Virtualized Micro Data Center

T46 PlantPAx Physical Infrastructure:
Virtualized Micro Data Center
Case Study
November 08, 2012
1. Why use virtualization in manufacturing?
2. PlantPAx virtualization
3. Physical Infrastructure: Best Practices
4. Physical Infrastructure: Integrated Solutions
5. Carotek Process Training Unit Case Study
6. Roadmap and Tools to Succeed
Virtualization for Process Plants
Game changer: Increase availability while reducing TCO!
Chris Di Biase
Rockwell Automation, Network and Security Services
3
What is virtualization?
Issues faced everyday
Benefits of Virtualization
High Availability!
Process Systems Today
Now virtualized!
Physical Infrastructure:
Best Practices
Integrated Solutions enable customers to grow their
business… fast and reliably!
Jason Campbell
Panduit Corp, Technical Systems Engineer
10
Key Physical Infrastructure concerns
when Virtualizing
Consolidating infrastructure means you need to get the details right!
-Thermal considerations
- Cable management
- Grounding/Bonding
- Physical security / Identification
- Connectivity and structured cabling designs for Fiber/Copper
Important to take an architecture view to succeed with your
virtualization project – leverage partners to address complete solution.
What can go wrong?
Downtime
• Security lapses
• Performance degradation
•
Bad examples
Cables coming into the
cabinet are coiled and laying
on top of the cabinet.
Cables no longer being used
are identified by tying them in
a knot.
13
No Patchfield is used for
cables connected to the
switches.
Equipment resting on the
equipment below it with no
support provided.
Some cables are identified
with a marker. Most not
identified at all.
Plantwide EtherNet/IP Ecosystem - Overview
Plantwide EtherNet/IP Ecosystem - Design and
Deployment
IT Convergence
Leader in
Industrial Network
Infrastructure
Because Infrastructure Matters
The Established
#1 Industrial Ethernet
Successful Network Convergence Requires
• Partner Collaboration
• Simplification
Network Testing, Verification &
• Innovation
Troubleshooting Tools
Physical Layer Infrastructure
http://www.ethernetippartners.net/
Use Validated Building Blocks
Physical Layer Design Considerations
NetworkPanel
Zone Solutions
Enclosure
Control
Simplifying
MicroBlock
Data network
Center
Building
forrisk,
Robust,
Mitigate EMI noise
save
Building
Block
for
Enterprise
infrastructure
from
Secure,
ScalableEtherNet/IP
Network
space
and optimize
to Plant-Floor
Convergence
Distribution
Enterprise
to Plant
connectivity
Leverage Reference Architecture & Validated Building Blocks
to Speed Deployment and Reduce Risks
Zone Enclosures – Optimized for Stratix
Physical Layer Design Considerations
 Integrated Solution for
Stratix 8300, 8000 and
new 5700 switches
 Robust, Secure,
Thermally tested
 Save time/cost/risk:
3 Sizes
– Convergence point:
Plant-floor controls
system engineer
and IT network
engineer
– UL508, CE rated
Solution contains all required hardware: fully integrated,
tested and documented.
Integrated Solution: PlantPAx Appliance
PlantPAx Virtualized System
PlantPAx System
Micro Data Center
•
•


Cisco Catalyst 3750 switches
Virtualized environment for running PlantPAx
software
o (6) physical servers
Storage: From EMC2
Panduit Optimized Physical Infrastructure
 Thermally tested
 24 RU Cabinet
 Power Outlet Units
 Cable Management
 Grounding/Bonding
Solution contains all required hardware & software; fully integrated, tested and
documented. PlantPAx Virtualized Solution delivered to customer ready to deploy in
manufacturing
Panduit Micro Data Center Video (Youtube)
Process Training Unit:
Virtualized Micro Data Center
Game changer: Increase availability while reducing TCO!
Deryl Bell,
Matt Goyak,
Carotek, Inc,
24
The Power of Solutions!
Power
The Power of Solutions!
Electrical Shop:
1. Authorized Systems Integrator for Rockwell
Automation.
2. 15,000 square foot facility.
3. 5-ton overhead crane.
4. “Clean Room” area for software development
and testing.
5. Repair, calibration, and testing area for
instrumentation.
6. Certified UL® and CSA® approved shop.
The Power of Solutions!
Mechanical Shop:
1. 36,000 square foot facility.
2. 25 & 10 ton overhead cranes.
3. ASME Section IX & AWS D1.1, D1.6 code
welding.
4. Fabrication to ASME B31.1 & B31.3.
5. Gauge and seal testing and assembly
station.
6. Complete systems check-out and testing
capabilities.
7. Paint spray booth; 16’x16’x36’
8. Drive-in and Pull-up docks.
PTU - Process Training Unit
A PTU is a “miniplant” where students can explore concepts in action with
Endress+Hauser instrumentation, the Rockwell Automation PlantPAx™
process automation system, and Panduit’s Micro Data Center.
Copyright © 2008 Rockwell Automation, Inc., {Insert Partner Name}. All rights reserved.
29
PTU - Process Training Unit
Hands-on learning:
1. A fully functional “Mini Process Plant”
combined with classroom education.
2. Designed to teach fundamental, theoretical,
and practical knowledge of instrumentation
with an emphasis on service & maintenance.
3. Features over 90 field instruments
communicating via Ethernet IP, Hart,
ProfibusPA, and Foundation Fieldbus.
4. Contains the latest in On/Off, Control Valves &
Pump technology.
5. PTU is controlled by a Rockwell PlantPAx
process automation system.
6. Qualifies for Professional Development Hours
(PDH’s).
Process Integration
•
-
Customer challenges
Limited capital budgets & IT resources.
“Legacy” software and infrastructure.
Inadequate or out-dated plant standards.
• How virtualization helps us help our customers:
- Permits quick development, testing and deployment across
multiple hardware & software platforms.
- Allows for scalability.
- Eases the management & support of multiple software versions
across different operating systems.
- Provides a cost effective redundant solution.
Process Integration
• Case Study – Energy Industry – Crude Gathering
- Four (4) unique operating systems at terminals scattered across
three (3) states.
- Limited capital for new hardware.
• How virtualization was applied:
- SCADA, Historian, SQL Server, and POS systems were
consolidated on a single IT resource.
- Development and testing took place on virtualized systems.
- Software solutions were easily scaled up as the system
quadrupled in size.
Process Integration
• Case Study – Food and Beverage Industry - Distillery
- New construction.
- Latest technologies were utilized.
• How virtualization was applied:
- SQL Server 2008, FactoryTalk View SE Server, View Point,
Vantage Point, Historian, and Maintenance/Engineering systems
were consolidated on a single IT resource.
- Software solutions were easily scaled up as the system
eventually doubled in size.
- Disaster recovery following a hurricane event.
Process Training Unit: PlantPAx
PlantPAx Virtualized environment • Speed Deployment and High
Availability
• Robust Physical Infrastructure:
• Cable Management
• Grounding/Bonding
• Fiber, Copper Connectivity
• Physical Security
• Identification
• Power Outlet Units
Summary
Benefits of Virtualization
Learn More
• Carotek Process Training Unit
– Training classes
– Process Summits
http://www.carotek.com/Carotek_PTU/ProcessTrainingUnit.htm
• Rockwell Automation
– PlantPAx Appliances
– Network and Security Services
www.rockwellautomation.com/plantpax
www.rockwellautomation.com/
• Panduit
– Physical Infrastructure solutions and services
– System Integrator Partner program
– Panduit Certified Installers
www.panduit.com/ia