virtualization in manufacturing industries

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

TF02 – Virtualization in Manufacturing

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 2

Agenda

Software Licensing Considerations

Virtualization and Rockwell

Virtualization for Production

Virtualization for Engineers

Overview


What is Virtualization?

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 Operating System

Application


What can be virtualized in Automation?

4

Level 5

Level 4

Level 3

Level 2

Level 1

Level 0

Terminal Services

Patch Management AV Server

Application Mirror Web Services Operations Application Server

Enterprise Network

Site Business Planning and Logistics Network E-Mail, Intranet, etc.

FactoryTalk Application

Server

FactoryTalk Directory

Engineering Workstation

Domain Controller

FactoryTalk Client

Operator Interface

FactoryTalk Client

Engineering Workstation

Operator Interface

Batch Control

Discrete Control

Drive Control Continuous

Process Control Safety Control

Sensors Drives Actuators Robots

Enterprise Zone

DMZ

Industrial Zone

Cell/Area Zone

Web E-Mail

CIP

Firewall

Firewall

Site Operations and Control

Area Supervisory Control

Basic Control

Process


Long ICS upgrade cycles vs. short IT upgrade cycles

Space, power, cooling and management limitations

Management of operator and engineering workstations

Management of multiple incompatible software versions

Higher downtime costs

Virtualization is widely adopted by IT and growing in Manufacturing Manufacturing has some unique Considerations and Opportunities

Address with Virtualization Value Propositions

System longevity with HW/SW abstraction

Server consolidation

Centralized server management and deployment

Centralized workstation management and deployment

Improve reliability with management and recovery features

Considerations for Manufacturing


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

Able to upgrade Hypervisor without modifying the virtual machine

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


Operating System Support

Windows Server 2003 (32/64) Windows Server 2008 (32/64) Windows Home Server 2011 Windows Storage Server 2008 R2 Windows Small Business Server 2011 Windows 7 (32/64) Windows Vista (32/64) Windows XP (32/64) RHEL 5 (32/64) RHEL 6 (32/64) SLES 10 (32/64) SLES 11 (32/64) CentOS 5 (32/64) CentOS 6 (32/64)

MS Hyper-V R2 with SP1

Total: 25

vSphere = Most guest OSs; More versions of Windows See http://www.vmware.com/technical-resources/advantages/guest-os.html

Windows Server 2003 (32/64) Windows Server 2008 (32/64) Windows 7 (32/64) Windows Vista Windows XP RHEL 4 RHEL 5 (32/64) RHEL 6 (32/64) SLES 9 SLES10 (32/64) SLES11 (32/64) Debian Lenny 5 Debian Squeeze 6 (32/64) CentOS 4 CentOS 5 (32/64) Oracle OEL 5 (32/64) Oracle Linux 6 (32/64) Ubuntu 10 (32/64)

Total: 30

Citrix XenServer 6

MS-DOS 6.22 Windows 3.1 Windows 95 Windows 98 Windows NT Windows Preinstallation 2 (32/64) Windows XP (32/64) Windows Vista (32/64) Windows 7 (32/64) Windows 2000 WinServer 2003 (32/64) WinServer 2008 (32/64) RHEL 2.1 RHEL 3 (32/64) RHEL 4 (32/64) RHEL 5 (32/64) RHEL 6 (32/64) SLES 8 SLES 9 (32/64) SLES 10 (32/64) SLES 11 (32/64) Debian 4 (32/64) Debian 5 (32/64) Debian 6 (32/64) CentOS 4 (32/64) CentOS 5 (32/64) CentOS 6 (32/64) Oracle OEL 4 (32/64) Oracle OEL 5 (32/64) Oracle Linux 6 (32/64) Asianux 3 (32/64) Asianux 4 (32/64) Ubuntu 7 (32/64) Ubuntu 8 (32/64)

Ubuntu 9 (32/64) Ubuntu 10 (32/64) Ubuntu 11(32/64) FreeBSD 6 (32/64) FreeBSD 7 (32/64) FreeBSD 8 (32/64) Solaris 8 Solaris 9 Solaris 10 (32/64) OS/2 Warp 4 NetWare 5 NetWare 6 eComStation 1 eComStation 2 SCO UnixWare 7 SCO OpenServer 5 Mac OS X 10 (32/64)

Total: 85

VMware vSphere 5

Data collected Mar 1, 2012

http://www.vmware.com/technical-resources/advantages/guest-os.html






Server Consolidation

• Many physical servers

- Under utilized

- Requiring maintenance

- Generating heat

- Consuming energy

• Fewer physical servers – More efficiently utilized

– Easier to maintenance

– Generating less heat

– Consuming less energy


Virtual Machine Deployment Projection

Source: IDC

9

“Total virtual OS instances will contribute 70.2% of total OS instances in 2012 and reach 82.4% of total OSs in 2016” -- Gartner 23 October 2012


Agenda





Overview


Type 2 / Hosted Virtualization

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

APP

APP

Windows, Linux or MacOS

Hypervisor

AP

P

AP

P

AP

P


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 Player Virtual Machine Settings

VM editing allows modification of basic hardware features including:

Change number of CPU‟s exposed to the VM

Change amount of RAM allocated to the VM

Add or remove disks


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.


