iconics worldwide customer summit – september 2006 hmi-10: redundancy strategies for plant...
TRANSCRIPT
ICONICS Worldwide Customer Summit – September 2006
HMI-10: Redundancy Strategies for Plant OperationsHMI-10: Redundancy Strategies for Plant OperationsJohn Pettit
2
IntroductionIntroduction
ICONICS Team
John Pettit, VP of Business DevelopmentDave Oravetz, VP of EngineeringMatt Michel, Senior DeveloperClive Walton ICONICS, UK Managing Dir.Jan Burian Senior DeveloperPetr Votava QA Manager
Marathon Technologies
Michael Bilancieri Director of Products
3
WelcomeWelcome
What is important•Uptime•Data Integrity•Record Keeping•Traceability
4
GoalGoal
Achieve•High Reliability•High Availability•Five 9’s Level of Performance
5
Goal - A Look BackGoal - A Look Back
Require Sourcing Systems• From One Vendor- Proprietary Hardware and Software- OS, Hardware, Networks and Protocols
Compromising - Your ability to chose- Your ability to grow- Your ability to improve
6
Good News – Today!Good News – Today!
You have choices• You can use Open control systems technology
Show you the Choices
Fault Tolerant SolutionsClusters / High Availability SolutionsGENESIS32 Redundancy
Review the features and advantages of each
7
Introduction to FT, Cluster, and Introduction to FT, Cluster, and Other High-Availability Other High-Availability
SolutionsSolutions
Dave Oravetz, VP of Engineering
• Fault Tolerant Solutions
• Clusters / High Availability Solutions
8
1. Fault Tolerant Solutions
2. Clusters / High Availability Solutions
3. GENESIS32 Redundancy
Approaches to RedundancyApproaches to Redundancy& Fault Tolerance& Fault Tolerance
9
Fault Tolerant SolutionsFault Tolerant Solutions
What is Fault Tolerance / Redundancy?• Ability to continue without stoppage when a
hardware or software failure occursWhat is a Fault Tolerant Server?• Single box replacement for a workstation /
Server• Designed for 99.999% or greater uptime
- No more than 5 minutes of downtime / year
• Replicated, fault-tolerant hardware components• “Lockstep” technology at the instruction level
10
Fault Tolerant SolutionsFault Tolerant Solutions
Primary Vendors•Stratus•NEC•Marathon Technologies
11
Stratus/NEC SolutionsStratus/NEC Solutions
Stratus / NEC Fault Tolerant ServerUses replicated, fault-tolerant hardware componentsCore Elements• LockStep Technology• Failsafe Software• ActiveService Architecture
12
Fault Tolerant ServersFault Tolerant Servers
Architecture
13
Stratus Fault Tolerant Stratus Fault Tolerant ServersServers
Stratus ftServer W Series• 2400
- One pair of 3.2 Ghz Xeon processors- 1 MB iL2 Cache- 1 to 4 GB DDR DIMM- Windows Server 2003 Standard Edition- Limited Hot-swap capability
• 4300- Up to two pair of 3.2 Ghz Xeon processors- 1 MB iL2 Cache- 1 to 4 GB DDR DIMM- Windows Server 2003 Enterprise Edition
• 5700- Dual-core 2.80 GHz Xeon processors- 2 MB iL2 Cache- 2 to 16 GB DDR2 - Windows Server 2003 Enterprise Edition
14
ICONICS / Stratus ICONICS / Stratus InstallationsInstallations
Bombardier• Dallas / Fort Worth Airport• London Heathrow Airport• Madrid Airport• Taiwan Meihu AirportUK – United BiscuitsUK – Rhodia ChemicalsDenmark – WindfarmHong Kong – Flood Water monitoring
15
1. Fault Tolerant Solutions
2. Clusters / High Availability Solutions
3. GENESIS32 Redundancy
Approaches to Redundancy Approaches to Redundancy TechnologyTechnology
16
ClusteringClustering
What is Clustering•Grouping of Independent server
nodes•Appears on network as a single
system•Provides Backup Operations
17
MSCS ClusterMSCS Cluster
Cluster Service monitors health & invokes Failover
Microsoft Cluster Microsoft Cluster ServiceService
AppApp
18
Microsoft Cluster SupportMicrosoft Cluster Support
Microsoft Cluster Service (MSCS)•Widely used•Heartbeat technology to detect failure•Restart failed applications on same
node•Move applications upon node failure• Intended for file servers, print servers,
database servers, and other servers
19
Microsoft Cluster SupportMicrosoft Cluster Support
