Virtualizing Plant Applications

Frank Hill
Manufacturing Industry BD
March 7, 2013
Stratus Technologies

Delivers the highest availability in the industry

using fault-tolerant technologies combined with proactive
availability management and monitoring services

 Patented, time-tested technologies for over 30 years

 Global sales and support
 750 employees Stratus

 Engineering-centric culture
 A Global Encompass Partner for six years
 Industrial solutions is our largest segment!

Minimizes average server downtime to 1 minute/year

Stratus Technologies: Uptime = Peace of Mind 2

Gordon E. Moore

On April 19, 1965 Electronics Magazine

published a paper by Gordon Moore in
which he made a prediction about the
semiconductor industry that has
become the stuff
of legend. Known as Moore's Law, his
prediction has enabled widespread
proliferation of technology worldwide,
and today has become shorthand for
rapid technological change.
Gordon E. Moore, Co-founder, Intel Corporation.
 2005 Intel Corporation.

3
46 Years later, Moore was right.

CPU Power
multi-core technology
now standard

Memory
Now very large &
very affordable

Disk Capacity
They just keep
expanding in size
4
Welcome back to the 1960s

IBM 370 Mainframe

5
Stratus Confidential
Heading Toward a Totally
Virtualized World
Percentage of x86-Architecture Workloads Running in VMs

90% 86%
84%
81%

80% 77%

72%

70% 65%

58%
60%
49%
50%

38%
40%

30% 27%

18%
20%
10%
10% 5%
2%

0%
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018

Source: Jeffries report dated 10/5/11, referencing Gartner report (3/4/11: Virtual Machines Will Slow in the Enterprise, Grow in the Cloud) 6
What is virtualization?
Platform virtualization allows one computer to do the job of multiple
computers, by sharing the resources of a single hardware across
multiple environments
Virtual Virtual
Container Container

App. A App. B App. C App. D

App. A App. B App. C App. D

Operating System Virtualization Layer

Hardware Hardware

‘Nonvirtualized’ system Virtualized system

A single OS controls all It makes it possible to run
hardware platform resources multiple Virtual Containers on a
single physical platform
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Virtualization Benefits

Test / Dev Server consolidation

and
Environment
Management

Legacy application
migration

Disaster recovery 8
Leveraging Virtualization and
Consolidation
VM1 VM2 VM3
App2
App 1 App2 App3
OS
OS OS OS
App 1 App3
Server 2
OS OS Virtualization Layer

99.999+%
Server 1 Server 3 uptime

“If you put all your eggs in one basket make sure you use a
strong basket or you’ll end up with a mess.”

9
Rockwell’s Virtual Image
Templates
 New option to deploy the PlantPAx
process automation system.
 Deliver the core system elements as
pre-configured, drop-in templates on a
USB
hard drive.
 Operate in an open virtual-format file,
officially supported by VMWare vSphere,
which includes the:
• Engineering Workstation (EWS)
• Operator Workstation (OWS)
• Process Automation System Server
(PASS)
 Pre-installed and pre-configured, Virtual
Image Templates reduce validation costs
and initial engineering time, simplify
upgrades and patch management
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Stratus Fault-Tolerant Servers

 Redundant hardware
 Zero failover time
 Application transparency
 Hot-swappable components
 Hardened drivers
 In-flight data integrity
 24/7/365 service infrastructure
 Typical configurations
$15,000 to $35,000
Automated Uptime Layer
ActiveService Architecture at Work

1. Unit fails - system isolates fault

Call and continues operation with
Home redundant unit

Two-way
Customer 2. Call home technology reports fault
Assistance Center opens support issue with the Stratus
Customer Assistance Center (CAC)

3. CAC contacts customer to confirm

Next Day issue and initiates shipment of
Delivery replacement part
Service
4. Customer receives and replaces part -
system synchronizes with
replacement and continues operation
 Stratus Confidential

