Using Virtualization and XML to Maximize your HMI

Using Virtualization and XML to Maximize your HMI Investments Dallas West Jim Craib March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Agenda l l l l l Introductions Is It Time To Upgrade or Prolong Life? Why, and How Much Will it Cost? Industry Changing Technologies What is Virtualization? Advantages of Virtualization? Case Study What Does the Future Hold? Conclusions Questions & Answers March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Introductions l Jim Craib ¡ President, Orion Automation and Controls Engineering ¡ 25 Years of Automation and Controls Experience ¡ 16 Years of PLC/HMI Experience ¡ 10 Years of Experience Managing Automation Projects ¡ BBA Degree from Golden Gate University ¡ ISA Member since 1988 March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Introductions l Dallas West ¡ ¡ BS. Biotechnology Hons. (1999) BS. Chemical Engineering (2001) Joined Genentech SSF Automation 2004 Current Role: l l l Cell Culture Automation Manager DCS & PLC Batch Operations Currently Reading ¡ ¡ ¡ www. digg. com Globaleconomicanalysis. blogspot. com Blink by Malcolm Gladwell March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Is the Time Right? l Has the vendor released a major revision? l Is the vendor planning to end support? l Does the system often crash or have performance issues? l Can operations staff perform their jobs effectively and efficiently? March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

What Will it Cost? l Engineering Design and Documentation ¡ $1, 000 to $25, 000 l Screen and Database Conversion ¡ $0 to $5, 000 per screen or database tag l Hardware (COTS PC or Industrial PC) ¡ $400 to $20, 000 March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

What Will it Cost? l Software (OS and Vendor HMI Package) ¡ $1, 000 to $50, 000 l Commissioning and Qualification ¡ $0 to $5, 000 per screen l Validation ¡ $5, 000 to $100, 000 March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

How Long Will It Take? l Conceptual/Preliminary/Detailed Design ¡ 1 to 3 months l Development/Build/Testing ¡ 1 to 6 months l Deployment/Training ¡ 1 to 3 months March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Industry Changing Technology March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Napsters Impact on the Music Industry l Global music sales dropped from: ¡ $38 Billion in 1999 ¡ $32 Billion in 2003 l Stan J. Liebowitz argues in a series of papers (2005, 2006) that file sharing had a significant negative impact on record sales. March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Then Came Apple March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

So What? is to the March 31 st and April 1 st, 2009 Music Industry Automation Industry Mile High Industrial and Automation Conference

What is Virtualization? l Virtualization provides a means to run multiple instances of varying operating systems simultaneously on the same computer. March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Guest OS Host OS March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Types of Virtualization l Server Virtualization l Desktop Virtualization l Presentation Virtualization l Application Virtualization March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

How does it work? March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

How does this relate to HMIs? l The story of Jimmy March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Slide from a 2008 Automation Vendor Conference l 1987 – Product Life Cycle for an average HMI Console: ¡ 20 Years l 2007 – Product Life Cycle for an average HMI Console: ¡ 5 - 7 Years "Modern Technology has changed the Process Control Industry!" March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Case Study BATT PROC FORCE AB COMM Ethernet AB Win. View HMI AB PLC 5/80 E Controlling a Chromatography Skid March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

