Virtualization
Industrial Control System Virtualization for Process Applications
Through virtual Programmable Logic Controllers (vPLCs), HMIs, and other workstations, traditionally hardware-bound operational technology (OT) workloads can be run as software on standard servers. This allows for industrial control system (ICS) virtualization, where workloads can be tested, optimized, and reconfigured entirely virtually, bridging the gap between planning and commissioning.
Cross Company has been involved with virtualization in the controls industry since the beginning. In fact, we helped one of our partners, Siemens, with their very first installation in the United States, at a long-time customer’s distillery. And we can leverage that experience to offer ICS virtualization services to any of our process manufacturing partners.
How Process Virtualization Can Benefit Your Operation
Virtualization has many benefits in a process industry setting. While it’s not necessarily the way things have always been done, the tangible savings that can be realized is worth the effort to change.
Virtualization allows you to have more computers but take up less space. So if you have two servers, each with ten virtual machines on them, you actually have twenty computers in the footprint of two. This reduces hardware, utilities and maintenance time and cost.
It allows you to keep fewer spares, as you don’t have to have additional hardware just in case something breaks, reducing overall operating costs.
It’s also easier to do back ups by taking a snapshot at a particular time, just in case something gets corrupted in your control system. Not only does this reduce risk, but it helps you get back up and running faster.
In industrial environments, customers frequently have older operating systems which depend on certain hardware to work. Think Windows NT. And when you can’t get that specific hardware that works with Windows NT because it’s been obsolete for five years, it may be time to virtualize. Virtualization removes the hardware requirement because the software emulates the hardware, thereby decoupling the operating system from the underlying hardware, again reducing risk.
Virtualization is a convenient way to access and manage your computers. Instead of using a viewer to provide remote support access, like Team View or Microsoft Teams, there’s an inherent mechanism for you to access the individual virtual machines.
When a customer is doing a migration, virtualization lets them save money on computer hardware. ($6,000 for an industrial computer vs. $500 for a license. When you need 40 computers, this adds up!)
Once you’re on the Virtualization as a Service (VaaS), it’s very easy to manage and expand. If you need another computer, it’s as simple as getting another software license for a base computer
Benefits Of Process Virtualization
Cross’s Process Solutions Group uses virtualization themselves, providing several benefits to our customers. These include:
Increased Productivity and Accuracy
It allows us to do development on the equivalent of a customer’s system using only one laptop. We can code directly in a virtual version of your environment, making us more productive and more accurate.
Higher Quality Factory Acceptance Testing
For Factory Acceptance Testing (FAT), virtualization allows us to replicate the customer’s environment so we can have higher quality and more efficient acceptance testing.
Wider Support Capability
Virtualization allows us to support multiple versions of the same software system so when we are developing, we can have different versions of Siemens PCS7, for example, (corresponding to different customer’s systems) all on the same laptop.
Certifications
As mentioned earlier, we have been involved in virtualizations since Siemens brought their product to the USA. We’ve been doing virtualizations consistently since then so we are very familiar with the process.
Finally, we’ve developed best practices for installation to minimize downtime. A virtual system can take as little as just one to two days to install, whereas a physical system can take four or five times as long.
How Cross Can Help
If you believe virtualization can help you in either your greenfield project or your replacement/upgrade, Cross’s Process Solutions Group is the team to work with.
How Cross Can Help
If you believe virtualization can help you in either your greenfield project or your replacement/upgrade, Cross’s Process Solutions Group is the team to work with.
As mentioned earlier, we have been involved in virtualizations since Siemens brought their product to the USA. We’ve been doing virtualizations consistently since then so we are very familiar with the process.
Finally, we’ve developed best practices for installation to minimize downtime. A virtual system can take as little as just one to two days to install, whereas a physical system can take four or five times as long.
Offering Solutions From Leading Brands
How We Get It Right Every Time
Successfully executing a complex project like process control system upgrades, legacy control system migration, greenfield integration, or control system design takes more than guesswork. At Cross Company, we don’t believe in a “see what happens” approach.
That’s why we’ve developed a comprehensive project execution model to ensure every project flows perfectly, no matter the scope.
From Basis of Design (BOD) and/or Functional Design Specification (FDS) to Factory Acceptance Testing (FAT) to Start-Up and Commissioning, we detail and document every step of the process. That way, your project goes exactly as expected.
We can even provide initial documentation as a separate offering. Take a look at the full model or contact Cross Company’s Process Solutions group to learn more.
Why Cross Virtualization?
At Cross Process Solutions, we understand that each manufacturing operation is a unique entity with its distinct set of challenges and aspirations. Our approach is centered on providing customized solutions that align with your specific needs and goals, driving innovation across both your products and processes.
Embracing complete solutions for your process is not merely a choice but a necessity for businesses striving to thrive in the digital age. Whether you seek to enhance product quality, reduce costs, or minimize your environmental footprint, Cross Company Process Solutions has the tailored solutions to meet your unique needs.
Contact us today to embark on a journey toward operational excellence and sustainable success.
Related Solutions for Process Applications
At Cross, we offer much more than just process facility virtualization solutions. We can also provide the solutions our process manufacturing partners need to succeed. Check out our other process solutions equipment and see for yourself.