Product Specifications
2700 4700 6400
Low-end system Mid-tier system High-end system
Note: All I/O options
specified in logical
count, physical count is
2 times numbers
specified

Processors 1-socket 2-socket 2-socket

CPU Quad-core 1.8 GHz Quad-core 1.8 GHz Octa-core 2.6 GHz
QPI Performance 6.4 GT/s QPI 6.4 GT/s QPI 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)

2 x PCIe 2 x PCIe 4 x PCIe

PCI Slots Embedded
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
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Example: Amalgamated Sugar

Sugar plants in Idaho rely on Rockwell

Software to perform many functions including
visualization using RSView. Stratus fault-
tolerant servers gave Amalgamated the
confidence to virtualize these applications and
achieve a significant savings

 Stratus® ftServer® systems  VMware vSphere™ virtualization

 Total Assurance support services

 (1) ftServer 4500 running VMware at each plant

 Each server runs 4-8 VMs including RSView, domain name server, and domain
controllers
 Benefits include eliminating unplanned downtime, lowering costs, and simplifying
management of infrastructure

Uptime = Savings 14
VMware Server Sizing Tool

 A Single Page Excel

Spreadsheet

 Sizing tool based on Rockwell

PROCES-WP007A-EN-P.PDF

 Get the latest sizing tool at

www.stratus.com/RA

 Stratus System Engineers will

review your configuration
and develop a quote

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Advantages of the ftServer

 Even small projects can leverage ftServers - $15,000

 The ftServer scales up to 16 cores (+Hyper-Threading), 256GB

Memory, 2.4TB mirrored internal storage
 The ftServer cost is less than VMware HA

 Delivers true fault-tolerance for all VMs – 99.99932% uptime

 Simplifies project planning with a sizing tool and access to

Stratus System Engineers
 Simplifies project deployment

 Simplifies on-going support with plug-and-play components

 The ftServer is sold through Value Added Resellers

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Questions?
VMware HA vs. Stratus ftServer

VMware HA Configuration

vCenter Server

DB APP DB APP

OS OS OS OS

VMware ESXi VMware ESXi

Availability

Cost/Simplicity
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VMware HA vs. Stratus ftServer

You don’t need:

VMware
StratusHA
® ftServer
Configuration
® Configuration  vCenter Server

 Multiple licenses

 Second server

 Redundant Switches
DB APP APP  External storage

OS OS OS

VMware ESXi

Availability

Cost/Simplicity
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Example: NASA Kennedy Space
Center

Losing control during a launch procedure

is not an option. So Stratus ftServer
platforms were selected to support
virtualization of Rockwell applications.
The first pilot project has been
implemented and is running flawlessly

 Stratus® ftServer® systems  VMware vSphere™ virtualization

 Total Assurance support services

 (1) ftServer 4500 running VMware supporting three virtual machines

 Benefits include migration of Rockwell software off of old computer hardware,
better DR options, and uptime assurance for all virtual machines

Uptime = Safety 20
 Pinellas County, Florida USA
Water Treatment Plant
Human Machine Water Treatment
Interface Clients Solution

Site Control Room

HMI Historian SCADA Data Maintenance
Analyst Calibration

VMware vSphere

Wireless Remote Programmable Programmable

Control Vehicles Logic Logic
Controllers Controllers

Water Treatment Tanks

Example: Transneft Pipeline

The plug-and-play simplicity of the ftServer

platform allows deployment of SCADA into very
remote locations and keeps it up and running.
Sites often have limited or no computer
expertise so keeping the infrastructure simple is
essential.

 Stratus® ftServer® systems  Windows 2008

 Transneft the state-owned Russian oil transportation company has 30,000 miles of
pipeline
 SCADA is being deployed for monitoring pipeline conditions including: leak
detection, seismic control, and data acquisition
 A Stratus ftServer was deployed every 190 miles along an upgraded segment
 57 ftServers
 downtime!
Uptime = Supportable 22