Microsoft Cluster Service (MSCS)•Application state not saved by cluster•Applications are responsible for this•Failover time:- Seconds to Minutes- Depends on Custer Configuration- Depends on Application
• ICONICS Software can run on Clusters- Contact ICONICS for more Information
20
GENESIS32 Applications• WebHMI Server
BizViz Applications• BridgeWorX• PortalWorX• ReportWorX• MobileHMI
Cluster Server – ICONICS Cluster Server – ICONICS ApplicabilityApplicability
21
1. Fault Tolerant Solutions– Stratus / NEC FT Server– Marathon everRun FT
2. Clusters / High Availability Solutions
– MS Clustering Technology– Marathon everRun HA
3. GENESIS32 Redundancy
Approaches to Redundancy Approaches to Redundancy TechnologyTechnology
22
Introducing Marathon Introducing Marathon TechnologiesTechnologies
Michael Bilancieri Director of Products
23
23
Marathon everRun™
The Next Generation in High Availability
24
Marathon everRunMarathon everRun
What we do? • Provide simple and affordable alternatives to clusters and proprietary
hardware• Automated, yet comprehensive application availability on standard servers• Deliver turn-key availability solutions• High Availability and Fault Tolerance for ANY Windows application
How do we do it?• We use a patented virtualization architecture instead of traditional
clustering/failover technologies• Create a single Windows platform environment using two servers• ComputeThru® instead of failover• Provide Intelligent Policy Management – automatic vs. scripted, manual
policy
25
everRun Product FamilyeverRun Product Family
everRun HA• High availability for any Windows application• Complete data and transactional integrity• For applications with a small Recovery Time
Objective
everRun FT• Fault Tolerance for any Windows application• Zero downtime - Zero data loss• For critical applications requiring Zero Recovery
Time
everRun SplitSite• Supports both everRun HA and everRun FT• Continuous operations through a site disaster• Geographically separate Servers
26
everRun Virtual VieweverRun Virtual View
27
Marathon everRunMarathon everRun
ArchitectureArchitecture
Virtual Server
Processors
Virtual OS
CoServer
Processors
CoServer OS
Virtual Server
Processors
Virtual OS
CoServer
Processors
CoServer OS
Storage
PublicEthernet
CoServer 1
Gig-e
Main
Mem
ory
Main
Mem
ory
CoServer 2
Virtualized into a single Windows environment
Storage
PublicEthernet
Back to Logical View
28
everRun - Unique ValueeverRun - Unique Value
No failover configuration & management• All fault management and policies are embedded and automatic
Supports ANY Windows application• No scripting or ongoing maintenance
• All migration policies embedded
• Failure management transparent to the application
Simple – to deploy and manage• Single Windows environment
• No scripting or custom coding for application support
• Doesn’t require specialized expertise
No shared-disk subsystem• Data redundancy – zero data loss• No single point of failure
29
everRun Advantages everRun Advantages
Complete system and data protection
• No single point of failure
Appears as a single reference system
• One system to install and manage• One application license
Protect ANY application out-of-the-box
• No need for ‘cluster aware’ versions• No scripting
SplitSite allows miles of separation between servers
• Complete protection from site failures
Embedded fault & policy management
• No configuration required
No proprietary hardware• Works with standard Intel and AMD
servers
Hardware layer masked from application environment
• Automated error handling and correction
ComputThru technology redirects I/O away from failed devices
• Automatic• No interruption of application• Extremely resilient application
environment
30
Matt Michel, Senior Developer
• ICONICS DataWorX32 Professional
GENESIS-32 Redundancy GENESIS-32 Redundancy SolutionsSolutions
31
DataWorX32 V9 – StandardDataWorX32 V9 – Standard
Aliased Tag ReferencesOPC Data Access Redundancy via aliased tag referencesOPC Data Access BridgingOPC Data Aggregation (Patented)OPC Tunneling
