White Paper

Leveraging Virtualization for Higher Business Continuity within Industrial Facilities

Author: Jim Frider, Product Marketing Manager, Invensys Operations Management

Whats Inside:
1. Executive Summary 2. Introduction 3. What is Virtualization? 4. History of Virtualization 5. Virtualization The Phases of Adoption 6. Benefits to IT, Operations and Engineering 7. Levels of Availability 8. Implementation Scenarios 9. Virtualization of ArchestrA System Platform and Wonderware InTouch Applications 10. Summary 11. Glossary of Virtualization Terms

Leveraging Virtualization for Higher Business Continuity within Industrial Facilities

1. Executive Summary
Virtualization offers the promise of lower IT costs and higher levels of business continuity for industrial companies. This paper provides a basic introduction to virtualization and how it can specifically benefit industrial companies. High availability and disaster recovery scenarios are presented along with expected system performance targets for system downtime after an event or system failure.

2. Introduction
Today, many of the worlds top companies are using software virtualization technology to deliver significant cost savings, improved efficiency, greater agility, enhanced system availability and improved disaster recovery capabilities. The typical industrial facility, including manufacturing plants, utilities and processing companies, has many important software applications that can be virtualized. Software like Human Machine Interface (HMI) applications, process data historians and manufacturing execution systems (MES) along with other analytical and reporting applications can all be virtualized. In this paper we will discuss what software virtualization is, its history, what benefits can be expected, and some typical ways to implement software virtualization.

3. What is Virtualization?
In simple terms, virtualization is the creation and employment of a virtual (software emulated) version of an actual version of something. Broadly speaking, virtualization can apply to physical devices, operating systems, network resources, device drivers or any actual thing for which a virtual equivalent can be substituted. Virtualization is a form of software abstraction, which allows users to manipulate the virtual versions of things in ways which would be impossible for their physical counterparts. It is this fundamental ability to manipulate the virtual versions of things that provides the power and flexibility to derive so many benefits from the use of virtualization technology. Hardware Virtualization Hardware virtualization employs software technology, like that offered by Microsoft and VMware, to transform or virtualize a computer to create a virtual computer that can run its own operating system and applications just like a physical computer. With virtualization, several applications and their required operating systems can run safely at the same time on a single physical computer with each having access to the resources it needs when it needs them. Today, this is all possible with commercial off-the-shelf computer hardware and operating systems. At the heart of the virtualization process is a software component called the hypervisor, a term first coined during the early IBM mainframe days. There are two general categories of hypervisor. Type 1 hypervisors run directly on the physical host hardware and manage guest or virtual machines so their operating systems can run concurrently on the physical host hardware. This is achieved by intercepting or trapping instructions from the guest operating systems and resolving them so that the guests function properly in their virtualized environment. VMware ESXi and Microsoft Hyper-V are examples of type 1 hypervisors. Conversely, type 2 hypervisors run on top of the host operating system and are not as commonly used with PC-based systems.

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Leveraging Virtualization for Higher Business Continuity within Industrial Facilities

Desktop Virtualization Besides the virtualization of industrial applications, another area of virtualization that is gaining momentum is the virtual desktop interface (VDI). Commonly used desktop applications and their required system resources are contained within a VDI and accessed from a network server. As none of the software runs on the users local machine, less costly computer equipment can be used. IT support responsibilities are reduced and the burden of data backup can be removed from the user. Besides the many IT related benefits, VDI users have the added benefit of being able to access their virtualized desktop from a variety of other devices including their smart phone, tablet or home computer. Virtualization Platforms Many companies are now using virtualization at the enterprise level to create entire virtualized computing infrastructures that allow IT departments to automatically deploy computing resources when and where they need them, with a minimum of manual IT intervention. Cloud-based implementations promise even more flexibility and economy by outsourcing computing resources to vendors such as Microsoft with their Azure platform as well as others. Virtualization platforms are already providing businesses of all kinds with tremendous IT cost savings and improved infrastructure utilization.

