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

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Presentation on theme: "March 31st and April 1st, 2009Mile High Industrial and Automation Conference Using Virtualization and XML to Maximize your HMI Investments Dallas West."— Presentation transcript:

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

21 March 31 st and April 1 st, 2009Mile High Industrial and Automation Conference System Highlights Mature HMI No changes made in year prior to project Existing HMI met all current user requirements Problem 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?

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

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

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

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

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

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

28 March 31 st and April 1 st, 2009Mile High Industrial and Automation Conference Limitations Not all I/O is easily virtualized Rockwell: DH+ connections Foxboro: Nodebus connections Non x86 machines cannot currently be virtualized to run on a x86 machine. 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.

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

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

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

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

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

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

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

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

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

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

39 March 31 st and April 1 st, 2009Mile High Industrial and Automation Conference Attention all Vendors!!! Whos 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 XSLTs for the regulated industries?

40 March 31 st and April 1 st, 2009Mile High Industrial and Automation Conference Conclusion When your ready to upgrade Explore how you can use XSLT translations to make your next upgrade more cost effective! Dont be a victim of Microsoft! Use Virtualization to maximize your HMI investments!

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

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

43 March 31 st and April 1 st, 2009Mile High Industrial and Automation Conference What is Virtualization? "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."


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