then seamlessly migrate to a production server cluster.
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Workstation vs. Player
Workstation Support for VM groups Basic VM sharing / serving
support Integration with VMware vSphere Snapshots – create restore
points for destructive tests
Player • Free – for noncommercial use • Basic virtual machine creation
and management • Common hypervisor technology
with Workstation
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 13
Agenda
Virtualization & Rockwell
Virtualization for Production
Virtualization for Engineers
Overview & Drivers
Additional Options
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Server (aka Bare Metal) Virtualization
Hypervisor
OS
App
OS
App
OS
App
Bare Metal or “Server” Hypervisor replaces host operating system and manages host hardware and resources Advantages: • Reduced host maintenance • Improved host reliability • Reduced security surface area • Data center level vendor support
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
VMware vSphere Overview
Combines multiple servers and storage units into a pool of resources that can be divided between applications
Provides central management for servers and their applications
Advanced high availability and disaster recovery features
Intended to provide a highly available, always on back end for server applications and desktops. Can segment hardware into multiple priority groups allowing development testing and production to share the same hardware.
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Centralized management (servers)
• Monitor all host servers and virtual machines • Deploy new VM’s from template • Attached to the console session to manage installed applications • Shutdown / reset problem VM’s • (optional) Backup and restore virtual machines with integrated
addons
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Manageability: vMotion
VMware ESXi VMware ESXi VMware ESXi
Resource Pool
Operating Server Operating Server Operating Server
• Migrate a running VM from one physical server to another
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Manageability: Distributed Resource Scheduler
VMware ESXi VMware ESXi VMware ESXi
Resource Pool
Operating Server Operating Server Operating Server
• Management server monitors host load and virtual machine placement vs. defined rules.
• Either suggests or automatically executes vMotion operations
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
VMware ESXi VMware ESXi VMware ESXi
Resource Pool
Failed Server Operating Server Operating Server Operating Server
Reliability: High Availability
• Hosts monitor each other and their virtual machines for failure
• Failed virtual machines automatically restarted where resources are available.
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
VMware ESXi VMware ESXi VMware ESXi
Failed Server OperatingServer OperatingServer
No Reboot Seamless Cutover
OperatingServer
Reliability: VMware Fault Tolerance
• Virtual machines execute simultanously on two physical servers
• Bumpless failover in the event of a HARDWARE falure
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
VMware View Overview
Central management for both engineering and operations clients
Rapid deployment of new desktops and updates Run virtual machines on production server cluster,
or on engineering laptop Client can run on a range of devices from desktops
to tablets End user focuses on using the applications rather
than managing his virtual machine library
Aimed at systems that could benefit from centralized management
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Client Virtualization
Thin Client
Desktop
Laptop
VMWARE VIEW MANAGER
Centralized Virtual Desktops
VMWARE VIEW SECURITY SERVER
Remote Client
Extend server virtualization benefits to clients: • Software independence from hardware • Lower Administration and Support Costs • Rapid Desktop Deployment • Leverage VM Availability Features • Centralized disaster recovery • Integrated Secure Remote Access • Offline Mode
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Centralized management (clients)
• View status of current clients • Reset problem clients • Provision new systems • Rapidly deploy tested patches
or software updates • Entitle or revoke user access
VMware View VDM can also be used to manage access to Microsoft Terminal Services
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
VMware View vs. Workstation
VMware View Production Environments Centralized management Composer functionality for rapid patch
and update deployment Securely provision environments for
contractors and vendors Thin client support
Execution occurs in the data center not at the client endpoint
Offline mode support Allows disconnect use of desktop
for traveling users
Workstation • Development for SI/Engineers • Decentralized management • Lower hardware costs for small
deployments • Broader OS support
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Typical Hardware Architecture
In the data center • Storage Array (iSCSI, FC, NFS) • 2-5 Physical Servers • Redundant Gigabit Switches
In the office and on the shop floor • legacy desktops • ruggedized laptops • solid state thin clients • Tablets (iPad / Android)
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Server Considerations
CPU 2 CPU sockets with 4-8 cores each Consolidation Ratios of 8 – 20 VM’s per Server
Memory 32-128GB physical RAM per server Suggested initial allocations
Operator Workstations: 2 GB Engineer Workstation: 4 GB HMI/Historian Server: 4 GB
Monitor actual memory usage and adjust allocations up or down depending on actual application usage
Number of Servers For redundant systems, 3 physical servers is a suggested minimum, allowing for full
application redundancy during infrastructure maintenance periods.
