© 2016 Stratus Technologies. All Rights Reserved. 1

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Best Practices to Modernize and Simplify Your Industrial Control Systems

John Fryer, Senior Director of Industry Solutions, Stratus

© 2016 Stratus Technologies. All Rights Reserved. 2

Agenda

• Typical challenges with Industrial Control Systems

• The impact of new technologies

• Modernizing an ICS with best practices

– Virtualization

– Enabling new applications that simplify operation

– Protecting your virtualized environment

• Modern solutions are more than just technology

• Key considerations

• Why Stratus?

• Case studies

• Next steps

© 2016 Stratus Technologies. All Rights Reserved. 3

Typical comments we hear about ICS’s

“Our systems are so oldand fragile we dare not change anything in case

it breaks”

“We are adding more and more complexity to our systems making

them more breakable”

“IT does a great job ofscheduling planned downtime, but the

bigger issue isbreak/fix ”

“I can’t even count the number of

devices we have to manage these days”

“We do not have technical IT skills tofix system issues atremote locations”

“When applications stopworking we don’t even

know until other issues arise”

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Tomorrow’s advancements will create more complexity and risk

Business goals

• Increase output

• Improve quality

• Be more agile

Challenges

• More fire drills

• Increased complexity

• Additional (IT) support

Technology drivers

• Virtualization

• Industrial Internet of

Things (IIoT)

• Cloud/Big data analytics

• Plant interconnectivity

• Cyber-security

© 2016 Stratus Technologies. All Rights Reserved. 5

Poll question 1

• What do you see as the biggest challenge with your current

ICS?

– Keeping aging applications running

– Keeping aging platforms running

– Getting IT support when something goes wrong

– Complexity of managing the overall ICS environment

– Adding new functionality without disrupting operations

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Primary

ICS

serverThick clients

Backup

ICS

server

PLCs and Automation devices

Historian

server

Disruption in Industrial Automation – Current state

ICS isolated to secure plant floor devices

Mixed O/S environments with security

holes

Each system individually managed

Local workstation required to access

information

Complex redundancy where most

critical

Break/fix or constant

monitoring

Reactive ComplexIT

“heavy”

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Rely less on ITBe more proactive Reduce complexity

What do best practices look like?

• Detect issues before they become

bigger problems

• Protect your entire IA technology stack

• Always keep your ICS apps running

(Historian, HMI, MES and MOM running

etc)

• Easily take advantage of new

technologies

• Consolidate 5+ servers into a single

system

• Get built-in hardware redundancy with

that single system

• Purchase and manage fewer software

licenses

• Use a single system view for all your OT

and IT applications

• Get proactive notification of potential

problems

• Automate hardware remediation

• Easily swap hardware components by

yourself

• Get instant access to IT specialists with

IA expertise

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Modernizing IA eliminates disruption

Secure connectivity to the plant floor

devices

Secure advanced data

historian & analysis

Centralized management

and thin clients

Access to your information

anytime, anywhere

Simplified virtualization &

continuous availability

Optimize with tasks &

analytics

Go To Market Partners

Proactive remediation &

on demand support

Thick, Managed thin, Mobile, and Web clients

PLCs and Smart automation devices

leveraging OPC

Microsoft

Proactive Simple IT “lite”

© 2016 Stratus Technologies. All Rights Reserved. 9

Poll question 2

• When are you planning to update your ICS and move to

virtualization?

– Already virtualized

– In the next 12 months

– 1-3 years

– No current plans

– Need to learn more about virtualization first

© 2016 Stratus Technologies. All Rights Reserved. 10

Protecting virtualized environments

Standard

Servers

• Single Points of failures

cause downtime and data

loss

Virtualization HA

OS

APP

OS

APP

OS

APP

OS

APP

OS

APP

OS

APP

• Not optimized for availability

• Very similar to a cluster

External LAN

LAN 1 LAN

2

Heartbeat 1

Heartbeat 2

Clusters

• Management complexity adds

risk and expense

1-4 Hour Service

Response to fix

Days of outage in

remote locationsFAILURE RECOVERY

NOT FAILUREPREVENTION

FAILURE RECOVERY

NOT FAILUREPREVENTION

Scripts must be executed •Still experience failover•Cannot move apps from a failed server

Fault tolerance is the preferred solution

Integrated Redundant

& Fault-tolerant

Solution

No downtime or data loss

Simple integrated

solution

Easy to service

FAILURE PREVENTION

• No single points of failure

• Optimized for IA applications

© 2016 Stratus Technologies. All Rights Reserved. 11

Key considerations for modernizing an ICS

What is my tolerance for

unplanned downtime?

What hardware/application

protection do you need ?

Would an increased level of “9’s” generate savings

and/or increased productivity?

How do you restore normal application processing

and how does this affect your ROA?

How important is your (in-

flight) data?

Is there a seamless migration

path?

Are specialized skillsets

required?

Is the solution future-ready

with the best ROI?

Does data loss present risks for asset management

& IIoT analytics and/or regulatory requirements?

How much impact will an upgrade transition have to

your operations?