System Highlights l Mature HMI ¡ No changes made in year prior to project l Existing HMI met all current user requirements l Problem ¡ ¡ l HMI PC would crash unexpectedly HMI PC hardware was failing causing unplanned downtime Question ¡ How can we extend the useful life of the existing system while minimizing our investment costs? March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Case Study Solution Windows 95 Virtual Machine was created in a VMWare ACE Environment l HMI software was loaded and configured within the Virtual Machine. l Virtual Machine package was installed on a new Corporate Standard PC. l March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Case Study Demo March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Case Study Outcome l Total invested cost = $2, 000 Virtualization Software: $80 ¡ Corporate IT issued desktop computer: $750 ¡ Engineering Time: ¡ l l l Time to deploy preconfigured Virtual Machine: ¡ l Rebuilding New Image: 2 hrs x $200 per hr HMI Application Configuration: 4 hrs x $200 per hr 15 minutes Cost savings on a 5 -7 year basis: ¡ Ranges from $38, 000 to $123, 000! March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Case Study Outcome l Based upon this success, other production systems were virtualized, including: Windows 95 Systems ¡ Windows NT Systems ¡ Windows 2003 Server Systems ¡ l Quote from Operations Staff ¡ “I never knew Windows 95 could run so fast!” March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Advantages for End Users Increases the longevity of a HMI Application l Decreases downtime in the event of a failed HMI PC l Breaks the dependency between HMI Software and Hardware. l l Bottom Line It’s easier to do than a full HMI Upgrade! ¡ It’s going to save you downtime and money! ¡ March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Attention all Vendors!!! l l Who’s going to be the next Apple? Who’s going to be the first to sell a prepackaged Virtual Machine? l l How many calls do your Call Centers get for Software Configuration issues? ¡ l Think i. Tunes for Automation Software! Potential Call Center call volume reduction Competitive Advantage for whoever gets there first! ¡ My HMI will run indefinitely, Vendor Y’s is only good for 5 -7 years. March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Limitations l Not all I/O is easily virtualized ¡ ¡ l Non x 86 machines cannot currently be virtualized to run on a x 86 machine. ¡ l Rockwell: DH+ connections Foxboro: Nodebus connections ie. ) Sun SPARC Workstations cannot be virtualized to run on Windows Machine. Licensing Disclaimer ¡ Read your EULA to determine what impact virtualization might have on any licensing agreements you have. March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

What’s Does the Future Hold? l Seamless Software Upgrades ¡ At some point your going to want to upgrade Take advantage of new features l Take advantage of increased support l l How will you do it in the most cost effective means? ¡ XML & XSLT! March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Google Translate March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Google Translate March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

What the XML is XSLT? XML - e. Xtensible Markup Language. • • Provides an means to expose data within an application file. Once the data is visable we can do something to it! XSLT - e. Xtensible Stylesheet Language Transformation • XML-based language used for doing some sort of action to an XML document or file. March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

XSLT Translation Process Input Data XML Input March 31 st and April 1 st, 2009 Magic Output. Black Data Box XSLT Mile High Industrial and Automation Conference

XSLT Translation Process Microsoft Excel Input XML Input March 31 st and April 1 st, 2009 Magic Microsoft Word Black RSBatch Manufacturing Box Recipe Output Formula XSLT Mile High Industrial and Automation Conference

XSLT Demo March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Black Box Revealed March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Unlock the possibilities!!! HMI Rev Old Input XML Input March 31 st and April 1 st, 2009 Magic Black HMI Rev New Output. Box XSLT Mile High Industrial and Automation Conference

Unlock the possibilities!!! Vendor A Code XML Input March 31 st and April 1 st, 2009 Magic Black Vendor B Code Box XSLT Mile High Industrial and Automation Conference

Attention all Vendors!!! l Who’s going to be the first to offer XSLTs that… ¡ Transform design docs to code/HMI? ¡ Transform design docs to commissioning test scripts? ¡ Transform a competitors code/HMI to yours? ¡ Validate your XSLT’s for the regulated industries? March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Conclusion l When your ready to upgrade ¡ Explore how you can use XSLT translations to make your next upgrade more cost effective! l Don’t be a victim of Microsoft! ¡ Use Virtualization to maximize your HMI investments! March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Questions and Comments? March 31 st and April 1 st, 2009 March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Appendix March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

What is Virtualization? l "Virtualization is a framework or methodology of dividing the resources of a computer into multiple execution environments, by applying one or more concepts or technologies such as hardware and software partitioning, time-sharing, partial or complete machine simulation, emulation, quality of service, and many others. " March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference