Using Virtualization and XML to Maximize your HMI Investments

1. Using Virtualization and XMLto Maximize your HMIInvestments Dallas West Jim Craib Mile High Industrial and Automation Conference

2. 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 Mile High Industrial and Automation Conference

3. 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 Mile High Industrial and Automation Conference

4. 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 • www.digg.com • Globaleconomicanalysis.blogspot.com • Blink by Malcolm Gladwell Mile High Industrial and Automation Conference

5. 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? Mile High Industrial and Automation Conference

6. 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 Mile High Industrial and Automation Conference

7. 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 Mile High Industrial and Automation Conference

8. 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 Mile High Industrial and Automation Conference

9. Industry Changing Technology Mile High Industrial and Automation Conference

10. 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. Mile High Industrial and Automation Conference

11. Then Came Apple Mile High Industrial and Automation Conference

12. Virtualization Automation Industry is to the So What? Music Industry is to the Mile High Industrial and Automation Conference

13. What is Virtualization? • Virtualization provides a means to run multiple instances of varying operating systems simultaneously on the same computer. Mile High Industrial and Automation Conference

14. Guest OS Host OS Mile High Industrial and Automation Conference

15. Types of Virtualization • Server Virtualization • Desktop Virtualization • Presentation Virtualization • Application Virtualization Mile High Industrial and Automation Conference

16. How does it work? Mile High Industrial and Automation Conference

17. How does this relate to HMIs? • The story of Jimmy Mile High Industrial and Automation Conference

18. Mile High Industrial and Automation Conference

19. 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: • 5 - 7 Years "Modern Technology has changed the Process Control Industry!" Mile High Industrial and Automation Conference

20. BATT PROC FORCE COMM A B A B Case Study Ethernet WinView HMI AB PLC 5/80E Controlling a ChromatographySkid Mile High Industrial and Automation Conference

21. 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? Mile High Industrial and Automation Conference

22. 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. Mile High Industrial and Automation Conference

23. Case Study Demo Mile High Industrial and Automation Conference

24. 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! Mile High Industrial and Automation Conference

25. 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!” Mile High Industrial and Automation Conference

26. 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 • It’s easier to do than a full HMI Upgrade! • It’s going to save you downtime and money! Mile High Industrial and Automation Conference

27. Attention all Vendors!!! • Who’s going to be the next Apple? • Who’s 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 Y’s is only good for 5-7 years. Mile High Industrial and Automation Conference

28. 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. Mile High Industrial and Automation Conference

29. What’s 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! Mile High Industrial and Automation Conference

30. Google Translate Mile High Industrial and Automation Conference

31. Google Translate Mile High Industrial and Automation Conference

32. 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. Mile High Industrial and Automation Conference

33. XSLT Translation Process MagicBlackBox Input Data OutputData XML Input XSLT Mile High Industrial and Automation Conference

34. XSLT Translation Process MagicBlackBox RSBatchRecipe Output Microsoft WordManufacturing Formula Microsoft ExcelInput XML Input XSLT Mile High Industrial and Automation Conference

35. XSLT Demo Mile High Industrial and Automation Conference

36. Black Box Revealed Mile High Industrial and Automation Conference

37. Unlock the possibilities!!! MagicBlackBox HMI Rev Old Input HMI Rev NewOutput XML Input XSLT Mile High Industrial and Automation Conference

38. Unlock the possibilities!!! MagicBlackBox Vendor A Code Vendor BCode XML Input XSLT Mile High Industrial and Automation Conference

39. Attention all Vendors!!! • 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? Mile High Industrial and Automation Conference

40. Conclusion • When your ready to upgrade • Explore how you can use XSLT translations to make your next upgrade more cost effective! • Don’t be a victim of Microsoft! • Use Virtualization to maximize your HMI investments! Mile High Industrial and Automation Conference

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

42. Appendix Mile High Industrial and Automation Conference

43. 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." Mile High Industrial and Automation Conference