4. History of Virtualization
The high cost of mainframe computers in the 1960s led IBM engineers to develop ways to improve the efficiency of their equipment. By logically partitioning their machines they were able to offer multi-tasking. For the first time multiple applications could run at the same time significantly improving utilization. As low cost PC-based client-server architectures became the computing standard in the 1980s and 1990s the focus shifted to exploiting this new architecture by delivering more computing resources and applications to more users. Virtualization was not a technology considered by most IT departments. However, by the late 1990s the sheer number of servers and desktop machines reached the point where virtualization technology became viable as a cost reduction strategy. In 1999, VMware released their first virtualization products and by 2005 processors became available that directly supported virtualization. Today, a majority of large corporations are using virtualization to reduce their IT costs.

5. Virtualization The Phases of Adoption

Industrial companies often adopt virtualization technology in two phases; we will call them Virtualization 1.0 and Virtualization 2.0. Virtualization 1.0: In this first phase the emphasis is on IT and how virtualization can be used to lower IT costs, improve IT staff efficiency and improve hardware utilization. IT works on creating virtual machines of key applications and consolidating them on corporate servers. This first phase of virtualization allows companies to reduce their hardware costs, improve their server utilization and improve their ability to operate and maintain a wide range of software applications. IT service improves because IT takes on the responsibility for managing applications which have been reluctantly managed by the groups directly using the applications, like Operations or Maintenance. Human Machine Interface applications, process data historians and web report servers are examples. Virtualization 2.0: During the second phase of virtualization, companies often deploy multiple instances of the same application to ensure business continuity or to improve application performance via load balancing. For business continuity, multiple instances of an application, and the data servers furnishing it with data, are run simultaneously so that if the primary application or data server fails, the secondary application instance and data servers automatically take over and downtime is minimized. If simultaneous application instances are run on servers located in different physical locations, disaster recovery is much easier.

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Leveraging Virtualization for Higher Business Continuity within Industrial Facilities

Some applications can be run in load balancing mode when the processing load is shared across two or more virtual machines; improving the overall performance of the application without having to invest in a second physical server.

Figure A: Supervisory HMI System using Virtualization for High Availability

6. Benefits to IT, Operations and Engineering

Virtualization of industrial applications can benefit many groups within a business. Lets explore the benefits gained from virtualization based on business function, namely IT, Operations and Engineering. IT Benefits: There are three main areas of benefit from virtualization for the IT organization: COST REDUCTION Consolidation of Physical Servers virtualization allows much greater utilization of server hardware so fewer servers are required Energy Reduction fewer servers mean less energy is consumed in data centers Lifecycle Extension virtualized applications have a longer lifecycle because they are insulated from hardware or software technology shifts, generating more ROI for the business MANAGEMENT Hardware Upgrades fewer hardware upgrades are required over time, reducing capital expenditure requirements and IT workload Central Management the use of virtual machines facilitates centralized management of applications since fewer applications reside on local servers

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Leveraging Virtualization for Higher Business Continuity within Industrial Facilities

Fast Deployments self contained virtual machines can be easily deployed without having to install the required operating system, pre-requisite software or the application itself on a dedicated server Corporate Standard Libraries virtualized applications allow the creation of standardized application configurations that deliver maximum value to the business SUPPORT Virtual Desktops the use of virtual desktops allows much more efficient management of desktop machines Fast Deployment since application software doesnt reside on each desktop machine, new applications can be rolled out to a large number of users much faster More Effective Backup Procedure all data stays on corporate or cloud servers allowing more sophisticated backup operations to effectively eliminate data loss OPERATIONS BENEFITS: Business Continuity multiple instances of the same virtual machine can run in an automatic failover mode to help ensure business continuity. If the failover instance is located in a separate physical location disaster recovery is also enhanced Operational Cost reduction in physical server footprint leading to a higher return on capital and a reduction in the Mean Time To Recover (MTTR) Support thin client PCs on the plant floor running virtual desktops reduce the support burden and can be maintained by IT not Operations ENGINEERING BENEFITS: Development Costs virtualization lowers engineering infrastructure costs since fewer physical servers are required with fewer modifications needing to be made over time to keep applications running properly. Development Speed virtualized instances of object-based applications, like ArchestrA System Platform, can be developed and deployed faster than conventional applications Collaboration since multiple instances of a virtual machine can run at the same time developers can work in a more collaborative and efficient manner

