Virtualization For Manufacturing Industries: Mike Murphy - Schaedler Yesco Tim Mccain - Rockwell Automation

Electrical Lighting Automation DataComm
Virtualization for Manufacturing

Industries
-PRESENTED BY
Mike Murphy Schaedler Yesco

Tim McCain Rockwell Automation
Experience the Difference!
Agenda
Overview & Drivers
Virtualization for Engineers
Virtualization for Production
Virtualization & Rockwell
Additional Options
Copyright 2012 Rockwell Automation, Inc. All rights reserved.
Virtualization Adoption, by Industry

Server virtualization adoption, by industry. (Percent of respondents)
Using server virtualization in a production environment
Using server virtualization, but in a test environment only
Have not yet deployed server virtualization, but plan to
Have not deployed and have no current plans to
Education (N=59)
Manufacturing (N=74)
Health Care (N=51)
Professional Services (N=36)
Government (State & Local, N=48)
Financial (N=79)
30%
46%
Communications & Media (N=27)

Government (Federal, N=28)
36%
21%
Retail/Wholesale (N=25)
36%
20%
Transportation/Logistics (N=20)
0%
10%
20%
11% 4%
30%
40%
21%
21%
28%
16%
20%
30%
20%
30%
50%
60%
9%
15%
41%
44%
10%
19%
23%
48%
14%
25%
11%
50%
14%
12%
22%
53%
11%
20%
8%
61%
8%
8%
12%
71%
70%
80%
90%
100%
Virtual Machine Deployment Projection
Source: IDC
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
Application
Application
Application
Hypervisor
Operating
System
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
Increased Application Longevity

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
APP
APP
APP
OS
OS
OS
HW 8
HW10
HW 8
HW10
HW 8
HW10
VMware
VMwareESXi
ESX
ESX5.x+2
5.x+3
5.x+1
5.x
Server Consolidation
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
Agenda
Overview & Drivers
Additional Options
Hosted (aka Desktop) Virtualization

Hosted or Desktop
Application
App
App
OS
OS
Hypervisor
Hypervisor runs as an application on

another OS such as Linux or Windows
Advantages:
Low cost
Self administered
Independent of IT management and
controls
Host Operating System
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 VMs
Snapshot capabilities to allow rapid recovery from
botched upgrades or destructive tests
Basic server functions, for sharing VMs 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
13
Server (aka Bare Metal) Virtualization

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
Bare Metal or Server

App
App
App
OS
OS
OS
Hypervisor
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 VMs from template
Attached to the console session to manage installed applications
Shutdown / reset problem VMs
(optional) Backup and restore virtual machines with integrated
addons
Manageability: vMotion
Migrate a running VM from one physical server to
another
Resource Pool
VMware ESXi
VMware ESXi
VMware ESXi
Operating Server
Operating Server
Operating Server
Manageability: Distributed Resource

Scheduler
Management server monitors host load and virtual
machine placement vs. defined rules.
Either suggests or automatically executes vMotion
operations
Resource Pool
VMware ESXi
VMware ESXi
VMware ESXi
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.
Resource Pool
VMware ESXi
VMware ESXi
VMware ESXi
Operating Server
Failed Server
Operating
Server
Operating Server
Reliability: VMware Fault Tolerance

Virtual machines execute simultanously on two
physical servers
Bumpless failover in the event of a HARDWARE
falure
No Reboot
Seamless Cutover
VMware ESXi
VMware ESXi
VMware ESXi
OperatingServer
OperatingServer
Failed Server
OperatingServer
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
Centralized Virtual
Desktops
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
VMWARE VIEW
SECURITY SERVER
Remote Client
VMWARE
VIEW MANAGER
Thin Client
Desktop
Laptop
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
Workstation
Development for SI/Engineers

