EP16 Keeping your Connected Enterprise Always-On in the age of Virtualisation & IIoT

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1 EP16 Keeping your Connected Enterprise Always-On in the age of Virtualisation & IIoT Stefano Arondi, Project Manager - Automazioni Industriali Capitanio - AIC Giacomo Ghidini, Country Manager - Stratus Technologies Italy October 2017 PUBLIC Rockwell Automation TechED EMEA #ROKTechED Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 1

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3 AIC Today AIC Automazioni Industriali Capitanio srl - Odolo (BS) Italy Torbole Casaglia (BS) Italy AIC Capitanio Automation Systems India Pt. Ltd AIC North America Corp AIC South America Brazil

4 AIC Today 50+ employees 2500 m2 panel shop with 4 cranes 15/25ton 2016 turnover 12M - 14M$ 800+ applications 120+ customers 40+ countries, 4 continents UL listed equipment Rockwell Recognized System Integrator for Control, Power and Process 4

5 Typical structure of integrated SCADA system ERP Big Data ERP Network Level 2 Plant floor network 5

6 SCADA System Requirements Simple Fast Long Lifecycle Reliable 6

7 Traditional SCADA System Evolution Multiple Standalone Client / server Single Standalone 7

8 Single Standalone Simple management Non redundant Low communication load Requires spare hardware Simple Fast Long Lifecycle Reliable 8

9 Multiple standalone Complicated maintenance Redundant High communication load Simple Fast Long Lifecycle Reliable 9

10 Simple Client/Server Easier maintenance Redundant client only Low communication load Requires spare hardware Simple Fast Long Lifecycle Reliable 10

11 Redundant Client/Server Reliable configuration Low communication load Cold vs Hot redundancy Simple Fast Long Lifecycle Reliable 11

12 Virtualized Client/Server (1) Virtualized server: Redundant if cluster is implemented Low communication load Fault tolerance needs expensive licenses and special hardware setup High management complexity Easier to implement if only high-availability is implemented Simple Fast Long Lifecycle Reliable 12

13 Stratus Fault Tolerant Client/Server (2) Fault tolerant hardware: Redundant Low communication load Easy management Optimized using simple virtualization solutions Reduced obsolescence due to extended hardware support Fault tolerant support also for standard applications Simple Fast Long Lifecycle Reliable 13

14 Multi-path I/O How it works (1) Duplex Hardware Components PCI Embedded I/O PCI Embedded I/O Automated Uptime Layer Fault Detection & Isolation Automated Uptime Layer Fault Detection & Isolation CPU Chipset Memory CPU Chipset Memory Lockstepped CPUs Purpose build to provide availability unachievable by standard servers Provides Always-On Processing Manage like single x86 server Ideal for mission-critical apps in the data center or remote sites 14

15 How it works (2) PCI Embedded I/O Automated Uptime Layer Fault Detection & Isolation CPU Chipset Memory Single Software Image What your OSs, Applications, and Users see Transparent fault tolerance System is managed just like a stand-alone system 15

16 Simplified maintenance and diagnostics Proactive diagnostics from Stratus help keep systems under control Different service levels available to deliver required spare parts in short time Customer needs only change faulty disks or a complete half-unit, while system is running No need of IT skills to replace the faulty hardware Integration with HMI for immediate diagnostics via OPC 16

17 System repair procedure: error proof System automatically identifies the failed component and phones home to a Stratus Customer Assistance Center Normal processing continues throughout process! System automatically orders replacement part Next Day Delivery Service The component is installed by customer without tools and is automatically resynchronized without touching a keyboard 17

18 Typical SCADA structure with fault-tolerant hardware Many different technologies can be integrated to build a complete, fault-tolerant, and easy to maintain SCADA system 18 18

19 Stratus Fault-Tolerant Server (1) Stratus systems are designed to avoid any single point of failure, hence fault of any single component will not cause a service interruption To achieve this, all internal components are redundant Advanced monitoring allows a proactive reaction to faults Application server virtualization shall be used to optimize hardware utilization 19

20 Stratus Fault-Tolerant Server (2) Stratus servers obsolescence is reduced compared to mainstream machines thanks to spares availability for extended time after product line is updated, maximizing return on investment Stratus life cycle is by design longer than standard servers, for 10+ years 20

21 Virtualization with VMWare vsphere virtualization, installed in its most simple configuration, helps using the hardware platform at its maximum capabilities, being integrated with specific drivers from Stratus Management is simplified because the fault tolerance is granted by Stratus at hardware level, and to the virtualization infrastructure the server is presented as a single machine This leads to easier management and cheaper licenses 21

22 Applicative virtual machines All applications are executed in dedicated virtual machines, with the following advantages: Easy backup and restore (snapshots, hot backups etc.) Hardware independence Easier management Communication optimization Easier system upgrade and expansion with new features 22

23 Client Redundancy Client redundancy can be easily achieved installing multiple client stations and properly configuring the system This is done by making the clients interchangeable Due to software license and additional maintenance cost, client virtualization is only worth when the customer already has such infrastructure in place, for example for administrative offices 23

24 Typical steel rolling mill application Datacenter Control Room ERP Furnace Pulpit Rolling Mill Pulpit Cooling & Bundling Pulpits 24

25 Conclusions SCADA systems evolution required integration of different technologies, to achieve high availability and easy management Modern factories require a constant, reliable, 24/7 integration with higher level ERP systems, requiring and always on SCADA The combination of fault-tolerant hardware and virtual application servers is the solution to meet all requirements while keeping system maintenance easy for factory technicians Industry 4.0 and IIoT ready due to easy implementation of new application servers for data collection and management 25

26 AIC Automazioni Industriali Capitanio Your partner in steel process automation 26

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28 Complete A Survey Please take a moment to complete the brief session survey on our mobile app and let us know how we re doing! Download the ROKTechED app and login: Username: Last name Password: address used to register E M E A Locate the session in the Schedule icon Click on the Survey icon in the lower right corner of the session details Complete survey & submit Thank you! PUBLIC Rockwell Automation TechED #ROKTechED Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 28