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Storage Considerations
Storage Options Fibre Channel NAS iSCSI Direct Attached SAS Virtualized SAN
Selection Factors Capacity / Price / Performance Disk types (SCSI, ATA, FC, SATA) Access Time; IOPS; Sustained Transfer Rate Reliability (MTBF)
Virtual machine performance is highly dependent on I/O throughput of the storage array
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Virtualization requires additional networks to manage and isolate information traffic VM Network(s)
Ie./ Assembly Line 1 VLAN, Assembly Line 2 VLAN, DMZ Management / vMotion Storage Network (If applicable) Fault Tolerant Network
So how many NIC’s do I need on my server? 2 per traffic type. For a system with iSCSI, Fault Tolerance and a DMZ: 10
Gigabit Switches are required, 10GbE switches may be used Networks should be isolated by VLAN’s The NICs connected to the Servers act as Trunks into your vSwitches
Networking
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 29
Agenda
Virtualization & Rockwell
Virtualization for Production
Virtualization for Engineers
Overview & Drivers
Additional Options
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
FactoryTalk System Example
Active Directory FactoryTalk Directory Primary HMI Secondary HMI
Asset Centre Historian VantagePoint Batch
Engineering Workstations
Operator Workstations
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
FactoryTalk System Example
Active Directory FactoryTalk Directory Primary HMI Secondary HMI
Asset Centre Historian VantagePoint Batch
Engineering Workstations
Operator Workstations
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Rockwell Virtualization Progression
Design & Configuration
Production Management
Data Management
Quality & Compliance
Asset Management
Performance & Visibility
RSLogix 5 RSLogix 500 RSLogix 5000 RSLogix Architect RSNetworx RSLinx Classic & Enterprise Factory Talk Gateway FactoryTalk View SE & ME RSView32 FactoryTalk View Studio
November 2009 – “RA Products Supported with Vmware”
FactoryTalk Batch FactoryTalk Transaction Manager FactoryTalk Metrics FactoryTalk AssetCentre FactoryTalk Vantage Point FactoryTalk ProductionCentre FactoryTalk Historian SE & Classic Emonitor
Not SoftLogix!
Official statement of support: RA Knowledgebase Article 42682
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Rockwell Automation and VMware
Solution Provider Combine Rockwell’s industry
expertise with VMware technology to provide design, plan and deployment services for VMware based virtual infrastructure
Technology Alliance Partner Allow Rockwell Automation to
directly leverage the VMware resources needed to deliver enhanced value to shared customers.
33
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Rockwell Virtualization Progression
2010 2011 2012 2013
November 2010 – “RA Announces VMware Ready Software”
RSLinx Classic RSLinx Enterprise RSLogix 5000 FactoryTalk View SE FactoryTalk View Studio FactoryTalk Batch FactoryTalk AssetCentre FactoryTalk Vantage Point FactoryTalk Historian SE Factory Talk Gateway
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Rockwell Virtualization Progression
2010 2011 2012 2013
MANAGE / MONITOR
IMPLEMENT
AUDIT
HOURLY CONSULTING
DESIGN/PLAN
ASSESS
FY 2011 – Network and Security Services Group expands consultant services to Virtualized Systems
• Capacity Planner • Infrastructure Design • Hardware Procurement • System Validation • And much more…
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Rockwell Virtualization Progression
2010 2011 2012 2013
…with Virtual Appliances • System Elements as standard products – Reduced validation Costs! • Pre-installed & Pre-configured – Reduced Engineering Costs! • Hardware Independent – Increased Product Lifecycle!