VMware Workstation Main UI


VMware Workstation VM Summary


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


Type 1 / Server Virtualization

Hypervisor

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.


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 • Backup and restore virtual machines with integrated addons

(optional)


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: DRS


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 simultaneously on two physical servers

• Bumpless failover in the event of a HARDWARE failure


Increasing Uptime and Availability

Local Availability

vSphere High Availability

vSphere Fault Tolerance

vMotion and Storage vMotion

Data Protection

vSphere Data Recovery

Storage APIs for Data Protection

Local Site Failover Site

Disaster Recovery

vCenter Site Recovery Manager

Includes vSphere Replication

vSphere vSphere vSphere vSphere vSphere


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


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


Agenda





Overview


Process System Today

Process Control Ethernet

Plant Ethernet


Hardware Consolidation

- Process Automation System Server

- Operator Workstations x 16

- Engineering Workstation

- Batch Server

Process System with Virtualization

Servers (3)

SAN Device Virtualization Management Console

Infrastructure Clients

Centralized Infrastructure


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 566423

2009 2010 2011 2012 2013


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.

OEM

Allows Rockwell Automation to deliver solutions like the

Industrial Data Center and be the customer‟s first point of

contact for all related issues.

34

Rockwell Automation Participates in two VMware partner programs

Rockwell and VMware will continue to strengthen our partnership and add programs that benefit our shared customers.


Gartner, Inc. Magic Quadrant for x86 Server Virtualization Infrastructure, Thomas J. Bittman, Philip Dawson, Mark Margevicius, George J. Weiss, 30 June 2011.

VMware in the Leaders Quadrant for x86 Server Virtualization

“VMware is clearly ahead in”:

Understanding the market

Product strategy

Business model

Technology innovation, Product capabilities

Sales execution

“VMware Strengths”:

Virtualization strategy and road map that lead

to private and hybrid cloud computing

Technology leadership and innovation

High customer satisfaction

Large installed base (especially among large

enterprises) and service provider ecosystem


Citrix XenServer 6

>1 GB

Size Does Matter

VMware ESXi 5 144 MB

Windows 2008 R2 SP1 Server Core with Hyper-V

3.4 GB

Hyper-V with full Windows Server 2008 R2 SP1 is even bigger at…

9.8 GB

Hyper-V Server 2008 R2 SP1 expands to

5.6 GB



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

2009 2010 2011 2012 2013



FY 2011 – Network and Security Services Group expands consultant services to Virtualized Systems

• Capacity Planner • Infrastructure Design • Hardware Procurement • System Validation • And much more…

2009 2010 2011 2012 2013

3

8

ASSESS DESIGN IMPLEMENT VALIDATE MANAGE



Virtual Templates offer System Elements as standard products – Reduced validation Costs!

Pre-installed & Pre-configured – Reduced Engineering Costs!

Hardware Independent – Increased Product Lifecycle!

PASS Process Automation System Server

OWS Operator Workstation

EWS Engineering Workstation

Virtual Appliances FY2012 - Virtual Appliance Development

2009 2010 2011 2012 2013

App

Process Control Enet

Plant Enet

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!


9528-PAXVTENE, US List 2250.00

Virtual Machine Image Templates

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 – US List $11,817.00

OWS – Order 9528-OWSLICENE – US List $2444.00

PASS – Order 9528-PASS100ENE- US List $6403.00

9528-PASS250ENE - US List $8979.00

9528-PASSUNLENE – US List $14,645.00

*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

40



FY 2013 – Rockwell Automation Industrial Datacenter

• Standard, pre-assembled virtualization solution • Includes the hardware, software and services required to

successfully deploy virtualization

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

2009 2010 2011 2012 2013


Agenda





Overview


FactoryTalk Activation Considerations

FactoryTalk Activation is fully supported in a virtual environment.

Considerations for a virtualized activation server:

Licenses required are based on concurrent running instances

of software – whether virtualized or not.

Use concurrent activations centralized on an activation server

Use dongle based or disk serial number based activations

Virtualization does not change Rockwell Software licensing


VMware Licensing

For Development

VMware Player is free for noncommercial use

VMware Workstation is a retail and download product

For Production

VMware vSphere and VMware View are sold through resellers and hardware OEMs

VMware View is sold by concurrent user and is available either stand alone or as an

add-on for vSphere

VMware vSphere is sold in 3 editions with different functionality enabled

For more information see vmware.com


Microsoft Licensing for Virtualization

Servers:

Each host must be entitled for the virtual machine “high water mark”

Standard = 2 VM, Datacenter = unlimited VM‟s

Desktops:

Client device requires Windows Software Assurance (PC/laptop),

Virtual Desktop Access (thin client) subscription

License entitles use of up to 4 vm‟s

SQL Server

Licensed per VM or per Physical host server

Microsoft Windows licenses are tied to hardware not VMs http://www.microsoft.com/licensing/about-licensing/virtualization.aspx

http://www.microsoft.com/licensing/about-licensing/virtualization.aspx




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virtualization in manufacturing industries

Technology

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