Does extensive (and costly) training have to be

factored in?

Will the system support new applications, such as

IIoT, does to have a 5-7+ year lifespan?

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Stratus customer

The Stratus solution

Active

service

network

• Automatic

re-synchronization

• Hot swap replacement

• Overnight delivery

• Automatic replacement part

ordering and shipment

• Automatic hardware

problem detection

• OPC

• Application monitoring

and re-start

• Continuous operation during failures

• Automatic Uptime Layer

• Integrated redundancy

On demand

Support

services

• Proactive

recommendations to

address problems

• Proactive notification of potential

problems (failure or performance)

• Constant monitoring of ftServer

generated notifications

• 24x7x365 access to IA IT experts

ftServer

© 2016 Stratus Technologies. All Rights Reserved. 13

Textiles

Fabricated metals

Machinery

Material handling

Printing

Automotive

Food and beverage

Pharmaceuticals

Cement

Metals and mining

Water and waste

Pulp and paper

Chemical

Oil and gas

Power generation

Refining

Petrochemicals

Industry classificationDiscrete vs. Continuous automation

Discrete

Continuous

Source: Morgan Stanley research

Serving customers in every IA segment

© 2016 Stratus Technologies. All Rights Reserved. 14

The continuous application availability market leader

• Protecting lives, assets and revenues since 1980

• Over 40 hardware and software availability patents

Corporate headquarters

Maynard, Massachusetts USA

Systems installed

20,000+ worldwide

Global presence ~500 people

Americas – EMEA – APJ

Robust financial profile

Stable revenues, cash and profit

Key Industrial Automation and technology partnerships

© 2016 Stratus Technologies. All Rights Reserved. 15

Case study – Pinellas County Utilities

Initial situation• Upgrade outdated automation systems

• Decreasing tax base

• Increased regulations

• Reduced resources

ResultsIncreased efficiency• Fault-tolerant virtualized platform eliminates

unplanned downtime

• Simple to operate and service - no IT expertise

needed for maintenance

• Data always available for regulatory scrutiny

Reduced costs• Single virtualized platform at each location

• Automated support model reduces equipment

monitoring saving manpower

• Single copy of s/w required controlling costs

Key issues• Multiple remote control rooms

• Cost effective solution to limit

server costs

• Prevent control room

“blindness” through unplanned

downtime

• No data loss to meet new EPA

regulations

• Integration into new IT

infrastructure

• Maximize efficiency

Workload managed• 71 million gals clear water

• 30 million gals waste water

• 4.2 million residents

• 24 communities

• 2,000 miles of pipe

• 13 field wells

• 5 surface water sources

• 3 wastewater facilities

• 350 lift stations

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Dependable Gas Transmission

Requirements

Meet new Control Room Management (CRM) regulations

Operational simplicity

Real-time analytics without data loss

Several catastrophic incidents led the company to examine their 15,000 miles of pipeline, spread across 16 states, which transports over 1 trillion cubic feet of natural gas per year

Chosen solution

Stratus® ftServer® platform

Operationally simple system to run virtualized applications remotely without

IT expertise and real-time analytics for complete operational visibility

Business impact

100% operational continuity

Zero downtime

Zero data loss

Solutions considered

Multiple servers at each compressor station

Virtualization solution with manual specialized maintenance

“We can get a lot more flexibility by adding applications in the compressor stations without the need for IT expertise.”

Lead Automation Electrical Engineer

© 2016 Stratus Technologies. All Rights Reserved. 17

Dairy Farmers of America

Requirements

Requirements

24x7 monitoring of entire stack

Total hardware redundancy

Enough capacity to run all VMs on one server

No defined life expectancy

Simple implementation

Producer of milk, ice cream and other dairy products, sports drinks and salsa for well-known brands

Chosen solution

Stratus ftServer 6410 system

ACP ThinManager running 15 virtual machines supporting:

• PlantPAx, HMI, FactoryTalk, EWS, Histortian, and more

Upgrade server architecture to standardize, ensure absolute availability and improve operation speed of Portales plant without interrupting operation

Business impact

Eliminated downtime

Improved efficiency of overall system

Lowered implementation cost

Widened IT infrastructure

Solutions considered

‘High-end’ Dell/IBM/HP server farm

Rockwell Automation’s server offerings

Low-end solutions such as “Why don’t we just go down to Walmart and buy some servers?”

“Hours and perhaps days of downtime have been eliminated by removing the unsupported PCs and replacing them.”

Eric Miller, Engineering Manager

Dairy Farmers of America

© 2016 Stratus Technologies. All Rights Reserved. 18

Next steps / Where to get more information

• Next Steps

• Conduct an assessment of your business objectives

• For more information or to schedule a live demo, contact Greg Paden at Greg.Paden@stratus.com or call (978) 461-7579

• Connect, follow, consume and have a conversation with us!

• Blog: www.stratus.com/stratus-blog/

• LinkedIn: www.linkedin.com/company/stratus-technologies

• Twitter: www.twitter.com/StratusAlwaysOn

• YouTube: www.youtube.com/user/StratusTech

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Questions?