T46 PlantPAx Physical Infrastructure: Virtualized Micro Data Center Case Study November 08, 2012

1. Why use virtualization in manufacturing?

2. PlantPAx virtualization

5. Carotek Process Training Unit Case Study

6. Roadmap and Tools to Succeed

3. Physical Infrastructure: Best Practices

4. Physical Infrastructure: Integrated Solutions

Game changer: Increase availability while reducing TCO! Chris Di Biase Rockwell Automation, Network and Security Services

Virtualization for Process Plants

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What is virtualization?

Issues faced everyday

Benefits of Virtualization

High Availability!

Process Systems Today

Now virtualized!

Integrated Solutions enable customers to grow their business… fast and reliably! Jason Campbell Panduit Corp, Technical Systems Engineer

Physical Infrastructure:

Best Practices

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Key Physical Infrastructure concerns when Virtualizing

Consolidating infrastructure means you need to get the details right! -Thermal considerations

- Cable management

- Grounding/Bonding

- Physical security / Identification

- Connectivity and structured cabling designs for Fiber/Copper Important to take an architecture view to succeed with your virtualization project – leverage partners to address complete solution.

What can go wrong? • Downtime • Security lapses • Performance degradation

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Cables no longer being used are identified by tying them in a knot.

Bad examples

Cables coming into the cabinet are coiled and laying on top of the cabinet.

No Patchfield is used for cables connected to the switches.

Some cables are identified with a marker. Most not identified at all.

Equipment resting on the equipment below it with no support provided.

Plantwide EtherNet/IP Ecosystem - Overview

Plantwide EtherNet/IP Ecosystem - Design and Deployment

The Established #1 Industrial Ethernet

Leader in Industrial Network Infrastructure

Network Testing, Verification & Troubleshooting Tools Physical Layer Infrastructure

IT Convergence

http://www.ethernetippartners.net/

Because Infrastructure Matters Successful Network Convergence Requires

• Partner Collaboration • Simplification • Innovation

Control Panel Solutions Mitigate EMI noise risk, save

space and optimize EtherNet/IP connectivity

Simplifying network infrastructure from Enterprise to Plant

Network Zone Enclosure Building Block for Robust, Secure, Scalable Network

Distribution

Micro Data Center Building Block for Enterprise to Plant-Floor Convergence

Use Validated Building Blocks Physical Layer Design Considerations

Leverage Reference Architecture & Validated Building Blocks to Speed Deployment and Reduce Risks

Zone Enclosures – Optimized for Stratix Physical Layer Design Considerations

Integrated Solution for Stratix 8300, 8000 and new 5700 switches

Robust, Secure, Thermally tested

Save time/cost/risk:

– Convergence point: Plant-floor controls system engineer and IT network engineer

– UL508, CE rated

3 Sizes

Solution contains all required hardware: fully integrated, tested and documented.

Micro Data Center

• Cisco Catalyst 3750 switches • Virtualized environment for running PlantPAx

software o (6) physical servers

Storage: From EMC2

Panduit Optimized Physical Infrastructure Thermally tested 24 RU Cabinet Power Outlet Units Cable Management Grounding/Bonding

PlantPAx Virtualized System

PlantPAx System

Integrated Solution: PlantPAx Appliance

Solution contains all required hardware & software; fully integrated, tested and documented. PlantPAx Virtualized Solution delivered to customer ready to deploy in manufacturing

Panduit Micro Data Center Video (Youtube)

Game changer: Increase availability while reducing TCO! Deryl Bell, Matt Goyak, Carotek, Inc,

Process Training Unit:

Virtualized Micro Data Center

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The Power of Solutions!

Power

Electrical Shop: 1. Authorized Systems Integrator for Rockwell

Automation. 2. 15,000 square foot facility. 3. 5-ton overhead crane. 4. “Clean Room” area for software development

and testing. 5. Repair, calibration, and testing area for

instrumentation. 6. Certified UL® and CSA® approved shop.

The Power of Solutions!

The Power of Solutions!

Mechanical Shop: 1. 36,000 square foot facility. 2. 25 & 10 ton overhead cranes. 3. ASME Section IX & AWS D1.1, D1.6 code

welding. 4. Fabrication to ASME B31.1 & B31.3. 5. Gauge and seal testing and assembly

station. 6. Complete systems check-out and testing

capabilities. 7. Paint spray booth; 16’x16’x36’ 8. Drive-in and Pull-up docks.

A PTU is a “miniplant” where students can explore concepts in action with Endress+Hauser instrumentation, the Rockwell Automation PlantPAx™

process automation system, and Panduit’s Micro Data Center.

PTU - Process Training Unit

Copyright © 2008 Rockwell Automation, Inc., {Insert Partner Name}. All rights reserved. 29

PTU - Process Training Unit

Hands-on learning: 1. A fully functional “Mini Process Plant”

combined with classroom education. 2. Designed to teach fundamental, theoretical, and practical knowledge of instrumentation with an emphasis on service & maintenance. 3. Features over 90 field instruments

communicating via Ethernet IP, Hart, ProfibusPA, and Foundation Fieldbus.

4. Contains the latest in On/Off, Control Valves & Pump technology.

5. PTU is controlled by a Rockwell PlantPAx process automation system.

6. Qualifies for Professional Development Hours (PDH’s).

Process Integration

• Customer challenges - Limited capital budgets & IT resources. - “Legacy” software and infrastructure. - Inadequate or out-dated plant standards.

• How virtualization helps us help our customers: - Permits quick development, testing and deployment across

multiple hardware & software platforms. - Allows for scalability. - Eases the management & support of multiple software versions

across different operating systems. - Provides a cost effective redundant solution.

• Case Study – Energy Industry – Crude Gathering - Four (4) unique operating systems at terminals scattered across

three (3) states. - Limited capital for new hardware.

• How virtualization was applied: - SCADA, Historian, SQL Server, and POS systems were

consolidated on a single IT resource. - Development and testing took place on virtualized systems. - Software solutions were easily scaled up as the system

quadrupled in size.

Process Integration

• Case Study – Food and Beverage Industry - Distillery - New construction. - Latest technologies were utilized.

• How virtualization was applied: - SQL Server 2008, FactoryTalk View SE Server, View Point,

Vantage Point, Historian, and Maintenance/Engineering systems were consolidated on a single IT resource.

- Software solutions were easily scaled up as the system eventually doubled in size.

- Disaster recovery following a hurricane event.

Process Integration

Process Training Unit: PlantPAx

PlantPAx Virtualized environment - • Speed Deployment and High

Availability • Robust Physical Infrastructure:

• Cable Management • Grounding/Bonding • Fiber, Copper Connectivity • Physical Security • Identification • Power Outlet Units

Summary

Benefits of Virtualization

Learn More

• Carotek Process Training Unit – Training classes – Process Summits http://www.carotek.com/Carotek_PTU/ProcessTrainingUnit.htm

• Rockwell Automation

– PlantPAx Appliances – Network and Security Services www.rockwellautomation.com/plantpax www.rockwellautomation.com/

• Panduit

– Physical Infrastructure solutions and services – System Integrator Partner program – Panduit Certified Installers www.panduit.com/ia