32
Redundancy for:- OPC Data Access (non-aliased)- OPC Alarm and Event - OPC Historical Data Access- AlarmWorX32 Logger- TrendWorX32 Logger
Store and ForwardMonitorWorX Node Pair ManagementTag-based Redundancy Management
DataWorX32 V9 – DataWorX32 V9 – ProfessionalProfessional
33
Basic Requirements• Node Pair Definition• Logger Configuration• DataWorX32 Professional LicenseGENESIS-32 Administrative Servers• Security Server• License Server• Global Aliasing Server• Language Aliasing Server• GenEvent Server
Simplified ConfigurationSimplified Configuration
34
Simplified ManagementSimplified Management
New MonitorWorX32• Redundant Node Pair Management• Licensing• GenTray Support• More…
New “rdcy:” Tag References• Process Points in GWX, etc.• Writeable for Automated Management
35
OPC Data AccessOPC Data AccessRedundancy for any OPC DA Server
Professional Edition
Primary Secondary Primary Secondary Primary Secondary
Active Active Active
GraphWorX32
DataWorX32Pro
GraphWorX32
DataWorX32Pro
GraphWorX32
DataWorX32Pro
36
OPC Alarm / EventOPC Alarm / Event
Standby
Active Synchronized Alarm / Events
Primary Secondary Primary Secondary Primary Secondary
A/E Client UpdatesPrimary A/E
AlarmWorX32 Server
Secondary A/E
AlarmWorX32 Server
Active Active Active
AlarmWorX32 OPC AE Server Redundancy
Professional Edition
AlarmWorX32
DataWorX32Pro
AlarmWorX32
DataWorX32Pro
AlarmWorX32
DataWorX32Pro
DataWorX32Pro DataWorX32Pro
37
OPC Historical Data AccessOPC Historical Data Access
Active
Standby
Primary HDA Server
Centralized SQL / Oracle Database
(Stratus/Marathon)
Secondary HDA Server
TrendWorX32 HDA Server Redundancy – Central Database
Professional Edition
TrendWorX32
DataWorX32Pro
TrendWorX32
DataWorX32Pro
TrendWorX32
DataWorX32Pro
DataWorX32Pro DataWorX32Pro
38
OPC Historical Data AccessOPC Historical Data Access
Active
Standby
Primary HDA Server
Primary
SQL / Oracle Database
Secondary HDA Server
TrendWorX32 HDA Server – Duplicate Databases
Professional Edition
Secondary
SQL / Oracle Database
TrendWorX32
DataWorX32Pro
TrendWorX32
DataWorX32Pro
TrendWorX32
DataWorX32Pro
DataWorX32Pro DataWorX32Pro
39
New Store and Forward for New Store and Forward for LoggersLoggers
Active
Standby
Primary Logger
Secondary Logger
Synchronized Logger Clients
Store& FwdQueue
Store& FwdQueue
Logged Data
Primary
Centralized SQL / Oracle
Database
Secondary
AlarmWorX32 / TrendWorX32 Logger Redundancy
Note: TWX Logger now a separate
process
Alarm Server / DA Server
Professional Edition
DataWorX32Pro DataWorX32Pro
40
New Store and Forward for New Store and Forward for LoggersLoggers
Active
Standby
Primary Logger
Secondary Logger
Synchronized Logger Clients
Store& FwdQueue
Store& FwdQueue
Logged Data
Primary
Duplicate SQL /
Oracle Databases
Secondary
AlarmWorX32 / TrendWorX32 Logger Redundancy
Alarm Server / DA Server
Professional Edition
DataWorX32Pro DataWorX32Pro
41
Node Pair ConfigurationNode Pair Configuration
Launches Node Pair
Dialog
42
Logger ConfigurationLogger Configuration
Secondary Database
Store and Forward
43
Redundancy LicensingRedundancy Licensing
1. License required on redundant ICONICS servers (OPC DA excluded)
2. License required on client license
server (likely the ICONICS redundant
servers)
44
MonitorWorXMonitorWorX
Redundancy Tab
Bubble Notification
45
Redundancy Tag Redundancy Tag ReferencesReferences
via Unified Data Browservia Unified Data Browser
Redundancy Status
Tag Reference for Active state of AlarmWorX32 Server
OPC DA Servers
OPC A/E Servers
46
HMI-10 Redundancy Strategies HMI-10 Redundancy Strategies for Plant Operationsfor Plant Operations
Dave Oravetz
• Preferred Approaches
• Sample Configurations
47
ICONICS Preferred ApproachICONICS Preferred Approach
Three Tier Architecture
Layer 1 – Data Access
Layer 2 – Data Processing
Layer 3 – ICONICS ClientsGraphWorX32WebHMI ClientsPocket GENESIS
OPC ServersDataWorX32
AlarmWorX32TrendWorX32ScriptWorXWebHMIBizViz
48