Decentralized management
Lower hardware costs for small
deployments
Broader OS support
Execution occurs in the data

center not at the client endpoint
Offline mode support
Allows disconnect use of desktop

for traveling users
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 VMs 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
Networking
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 NICs 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 VLANs
The NICs connected to the Servers act as Trunks into your vSwitches
Agenda
Overview & Drivers
Additional Options
29
FactoryTalk System Example
Active Directory
Asset Centre
FactoryTalk Directory
Primary HMI
Secondary HMI
Historian
VantagePoint
Batch
Engineering Workstations
Operator Workstations
FactoryTalk System Example
Active Directory
Asset Centre
FactoryTalk Directory
Primary HMI
Secondary HMI
Historian
VantagePoint
Batch
Engineering Workstations
Operator Workstations
Rockwell Virtualization Progression

November 2009 RA Products Supported with Vmware
Design &
Configuration
Quality &
Compliance
Production
Management
Asset
Management
Data 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
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 Rockwells 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
FY 2011 Network and Security Services Group expands

consultant services to Virtualized Systems
ASSESS
MANAGE / MONITOR
Capacity Planner
Infrastructure Design
Hardware Procurement
System Validation
And much more
HOURLY CONSULTING
DESIGN/PLAN
AUDIT
IMPLEMENT
2010
2011
2012
FY2012 - Virtual Appliance Development
2013
Virtual Appliances
PASS
vApp
OS
Process Automation System

Server
vApp
vApp
OS
OWS
OS
Operator Workstation
Plant Enet
EWS
Engineering Workstation
App
vApp
vApp
OS
vApp
OS
vApp
OS
vApp
OS
vApp
vApp
OS
OS
OS
Process Control Enet
with Virtual Appliances
vApp
vApp
vApp
System Elements as standard products Reduced validation Costs!

Pre-installed & Pre-configured Reduced Engineering Costs!
Hardware Independent Increased Product Lifecycle!
OS
OS
OS
AS Batch
Application Server
Batch Management
AS Information
Application Server
Process Information
AS Asset Centre
Application Server
Asset Centre
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!
Virtual Templates
PASS
Process Automation System

Server
Plant Enet
App
vApp
vApp
OS
vApp
vApp
vApp
OS
vApp
OS
OS
Operator Workstation
vApp
vApp
OS
OS
OWS
vApp
OS
OS
EWS
Engineering Workstation
OS
Process Control Enet
Virtual Templates offer
System Elements as standard products Reduced validation Costs!

Pre-installed & Pre-configured Reduced Engineering Costs!
Hardware Independent Increased Product Lifecycle!
37
Whats 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
OWS Order
PASS Order
9528-EWSLICENE
9528-OWSLICENE
9528-PASS100ENE
9528-PAXVTENE
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
Whats the value of pre-configured?

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 POs

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
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.
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
41
Industrial Data Centers
Essentials
Essentials +
42
The Power of Collaboration
Bundle includes:
Servers and switches from Cisco

Cables, patch cords, cable management, testing,
validation, and assembly from Panduit
Storage from EMC
Virtual System Licenses from VMWare
PlantPAX Virtual Image Templates from Rockwell
43
Agenda
Overview & Drivers
Additional Options
44
Fault-Tolerant Servers
for Automation and MES
Resilient Servers
Duplex Hardware Components
Embedded I/O
PCI
Embedded I/O
Automated Uptime
Layer
Fault Detection &
Isolation
Automated Uptime
Layer
Fault Detection &
Isolation
Purpose build to provide Uptime

unachievable by standard servers
CPU
Chipset
Memory
CPU
Chipset
Lockstepped CPUs
Multi-path I/O
PCI
Memory
Manage like single x86 server

Ideal for mission critical apps in
the data center or remote sites
Multi-Path IO Devices
Fault Detection
&
Isolation
PCI
Enet
PCI
Fibre Channel
Stratus Direct
Attach Storage
Fault Detection
&
Isolation
Embedded IO
Network Switch
Bonding
Enet
Bonding
Network Fault Tolerance
Fibre Channel
Standard Intel PROSet teaming

Single virtual interface to the kernel
One MAC address
Avoids software handling of failures
Embedded IO
Storage Fault Tolerance
RAID1 internal disks

