Best Practices to Modernize and Simplify SCADA Systems

Transcription

1 Best Practices to Modernize and Simplify SCADA Systems John Fryer, Senior Director, Industry Solutions Brought to you by 1

2 Todays Speakers David Greenfield Moderator Director of Content/Editor-in-Chief Automation World John Fryer Speaker Senior Director Industry Solutions Stratus Technologies 2

3 Agenda Typical challenges with SCADA systems The impact of new technologies Modernizing IA with best practices Virtualization Enabling new applications that simplify operation Protecting your virtualized environment Modern solutions are more than just technology Key considerations Why Stratus? Case studies Next steps 3

4 Typical comments we hear about SCADA systems IT does a great job of scheduling planned downtime, but the bigger issue is break/fix Our systems are so old and fragile we dare not change anything in case it breaks I can t even count the number of devices we have to manage these days When applications stop working we don t even know until other issues arise We are adding more and more complexity to our systems making them more breakable We do not have technical IT skills to fix system issues at remote locations 4

5 Tomorrow s advancements will create more complexity and risk Business goals Increase output Improve quality Be more agile Technology drivers Virtualization Industrial Internet of Things (IIoT) Cloud/Big data analytics Plant interconnectivity Cyber-security Challenges More fire drills Increased complexity Additional (IT) support 5

6 Poll question 1 What do you see as the biggest challenge with your current SCADA system? Keeping aging applications running Keeping aging platforms running Getting IT support when something goes wrong Complexity of managing the overall SCADA environment Adding new functionality without disrupting operations 6

7 Disruption in Industrial Automation Current state Primary SCADA server Backup SCADA server Historian server Thick clients Reactive PLCs and Automation devices Complex IT heavy Complex redundancy where most critical Break/fix or constant monitoring Each system individually managed Mixed O/S environments with security holes ICS isolated to secure plant floor devices Local workstation required to access information 7

8 What do best practices look like? Be more proactive Reduce complexity Rely less on IT Detect issues before they become bigger problems Protect your entire IA technology stack Always keep your SCADA, Historian, HMI, MES and MOM running Easily take advantage of new technologies Consolidate 5+ servers into a single system Get built-in hardware redundancy with that single system Purchase and manage fewer software licenses Use a single pane of glass for all your OT and IT applications Get proactive notification of potential problems Automate hardware remediation Easily swap hardware components by yourself Get instant access to IT specialists with IA expertise 8

9 Modernizing IA eliminates disruption Thick, Managed thin, Mobile, and Web clients Microsoft Go To Market Partners PLCs and Smart automation devices leveraging OPC Proactive Simple IT lite Simplified virtualization & continuous availability Proactive remediation & on demand support Centralized management and thin clients Secure advanced data historian & analysis Secure connectivity to the plant floor devices Access to your information anytime, anywhere Optimize with tasks & analytics 9

10 Poll question 2 When are you planning to update your SCADA systems and move to virtualization? Already virtualized In the next 12 months 1-3 years No current plans Need to learn more about virtualization first 10

11 Protecting virtualized environments Standard Servers LAN 1 Clusters External LAN Heartbeat 1 LAN 2 Virtualization HA APP OS APP OS APP OS APP OS APP OS APP OS Integrated Redundant & Fault-tolerant Solution Heartbeat 2 Single Points of failures cause downtime and data loss 1-4 Hour Service Response to fix Days of outage in remote locations Management complexity adds risk and expense Scripts must be executed FAILURE RECOVERY NOT FAILURE PREVENTION Not optimized for availability Very similar to a cluster Still experience failover Cannot move apps from a failed server FAILURE RECOVERY NOT FAILURE PREVENTION No single points of failure Optimized for IA applications No downtime or data loss Simple integrated solution Easy to service FAILURE PREVENTION Fault tolerance is the preferred solution 11

12 Key considerations for modernizing SCADA platforms What is my tolerance for unplanned downtime? What hardware/application protection do you need? Would an increased level of 9 s generate savings and/or increased productivity? How do you restore normal application processing and how does this affect your ROA? How important is your (inflight) data? Does data loss present risks for asset management & IIoT analytics and/or regulatory requirements? Is there a seamless migration path? Are specialized skillsets required? Is the solution future-ready with the best ROI? How much impact will an upgrade transition have to your operations? Does extensive (and costly) training have to be factored in? Will the system support new applications, such as IIoT, does to have a 5-7+ year lifespan? 12

13 The Stratus solution Active service network Automatic re-synchronization Hot swap replacement Overnight delivery Automatic replacement part ordering and shipment Automatic hardware problem detection Stratus customer On demand Support services Proactive recommendations to address problems Proactive notification of potential problems (failure or performance) Constant monitoring of ftserver generated notifications 24x7x365 access to IA IT experts ftserver OPC Application monitoring and re-start Continuous operation during failures Automatic Uptime Layer Integrated redundancy 13

14 Serving customers in every IA segment Industry classification Discrete vs. Continuous automation Textiles Fabricated metals Machinery Material handling Printing Automotive Discrete Continuous Food and beverage Pharmaceuticals Cement Metals and mining Water and waste Pulp and paper Chemical Oil and gas Power generation Refining Petrochemicals Source: Morgan Stanley research 14

15 The continuous application availability market leader Corporate headquarters Maynard, Massachusetts USA Systems installed 20,000+ worldwide Global presence ~500 people Americas EMEA APJ Protecting lives, assets and revenues since 1980 Over 40 hardware and software availability patents Robust financial profile Stable revenues, cash and profit Key Industrial Automation and technology partnerships 15

16 Düsseldorf Water Authority Utilities company supplying more than 600,000 people fresh drinking water daily; 50 million cubic metres every year Upgrade system to ensure absolute availability of IT infrastructure in control rooms without interrupting operation Solutions considered Host servers on cluster systems Host servers on fault-tolerant servers Requirements No loss of data during migration No hidden costs Limited administration, IT technicians or retraining required Prepare for scalability Chosen solution Stratus ftserver system Wonderware SCADA Business impact Eliminated downtime Increased confidence in data storage Lowered implementation cost Widened IT infrastructure The higher availability and the easy administration of the Stratus ftserver were crucial in our decision. Heiko Jepp, Team Leader Water Mechanics Department Düsseldorf Water Authority 16

17 Dairy Farmers of America Producer of milk, ice cream and other dairy products, sports drinks and salsa for well-known brands Upgrade server architecture to standardize, ensure absolute availability and improve operation speed of Portales plant without interrupting operation Solutions considered High-end Dell/IBM/HP server farm Rockwell Automation s server offerings Low-end solutions such as Why don t we just go down to Walmart and buy some servers? Chosen solution Stratus ftserver 6410 system ACP ThinManager running 15 virtual machines supporting: PlantPAx, HMI, FactoryTalk, EWS, Histortian, and more Requirements Requirements 24x7 monitoring of entire stack Total hardware redundancy Enough capacity to run all VMs on one server No defined life expectancy Simple implementation Business impact Eliminated downtime Improved efficiency of overall system Lowered implementation cost Widened IT infrastructure Hours and perhaps days of downtime have been eliminated by removing the unsupported PCs and replacing them. Eric Miller, Engineering Manager Dairy Farmers of America 17

18 Dependable Gas Transmission Several catastrophic incidents led the company to examine their 15,000 miles of pipeline, spread across 16 states, which transports over 1 trillion cubic feet of natural gas per year Operationally simple system to run virtualized applications remotely without IT expertise and real-time analytics for complete operational visibility Solutions considered Multiple servers at each compressor station Virtualization solution with manual specialized maintenance Chosen solution Stratus ftserver platform Requirements Meet new Control Room Management (CRM) regulations Operational simplicity Real-time analytics without data loss Business impact 100% operational continuity Zero downtime Zero data loss We can get a lot more flexibility by adding applications in the compressor stations without the need for IT expertise. Lead Automation Electrical Engineer 18

19 Next steps / Where to get more information Next Steps Conduct an assessment of your business objectives Develop a business case for a Stratus solution For a plant modernization workshop to review our ability to support your business objective, contact Greg Paden at Greg.Paden@stratus.com or (978) NEW Online Cost of Downtime Calculator with real-time customization reporting Follow us on social and stay connected LinkedIn: Twitter: YouTube: Blog: 19

20 Questions? 20