ICONICS Preferred ApproachICONICS Preferred Approach
Layer 1 – Data Access Layer• One or more OPC Servers per node –
depending on performance• Optional Configurations:
- OPC Server Direct Connection to Layer 2- DataWorX32 Standard Installed for Aggregation or
Abstraction- Redundant OPC Servers- Redundant OPC Servers with DataWorX32 Standard
49
ICONICS Preferred ApproachICONICS Preferred Approach
Layer 1 - One or more OPC Servers
OPC Server
OPC Server
DataWorX32
OPC Server
DataWorX32
OPC Server
DataWorX32
• Direct Connect to Layer 2• DataWorX32 Standard for Aggregation or
Abstraction• DataWorX32 Professional Redundant Node Pairs
Layer 1: DataAccess
Layer 3
Layer 2
50
ICONICS Preferred ApproachICONICS Preferred Approach
Layer 2 – Alarm and Trend Servers
• Awx32 Server• Awx32 Logger• Twx32 Logger• Twx32 HDA Server
• Direct Connect to Layer 3
• DataWorX32 Standard for Aggregation (primarily Awx32 DA points)
• DataWorX32 Professional Redundant Node Pair
Layer 2DataProcessing
Awx32 Server
Awx32 Server
DataWorX32
Awx32 Server
DataWorX32
Awx32 Server
DataWorX32
51
ICONICS Preferred ApproachICONICS Preferred ApproachLayer 2 – Other
ICONICS Servers• Alarm Analytics• BridgeWorX• PortalWorX• ReportWorX• ScriptWorX• WebHMI
• Direct Connect to Layer 3
• Fault Tolerant Solution (everRun FT)
• Fault Tolerant Server (Stratus)
Layer 2DataProcessing
BridgeWorXB
ridg
eWo
rX
Brid
geW
orX
MarathonVirtual FT
Server
Brid
geW
orX
Brid
geW
orX
Stratus FT
Server
52
Alternative Approach – Layer 2Alternative Approach – Layer 2Layer 2 – Other
ICONICS ServersApplication Dependent• BridgeWorX• PortalWorX• ReportWorX• WebHMI
• High Availability Solution (everRun HA)
• Microsoft Cluster Server
Layer 2DataProcessing
Brid
geW
orX
Brid
geW
orX
MarathonVirtual HA
Server
Brid
geW
orX
Brid
geW
orX
Microsoft Cluster Server
53
HMI-10 Redundancy Strategies for HMI-10 Redundancy Strategies for Plant OperationsPlant Operations
Sample Configurations
54
MarathonVirtual FT
Server
Example Small Redundant Example Small Redundant SystemSystem
AlarmWorX32 ServerAlarmWorX32 LoggerTrendWorX32 LoggerDataWorX32 StdRSLINX OPC Server
WebHMILicensingSecurityMS SQL Server 2005
WebHMI Clients
Note, this is essentially Layer 1 and part of Layer 2
Note, this is the remainderOf Layer 2
55
Example Large Redundant Example Large Redundant SystemSystem
(Airport Application)(Airport Application)
DataWorX32 StdOPC DA Server
Awx32 ServerAwx32 LoggerTwx32 LoggerDwx32 Std
25 WebHMI Clients
…25 Redundant OPC DA Server Pairs
WebHMI
… ~10 Non- Redundant OPC DA Servers
Rep
ortW
orX
10 GENESIS32 Clients
56
ICONICSProduct
DataWorX32 Prof.
StratusFT
Server
Marathon
everRunFT
Cluster /
everRun HA
OPC Server
AlarmWorX32
TrendWorX32
ScriptWorX32 NA
WebHMI Server
NA
GENESIS32 Fault Tolerance GENESIS32 Fault Tolerance OptionsOptions
Recommended
Suitable
Not Recommended
57
ICONICSProduct
StratusFT
Server
Marathon
everRun FT
Cluster /
everRun HA
MobileHMI Server
ReportWorX
PortalWorX
BridgeWorX
BizViz Fault Tolerance BizViz Fault Tolerance OptionsOptions
Recommended
Suitable
Not Recommended
58
Open System – (OPC) Open System – (OPC) RedundancyRedundancy
Capabilities
ICONICS DataWorX
Pro
CiTech Matrikon ORB
KepWare Redundancy
Master
OPCRedundan
cy
Yes No Yes Yes
OPC DA Yes No Yes YesOPC A&E(Store & Fwd)
Yes No No No
OPC HDA(Store & Fwd)
Yes No No No
Automatic switching
Yes Yes Yes Yes
Supports multiple OPC Server pairs
Yes Yes Yes Yes
No programming or
application changes required
Yes Yes Yes Yes
59
Open System – (OPC) Open System – (OPC) RedundancyRedundancy
Capabilities ICONICS DataWorX
Pro
CiTech Matrikon ORB
KepWare Redundancy
Master
Hot, Warm, and Cold fail over functionality
Yes Yes Yes Yes
Configurable Server polling intervals
Yes Yes Yes Yes
Trigger fail over and fallback
Yes Yes Yes Yes
Monitor RedundancySystem status
MonitorWorXIncluded
Yes Yes Yes
Diagnostic and event logging
Yes Yes Yes Yes
E-mail notifications Via Opt AWX MMX
NO Yes Yes
ICONICS Worldwide Customer Summit – September 2006
Questions?