7. Levels of Availability
When we speak about a high availability solution we typically mean a solution with redundant software and/or hardware components that failover to an unaffected system to enable a pre-defined level of availability over a specific time frame. Levels of availability are detailed below. Availability
Level 0 Level 1 Level 2

Description
No redundancy Cold Stand-by High Availability (HA)

Expected Failover
None Availability: 99% Expected Downtime: 4 days/yr Availability: 99.9% Expected Downtime: 8 hrs/yr Availability: 99.99% Expected Downtime: ~52 mins/yr Availability: 99.999% Expected Downtime: <5 mins./yr

Details
No redundancy built into the system architecture. Primary and secondary systems, manual failover to secondary system, data periodically synchronized. Virtualization used for primary and secondary systems. Disaster recovery (DR) via virtual machine systems located in geographically separate locations. Full synchronization of primary and secondary systems . Fault tolerant hardware, lock step failover to redundant application instance.

Level 3 Level 4

Hot Redundancy Fault Tolerant

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Leveraging Virtualization for Higher Business Continuity within Industrial Facilities

8. Implementation Scenarios
High Availability Implementations It is possible to achieve Level 2 or even Level 3 availability for applications like HMI and Supervisory Control using two, preferably identical, hardware servers (bought at the same time) each loaded with an identical virtual machine. Identical hardware and virtualized applications help ensure that if a failover occurs there are no deviations in system performance resulting from differences in hardware or software. To achieve Level 4 availability usually requires an investment in fault tolerant hardware, including servers, disk systems, power supplies and network cards. At this availability level downtime is reduced to very low levels; less than 5 minutes per year, for example. The performance of any high availability (HA) solution is dependent on the quality and implementation of the HA architecture.

Figure B: High Availability Architecture using virtual machines for automated failover.

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Leveraging Virtualization for Higher Business Continuity within Industrial Facilities

Disaster Recovery Implementations With the risk of natural disasters and a growing threat from terrorism, many industrial companies are exploring ways to recover faster from possible catastrophic disasters. Virtualization provides a realistic and practical way to recover critical applications and their associated data more quickly and economically. Like High Availability, if identical physical servers and identical virtual machines are run together in failover mode, but located in different geographic locations, a Level 2 or Level 3 availability can be achieved.

Figure C: Disaster Recovery Architecture using virtualization located in geographically separated locations.

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Leveraging Virtualization for Higher Business Continuity within Industrial Facilities

High Availability Combined with Disaster Recovery The goal of a High Availability and Disaster Recovery (HADR) solution is to provide a mechanism to automatically shift data processing and retrieval for a critical industrial application to a standby system; for normal failure scenarios to a standby system in the same facility or, in the event of catastrophic events, to a standby system located in a different geographic location. By combining High Availability and Disaster Recovery architectures, industrial applications can be made highly available and able to quickly recover from a disaster.

Figure D: High Availability and Disaster Recovery Architecture using virtualization techniques.

9. Virtualization of ArchestrA System Platform and Wonderware InTouch Applications

ArchestrA System Platform and Wonderware InTouch 2012 are certified on both VMware ESXi 5 and Microsoft Hyper-V. From the previous discussion, two virtualization scenarios provide significant value for HMI and Supervisory applications: High Availability and Disaster Recovery. These virtualization scenarios focus on keeping productive processes up and running and protecting the valuable data generated from HMI and Supervisory systems. System performance during an event is largely dependent on the system architecture used. To help you understand best practices for high availability and disaster recovery for HMI and Supervisory applications using Wonderware InTouch and ArchestrA System Platform, please consult the ArchestrA System Platform Virtual Implementation Guide found on the Wonderware Developer Network website.

