Sustainable, Secure Virtual Infrastructure for PlantPAx

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Wilfrid Campbell
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1 Sustainable, Secure Virtual Infrastructure for PlantPAx Name Stewart Whitlow Huhtamaki, Manufacturing Systems Manager Larry Grate PREMIER, Account Delivery Manager Date Nov 5, Copyright 2012 Rockwell Automation, Inc. All rights reserved.

5 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 5 Who is Huhtamaki? 1920: Heikki Huhtamäki, at the age of 19, establishes Huhtamäki Industries a candy factory in rural Western Finland 1930s: Expansion into food and packaging industry 1960s: Packaging becomes a separate business. 1970s: Huhtamaki s packaging subsidiary becomes Europe s leading disposable cup producer s: Packaging businesses acquired in Europe, Oceania, Asia and USA. First biodegradable packaging developed For more info... Visit Huhtamamki s website at

6 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 6 Who is Huhtamaki? 2000s: Focus and expertise in molded fiber packaging, flexible packaging, release films and paper cup manufacture. Inauguration of new production sites in Asia. 2010: Huhtamaki celebrates its 90th anniversary year : Huhtamaki acquires: Paris Packaging Ample Industries Winterfield, LLC Huhtamaki has grown from a multi-industry company into a packaging specialist through more than 200 acquisitions and divestments since The company has over 15,000 employees working in 62 manufacturing operations in 31 countries. For more info... Visit Huhtamamki s website at

8 Copyright 2012 Rockwell Automation, Inc. All rights reserved. Who is Premier? Founded in 1991 Privately Owned 150+ Employees CSIA Certified (6 Years) Corporate Office Located in Smyrna, TN Regional Operations in S.E. U.S. Smyrna, TN Decatur, AL Cincinnati, OH For more info... Visit PREMIER s website at

9 Copyright 2012 Rockwell Automation, Inc. All rights reserved. Who is Premier? Rockwell Solution Partner Rockwell Control Solution Partner Rockwell Information Solution Partner Rockwell Process Solution Partner Information Competencies PLC/DCS Programming and Configuration HMI Development MES Solutions Legacy PLC/DCS Retrofits Coordinated Drives Solutions For more info... Visit PREMIER s website at

10 Copyright 2012 Rockwell Automation, Inc. All rights reserved. Who is Premier? Industries Automotive Chemical Consumer Products Food & Beverage Metals Pulp & Paper For more info... Visit PREMIER s website at

New challenges due to exposure: older operating systems, hardware, software, IT updates, Internet, and security Control systems were costly to maintain and inefficient Failing systems,

12 Problem Definition Expanded OSIsoft PI to all US sites in 2007 Gathered plant floor data for CI cost saving initiatives and OEE reporting. New data caused new issues Introduction of legacy control systems to the business networks Process network infrastructures were non-existent or part of the business network. New challenges due to exposure: older operating systems, hardware, software, IT updates, Internet, and security Control systems were costly to maintain and inefficient Failing systems, employee turnover and reduced support due to end of life systems. We were buying parts on ebay! Many brands of DCS and PLC systems at each site made internal support difficult at best. Copyright 2012 Rockwell Automation, Inc. All rights reserved. 12

13 Why Be Security Conscious STUXNet First control system virus High complexity Unconnected bi-directional Queensland Australia Disgruntled Contractor Over 46 intrusions before arrest CERT (Cyber Emergency Response Teams) Prior to 1998 Less than 2,000 incidents reported By 2001 Approximately 20,000 incidents reported In 2004 CERT abandoned keeping statistics because more than 140,000 cases were reported. Business Risk IT model does not provide enough security between sites One network model Copyright 2012 Rockwell Automation, Inc. All rights reserved.

15 Copyright 2012 Rockwell Automation, Inc. All rights reserved. Partnership Overview Rockwell Control System Familiarity DCS Control System Experience Network and Security Experience Previous Control Hardware and Software Design Partner Control Panel Construction Process Tuning and Optimization Support Multi-Site support capability (Bandwidth) Multiple years of experience working with Huhtamaki

16 Copyright 2012 Rockwell Automation, Inc. All rights reserved. Initial Configuration Rockwell Reference Architecture (PAx) Use of a Domain Separating FT Directory Server Use of Redundant HMI Servers AssetCentre for Disaster Recovery and version control To save Hardware costs used VMWare Workstation Host for Domain Controller Host for FTD Host for AssetCentre