App
Process Control Enet
Plant Enet
OS
vApp
OS
vApp
OS
vApp
OS
vApp
OS
vApp
OS
vApp
OS
vApp
OS
vApp OS
vApp
OS
vApp
OS
vApp OS
vApp
OS
vApp
PASS Process Automation System Server
OWS Operator Workstation
EWS Engineering Workstation
AS Batch Application Server – Batch Management
AS Information Application Server – Process Information
AS Asset Centre Application Server – Asset Centre
Virtual Appliances FY2012 - Virtual Appliance Development
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
PlantPAx Virtual Image Templates v3.00 Provide customer value by reducing Total Cost of Ownership
Templates provide a ‘drop in’ solution for customers existing IT architecture
Open Virtual Format (OVF) Format - Can work with any Virtual offering VMware ESXI officially Supported and Recommended!
37
Virtual Templates offer System Elements as standard products – Reduced validation Costs! Pre-installed & Pre-configured – Reduced Engineering Costs! Hardware Independent – Increased Product Lifecycle!
App
Process Control Enet
Plant Enet
OS
vApp OS
vApp
OS
vApp
OS
vApp OS
vApp
OS
vApp
OS
vApp OS
vApp
OS
vApp
PASS Process Automation System Server
OWS Operator Workstation
EWS Engineering Workstation
Virtual Templates
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
9528-PAXVTENE
What’s Provided?
When the templates are ordered the customer receives The 3 core PlantPAx system elements as Images on a USB Hard-Drive (HDD)
with all required Rockwell Software preinstalled, but NOT activated. 3 Microsoft Operating System Full Packaged Product (FPP) Licenses
The end-user must convert the FPP to a Microsoft Volume License within 90 days Templates require a Microsoft Volume License to run
• Customers should contact their Microsoft Rep. to convert the licenses
Activating the Templates EWS – Order 9528-EWSLICENE OWS – Order 9528-OWSLICENE PASS – Order 9528-PASS100ENE
9528-PASS250ENE 9528-PASSUNLENE *PASS Activation based on HMI display count of 100, 250, or Unlimited *Activations are in increments of 1 per image. Order 1 for each image required
38
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Rockwell Virtualization Progression
2010 2011 2012 2013
2013 – Industrial Data Center
Offering – a single SKU* that can be combined with the PlantPAx Virtualized System
*A turnkey solution is available through our NSS (Network Services) business today.
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
System Architecture PlantPAx Virtualization Infrastructure
New Rockwell Automation Industrial Data Center
Essentials Option Supports 15-20 virtual machines Support for VMware HA and application
redundancy
Essentials+ Option Supports up to 50 virtual machines Support for VMware HA, FT, and application
redundancy
Virtualized system infrastructure preconfigured and supported by Rockwell Automation
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
What’s the value of pre-configured?
41
System Design Industrial Network Architecture Design Product Selection – Generate BOM for enclosure, servers, storage, switching, cables, Cable Interconnect design Generate all system drawings and documentation
System Fabrication Load BOM into ERP/Business system and generate all PO’s Receive Product - open, check against order, inspect, receive in system, dispose Packaging
Build Cabinet Install all HW
Install all cables and wire markers Perform functional test (Green lights) Burn in system
Additional value of standard system The design has been Thermally Validated – can improve system reliability by more than
20 percent The Cabinet would meet applicable global standards (i.e. UL 508A ) Bundle would include either a 1 day or 3 day onsite start-up assistance package
Time Estimates
Design time 15 – 16 engineering days, assumes CCNA (Cisco Certified), VCP (VMware Certified), and storage experienced engineer with final approval from IT. Fabrication/test time; 7 – 8 days assumes trained technician level experienced employee.