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Leveraging Virtualization for Higher Business Continuity within Industrial Facilities

10. Summary
Todays virtualization software solutions from Microsoft, VMware and other vendors provide a cost effective way to improve the availability and disaster recovery capabilities of critical, industrial applications such as HMI and Supervisory systems. Standard, off the shelf computer hardware and software can be used to lower costs and reduce the level of expertise needed to implement these types of solutions. Any manufacturer, processor or utility needs to evaluate these new approaches so that they too can mitigate risks and ensure continuity at their facilities.

11. Glossary of Virtualization Terms

Child partition partitions made by the hypervisor in response to a request from the parent partition. There are a couple of key differences between a child partition and a parent/root partition. Child partitions are unable to create new partitions. Child partitions do not have direct access to devices (any attempt to interact with hardware directly is routed to the parent partition). Child partitions do not have direct access to memory. When a child partition tries to access memory the hypervisor / virtualization stack re-maps the request to different memory locations. Clone A VM clone is an exact copy of a VM at a specific moment in time. The most common use of a VM clone is for mass deployment of standardized VMs, called VM templates. VM clones also come in handy for test and development; because they allow use of a real workload without affecting the production environment. A VM clone is not appropriate for backup, disaster recovery, or other data protection methods. Clustered file system A clustered file system organizes files, stored data, and access for multiple servers in a cluster. Clustered file systems are most useful when clusters work together and require shared access, which individual file systems do not provide. A Windows or Linux clustered file system can also identify and isolate defective nodes in a cluster. A Windows clustered file system will isolate the node logically, while a Linux clustered file system will use a utility to power down the node. External virtual network A virtual network that is configured to use a physical network adapter. These networks are used to connect virtual machines to external networks. See also internal virtual network, private virtual network. Failover In server clusters, failover is the process of taking resource groups offline on one node and bringing them online on another node. Guest operating system This is the operating system/runtime environment that is present inside a partition. Historically with Virtual Server / Virtual PC, in a host operating system and a guest operating system the host ran on the physical hardware and the guest ran on the host. In Hyper-V, all operating systems on the physical computer are running on top of the hypervisor so the correct equivalent terms are parent guest operating system and child guest operating system. Many find these terms confusing and instead use physical operating system and guest operating system to refer to parent and child guest operating systems, respectively. Guests and hosts A guest virtual machine and host server are the two main building blocks of virtualization. The guest virtual machine is a file that contains a virtualized operating system and application, and the host server is the hardware on which it runs. The other important component is the hypervisorthe software that creates the guest virtual machine and interacts with the host server. The hypervisor also makes the host server run multiple guest virtual machines. Hypervisor The hypervisor is the lowest level component that is responsible for interaction with core hardware. It is responsible for creating, managing, and destroying partitions. It directly controls access to processor resource and enforces an externally-delivered policy on memory and device access. Live migration Virtual machine live migration is the process of moving a VM from one host server to another without shutting down the application. The benefits of virtual machine live migration are some of the biggest selling points for virtualization, affecting business continuity, disaster recovery, and server consolidation. Virtual machine live migration is a feature in all of the major virtualization platforms, including VMware vSphere, Microsoft Hyper-V R2, and Citrix Systems XenServer.

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Leveraging Virtualization for Higher Business Continuity within Industrial Facilities

