Rockwell Introductiontovirtualizationforcontrolsystems

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


Virtual Machine Deployment Projection

4

Source: IDC


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?


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


• 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


Agenda




Overview & Drivers

Additional Options


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


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.


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.


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


Agenda




Overview & Drivers

Additional Options


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


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.


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


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


Manageability: Distributed Resource Scheduler


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



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.



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


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


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


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


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


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)


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.


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


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


Agenda




Overview & Drivers

Additional Options


FactoryTalk System Example

Active Directory FactoryTalk Directory Primary HMI Secondary HMI

Asset Centre Historian VantagePoint Batch

Engineering Workstations

Operator Workstations


FactoryTalk System Example

Active Directory FactoryTalk Directory Primary HMI Secondary HMI

Asset Centre Historian VantagePoint Batch

Engineering Workstations

Operator Workstations


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


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



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



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…



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


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


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



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.


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


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.


Industrial Data Centers

Essentials

Essentials +


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


Agenda




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.


www.rockwellautomation.com

Follow ROKAutomation on Facebook & Twitter. Connect with us on LinkedIn.

Rev 5058-CO900C

Mike Murphy Industrial Automation Software Specialist [email protected]

Questions?

Thank you for attending!

Tim McCain Information Solutions Regional Manager [email protected]

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Rockwell Introductiontovirtualizationforcontrolsystems