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 42
Industrial Data Centers
Essentials
Essentials +
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 43
The Power of Collaboration
Bundle includes: • Servers and switches from Cisco • Cables, patch cords, cable management, testing,
validation, and assembly from Panduit • Storage from EMC² • Virtual System Licenses from VMWare • PlantPAX Virtual Image Templates from Rockwell
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 44
Agenda
Virtualization & Rockwell
Virtualization for Production
Virtualization for Engineers
Overview & Drivers
Additional Options
Fault-Tolerant Servers for Automation and MES
Duplex Hardware Components
Embedded I/O
PCI
CPU
Chipset
Memory
Automated Uptime Layer
Fault Detection & Isolation
Resilient Servers
Purpose build to provide Uptime unachievable by standard servers
Embedded I/O
PCI
CPU
Chipset
Memory
Automated Uptime Layer
Fault Detection & Isolation
Lockstepped CP
Us
Mul
ti-p
ath
I/O
Manage like single x86 server
Ideal for mission critical apps in the data center or remote sites
Multi-Path IO Devices
Network Fault Tolerance Standard Intel® PROSet teaming Single virtual interface to the kernel One MAC address Avoids software handling of failures
Bonding
Bonding
Stratus Direct Attach Storage Fault Detection
& Isolation
PC
I Fibre Channel
Enet
Embedded IO
Netw
ork Switch
Storage Fault Tolerance RAID1 internal disks Multi-path to external HW RAID
Fault Detection &
Isolation
PC
I
Fibre Channel
Enet
Embedded IO
47
Leveraging the ftServer for Virtualization and Consolidation
48
Virtualization Layer
App 1
OS
App2
OS
DB
OS
VM1 VM2 VM3
The Cost of Server Sprawl Initial Hardware, software, and
installation costs
Recurring costs for administration and support and utilities
Downtime and repair
The Benefits of Consolidation Fewer servers, easy provisioning,
better DR options
Plug-and-play operational simplicity and administration
No downtime or data loss
DB
OS
Server 3
App 1
OS
Server 1
App2
OS
Server 2
99.999+% uptime
Product Specifications 2700
Low-end system 4700
Mid-tier system 6400
High-end system
Processors 1-socket 2-socket 2-socket
CPU QPI Performance
Quad-core 1.8 GHz 6.4 GT/s QPI
Quad-core 1.8 GHz 6.4 GT/s QPI
Octa-core 2.6 GHz 8.0 GT/s QPI
CPU Cache 10 MB Shared 10 MB Shared 20 MB Shared
Memory Bandwidth 34.1 GB/s 68.2 GB/s 85.3 GB/s
Memory Slots 8 DIMM Slots 16 DIMM Slots 16 DIMM Slots
System Memory 32 GB 256 GB 256 GB
Embedded SAS, 2x ENET (10/100/1000) , 3x USB2.0 (rear), 1x USB2.0 (front), 2x COMM, VGA, BMC, DVD R/W (front)
PCI Slots Embedded
2 x PCIe 2 x PCIe 4 x PCIe
PCI Slot Expansion Not Available 2 x PCIe Gen 2 Included
RAID 1 Disk (Internal)
8 x 2.5” SAS Disks
Form Factor 4U Rack 4U Rack 4U Rack
Note: All I/O options specified in logical count, physical count is 2 times numbers specified
49
Stratus Confidential
Next Day Delivery Service
Automated Uptime Layer ActiveService Architecture at Work
4. Customer receives and replaces part - system synchronizes with replacement and continues operation
3. CAC contacts customer to confirm issue and initiates shipment of replacement part
1. Unit fails - system isolates fault and continues operation with redundant unit
2. Call home technology reports fault opens support issue with the Stratus Customer Assistance Center (CAC)
Two-way Customer
Assistance Center
Call Home
Welcome to ThinManager Platform 6
Platform Management Tool
Remote Desktop Services VMware
Virtualization IP Cameras
Industrial Thin Clients
XLi Compatible Office Clients
ThinManager iPad & iPhone
ThinManager Model
ThinManager provides Centralized Configuration, Management, and Security of Servers, Clients, Applications and Users in Terminal Services or VDI based Networks. ThinManager ensures your applications are securely available to the people that need them, when they need them, regardless of system conditions.
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
www.rockwellautomation.com
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Rev 5058-CO900C
Mike Murphy Industrial Automation Software Specialist [email protected]
Questions?
Thank you for attending!
Tim McCain Information Solutions Regional Manager [email protected]
Experience the Difference!
Electrical • Lighting • Automation • DataComm
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