Multi-path to external HW RAID
47
Leveraging the ftServer for

Virtualization and Consolidation
App2
OS
App 1
VM1
VM2
VM3
App 1
App2
DB
OS
OS
OS
DB
Server 2
OS
Server 1
OS
Virtualization Layer
99.999+%
uptime
Server 3
The Cost of Server Sprawl
The Benefits of Consolidation
Initial Hardware, software, and

installation costs
Fewer servers, easy provisioning,

better DR options
Recurring costs for administration

and support and utilities
Plug-and-play operational simplicity

and administration
Downtime and repair
No downtime or data loss

48
Stratus Confidential
Product Specifications
2700
Low-end system
4700
Mid-tier system
6400
High-end system
1-socket
2-socket
2-socket
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
10 MB Shared
10 MB Shared
20 MB Shared
34.1 GB/s
68.2 GB/s
85.3 GB/s
8 DIMM Slots
16 DIMM Slots
16 DIMM Slots
32 GB
256 GB
256 GB
Note: All I/O options

specified in logical
count, physical count is
2 times numbers
specified
Processors
CPU
QPI Performance
CPU Cache
Memory Bandwidth
Memory Slots
System Memory
Embedded
PCI Slots Embedded

PCI Slot Expansion
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
Not Available
2 x PCIe Gen 2
Included
8 x 2.5 SAS Disks
RAID 1 Disk (Internal)

Form Factor
4U Rack
4U Rack
4U Rack
49
Automated Uptime Layer
ActiveService Architecture at Work
Call
Home
Two-way
Customer
Assistance Center
Next Day
Delivery
Service
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)
3. CAC contacts customer to confirm
issue and initiates shipment of
replacement part
4. Customer receives and replaces part system synchronizes with
replacement and continues operation
Welcome to ThinManager Platform 6
Platform Management Tool

XLi Compatible
Office Clients
IP Cameras
Industrial
Thin Clients
ThinManager
iPad & iPhone
VMware
Virtualization
Remote Desktop
Services
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.
Thank you for attending!
Questions?
Tim McCain
Information Solutions Regional Manager
tjmccain@ra.rockwell.com
Mike Murphy
Industrial Automation Software Specialist
mmurphy@sydist.com
Follow ROKAutomation on Facebook & Twitter.

Connect with us on LinkedIn.
www.rockwellautomation.com
Rev 5058-CO900C
Electrical Lighting Automation DataComm
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Electrical Lighting Automation DataComm

Virtualization for Manufacturing

Mike Murphy Schaedler Yesco

Virtualization Adoption, by Industry

Communications & Media (N=27)

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Virtual Machine Deployment Projection

Traditionally the OS and its applications

This allows the ability to change hardware

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Increased Application Longevity

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

More efficiently utilized

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Hosted (aka Desktop) Virtualization

Hypervisor runs as an application on

Host Operating System

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

VMware Player Overview

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

VMware Workstation Overview

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Workstation vs. Player

Support for VM groups

Free for noncommercial use

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Server (aka Bare Metal) Virtualization

Bare Metal or Server

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

VMware vSphere Overview

Centralized management (servers)

Monitor all host servers and virtual machines

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Manageability: Distributed Resource

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Reliability: High Availability

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Reliability: VMware Fault Tolerance

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

VMware View Overview

Extend server virtualization benefits to clients:

Software independence from hardware

Centralized management (clients)

VMware View VDM can also be used to

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

VMware View vs. Workstation

Development for SI/Engineers

Execution occurs in the data

Allows disconnect use of desktop

Typical Hardware Architecture

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Virtual machine performance is highly dependent on I/O

Ie./ Assembly Line 1 VLAN, Assembly Line 2 VLAN, DMZ

Gigabit Switches are required, 10GbE switches may be used

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

FactoryTalk System Example

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

FactoryTalk System Example

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Rockwell Virtualization Progression

Official statement of support: RA Knowledgebase Article 42682

Rockwell Automation and VMware