17 Copyright 2012 Rockwell Automation, Inc. All rights reserved. Initial Configuration Physical HMI Servers Deployment of DMZ for security and Isolation Use of Thin Clients and ACP for Operator Stations Group Policy Changes

Migrate Legacy DCS systems (4) sites Implement a standard DCS platform to replace the (3) different control systems

18 Initial Configuration Process Network Isolation (10) sites Implement a BDP standard for process networks that would protect the plant floor. Protection will also provide time to replace legacy PLC and HMI systems. Migrate Legacy DCS systems (4) sites Implement a standard DCS platform to replace the (3) different control systems across the sites. Rockwell ProcessLogix (1999) Rockwell SLCs (1990) Valmet Damatic XD (1988) Copyright 2012 Rockwell Automation, Inc. All rights reserved. 18

Initial Configuration All sites agreed on ControlLogix and FactoryTalk platform from Rockwell Automation whether DCS or PLC would be used in control strategies Another milestone in company standards

19 Initial Configuration All sites agreed on ControlLogix and FactoryTalk platform from Rockwell Automation whether DCS or PLC would be used in control strategies Another milestone in company standards Single systems integrator was selected to develop and implement a new DCS solution and network isolation design at all sites. PlantPAx replaced the legacy DCS systems VMware Thin Clients FactoryTalk AssetCentre Redundant FactoryTalk View SE HMI servers Copyright 2012 Rockwell Automation, Inc. All rights reserved. 19

Initial Configuration PlantPAx was scheduled for go-live Part of a regular site maintenance shutdown Included a 12-hour shutdown to cut over the new system

Operator HMI PCs were changed out and thin client bricks were put in their place Operator visibility of the process went from (3) 20 displays to (6) 24

21 Initial Configuration PlantPAx was scheduled for go-live Part of a regular site maintenance shutdown Included a 12-hour shutdown to cut over the new system Actual DCS downtime was < 8 hours Finished before the site completed their planned maintenance work. Operator HMI PCs were changed out and thin client bricks were put in their place Operator visibility of the process went from (3) 20 displays to (6) 24 Number of ControlNet networks was reduced dramatically Number of controllers went from three to one Reduced old DCS controller cabinet space in half Copyright 2012 Rockwell Automation, Inc. All rights reserved. 21

22 Copyright 2012 Rockwell Automation, Inc. All rights reserved. Lessons Learned Initial Configuration Use of Workstation for Infrastructure hosting Upgrade to ESXI Thin Client Redundancy Limitations RA License Challenges Port Translation not present in DMZ for Remote Access

23 Copyright 2012 Rockwell Automation, Inc. All rights reserved. Final Solution Virtualized HMI Servers Virtualized OSI Server and Interfaces Use of Remote Desktop Gateway for Secure Access Virtualized Development Computers Use of RDP for Laptop Development Support Implemented Process Side wireless Access Use of script for automated Snapshot and Backup of Servers Use of VMWare Essentials for ESXI Licensing

29 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 29 Huhtamaki: Results Before DCS brand control system knowledge at each site was very poor. Control system strategies and standards were different at each site. DCS downtime was costing the site 80 hours of downtime per year. After Rockwell PlantPax utilizes Integrated Architecture which is understood by each site and corporate engineering staff. Control system standards are now used across all sites No DCS downtime. DCS annual support costs exceeded $100k / year for one site alone. DCS and PLC annual support costs for all sites is less than $75k. This totaled about a $150k / year in total savings.

30 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 30 Huhtamaki: Results Before Company Network traffic problems were creating 60hrs of machine downtime per quarter. IT patch updates were creating downtime to HMI PCs, DCS Servers, and Network Switches. After No traffic problems. Network traffic is now minimized to plant floor control systems and is maintained by control engineers. No more uncontrolled changes to the network. Plant floor is now isolated. IT updates are approved and applied by plant control engineers. No more automatic updates that break our systems. Control loop performance had degraded over time due to the complexity of manual tuning with external tools. All control loops were collected and tuned using FactoryTalk Gateway and lambda tuning methods. Control performance is very good even where complex control strategies were used. No external tools needed.

T14 - Network, Storage and Virtualization Technologies for Industrial Automation. Copyright 2012 Rockwell Automation, Inc. All rights reserved.

T14 - Network, Storage and Virtualization Technologies for Industrial Automation Rev 5058-CO900C Copyright 2012 Rockwell Automation, Inc. All rights reserved. 2 Agenda Overview & Drivers Virtualization