Logical processor This is a single execution pipeline on the physical processor. Earlier, if someone told you that they had a twoprocessor system, you would know exactly what they had. Today, if someone told you they had a two-processor system, you do not know how many cores each processor has, or if hyper threading is present. A two-processor computer with hyper threading would actually have four execution pipelines, or four logical processors. A two-processor computer with quad-core processors would, in turn, have eight logical processors. Network virtualization Network virtualization lets you combine multiple networks into one, divide one network into many and even create software-only networks between VMs. The basis of network virtualization is virtual network software, to which there are two approaches: internal and external. Internal network virtualization uses virtual network software to emulate network connectivity among VMs inside a host server. External network virtualization uses virtual network software to consolidate multiple physical networks or create several virtual networks out of one physical network. Parent partition The parent partition can call the hypervisor and request for new partitions to be created. There can only be one parent partition. Partition A partition is the basic entity that is managed by the hypervisor. It is an abstract container that consists of isolated processor and memory resources with policies on device access. A partition is a lighter weight concept than a virtual machine and could be used outside the context of virtual machines to provide a highly isolated execution environment. Physical computer The computer, or more specifically, the physical hardware that is running a virtual machine. Physical processor The physical processor chip found in a physical computer. Processor topology This is the concept by which your logical processors correlate to your physical processors. For example, a two processor, quad-core system and a four-processor, dual-core system both have eight logical processors but they have different processor topologies. Root partition This is the first partition on the computer. This is the partition that is responsible for starting the hypervisor. It is also the only partition that has direct access to memory and devices. Saved state A manner of storing a virtual machine so that it can be quickly resumed (similar to a hibernated laptop). When you place a running virtual machine in a saved state, the virtualization software stops the virtual machine, writes the data that exists in memory to temporary files, and stops the consumption of system resources. Restoring a virtual machine from a saved state returns it to the same condition it was in when its state was saved. Snapshot A VM snapshot backup is the most common way to protect a virtual machine. A VM snapshot is a copy of the state of a VM (and any virtual disks assigned to it) as it exists in server memory at a specific moment. The snapshot is usually saved to the SAN, where it can be recovered in case of a failure. Regular VM snapshot backups can significantly reduce recovery point objectives. Storage area network (SAN) A set of interconnected devices, such as disks and tapes, and servers that are connected to a common communication and data transfer infrastructure, such as fiber channel. Storage virtualization Storage virtualization separates the operating system from physical disks used for storage, making the storage location independent. The benefits of storage virtualization include more efficient storage use and better management. Dynamic provisioning is similar to storage virtualization, but it still requires more traditional storage management. Virtual hardware The computing resources that the host server assigns to a guest VM make up the virtual hardware platform. The hypervisor controls the virtual hardware platform and allows the VM to run on any host server, regardless of the physical hardware. The virtual hardware platform includes memory, processor cores, optical drives, network adapters, I/O ports, a disk controller and virtual hard disks. Virtualization lets a user adjust the levels of these resources on each VM as needed. Virtual machine A virtual machine (VM) is a file that includes an application and an underlying operating system combined with a physical host server and a hypervisor to make server virtualization possible. A virtual machine is a super-set of a child partition.

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A virtual machine is a child partition combined with virtualization stack components that provide functionality, such as access to emulated devices, and features like being able to save the state of a virtual machine. As a virtual machine is essentially a specialized partition, the terms partition and virtual machine are often used interchangeably. But, while a virtual machine will always have a partition associated with it, a partition may not always be a virtual machine. Virtual machine snapshot A virtual machine snapshot is a point in time image of a virtual machine that includes its disk, memory and device state at the time that the snapshot was taken. At any time it can be used to return a virtual machine to a specific moment in time. Virtual machine snapshots can be taken irrespective of the state or type of child guest operating system being used. Virtual network A virtual version of a physical network switch. A virtual network can be configured to provide access to local or external network resources for one or more virtual machines. Virtual processor A virtual processor is a single logical processor that is exposed to a partition by the hypervisor. Virtual processors can be mapped to any of the available logical processors in the physical computer and are scheduled by the hypervisor to allow you to have more virtual processors than you have logical processors.

Invensys Operations Management 5601 Granite Parkway III, #1000, Plano, TX 75024 Tel: (469) 365-6400 Fax: (469) 365-6401 iom.invensys.com Invensys, the Invensys logo, ArchestrA, Avantis, Eurotherm, Foxboro, IMServ, InFusion, SimSci-Esscor, Skelta, Triconex, and Wonderware are trademarks of Invensys plc, its subsidiaries or affiliates. All other brands and product names may be the trademarks or service marks of their representative owners. 2012 Invensys Systems, Inc. All rights reserved. No part of the material protected by this copyright may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying, recording, broadcasting, or by any information storage and retrieval system, without permission in writing from Invensys Systems, Inc.

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