Methods and apparatus to virtualize a process control system

Abstract

Methods and apparatus to virtualize a process control system are described. A described process control system includes a server cluster including one or more servers. When operating, the server cluster provides a virtual workstation or virtual server, a virtual controller to interoperate with the virtual workstation or server and to implement process control operations, and a virtual input/output device to interoperate with the virtual controller and coupled to one or more field devices within the process control system.

What is claimed is: 
     
         1 . An apparatus comprising:
 at least one memory;   instructions; and   processor circuitry to execute the instructions to:
 virtualize a workstation for a process control system, the workstation virtualized using a first physical server in a server cluster of at least two servers; 
 virtualize an input/output device for the process control system, the input/output device to run in a fault tolerant mode; 
 cause the virtualized input/output device to interoperate with a virtual controller in communication with the workstation, the virtualized input/output device to be communicatively coupled to a field device in the process control system, the field device to receive a control signal from the virtual controller; 
 provide a remote access user interface for the workstation, the remote access user interface including at least one of an operator interface, a diagnostics interface, or a configuration interface; and 
 in response to a maintenance action initiated via the remote access user interface, cause migration of the workstation to a second physical server in the server cluster different than the first physical server, the workstation to maintain communication with the virtual controller during the migration. 
   
     
     
         2 . The apparatus of  claim 1 , wherein the processor circuitry is to execute the instructions to migrate the workstation without loss of data and without a communications interruption between the workstation and the virtual controller. 
     
     
         3 . The apparatus of  claim 1 , wherein the processor circuitry is to execute the instructions to cause the migration of the workstation via a redundant back plane that includes a virtualized switch. 
     
     
         4 . The apparatus of  claim 1 , wherein the control signal includes at least one of a 4-20 mA analog input signal, a 4-20 mA analog output signal, a 24 VDC discrete input signal, or a 24 VDC discrete output signal. 
     
     
         5 . The apparatus of  claim 1 , wherein the processor circuitry is to execute the instructions to:
 provide the remote access user interface via a remote desktop service that stores user information on a storage area network; and   cause transmission of data from the workstation to the storage area network.   
     
     
         6 . The apparatus of  claim 1 , wherein the field device corresponds to at least one of a valve, a valve positioner, an actuator, a motor, or a sensor transmitter. 
     
     
         7 . The apparatus of  claim 1 , wherein the processor circuitry is to execute the instructions to launch guest operating systems corresponding to ones of the workstation, the virtual controller, and the virtualized input/output device, at least one of the guest operating systems being a real-time operating system. 
     
     
         8 . A computer readable storage device or storage disk comprising instructions which, when executed, cause processor circuitry to:
 virtualize a workstation for a process control system, the workstation virtualized using a first physical server in a server cluster of at least two servers;   virtualize an input/output device for the process control system, the input/output device to run in a fault tolerant mode;   cause the virtualized input/output device to interoperate with a virtual controller in communication with the workstation, the virtualized input/output device to be communicatively coupled to a field device in the process control system, the field device to receive a control signal from the virtual controller;   provide a remote access user interface for the workstation, the remote access user interface including at least one of an operator interface, a diagnostics interface, or a configuration interface; and   in response to a maintenance action initiated via the remote access user interface, cause migration of the workstation to a second physical server in the server cluster different than the first physical server, the workstation to maintain communication with the virtual controller during the migration.   
     
     
         9 . The computer readable storage device or storage disk of  claim 8 , wherein the instructions, when executed, cause the processor circuitry to cause the migration of the workstation without loss of data and without a communications interruption between the workstation and the virtual controller. 
     
     
         10 . The computer readable storage device or storage disk of  claim 8 , wherein the instructions, when executed, cause the processor circuitry to cause the migration of the workstation via a redundant back plane that includes a virtualized switch. 
     
     
         11 . The computer readable storage device or storage disk of  claim 8 , wherein the control signal includes at least one of a 4-20 mA analog input signal, a 4-20 mA analog output signal, a 24 VDC discrete input signal, or a 24 VDC discrete output signal. 
     
     
         12 . The computer readable storage device or storage disk of  claim 8 , wherein the instructions, when executed, cause the processor circuitry to:
 provide the remote access user interface via a remote desktop service that stores user information on a storage area network; and   cause transmission of data from the workstation to the storage area network.   
     
     
         13 . The computer readable storage device or storage disk of  claim 8 , wherein the field device corresponds to at least one of a valve, a valve positioner, an actuator, a motor, or a sensor transmitter. 
     
     
         14 . The computer readable storage device or storage disk of  claim 8 , wherein the instructions, when executed, cause the processor circuitry to launch guest operating systems corresponding to ones of the workstation, the virtual controller, and the virtualized input/output device, at least one of the guest operating systems being a real-time operating system. 
     
     
         15 . A method comprising:
 virtualizing, by executing an instruction with processor circuitry, a workstation for a process control system, the workstation virtualized using a first physical server in a server cluster of at least two servers;   virtualizing, by executing an instruction with the processor circuitry, an input/output device for the process control system, the input/output device to run in a fault tolerant mode;   causing, by executing an instruction with the processor circuitry, the virtualized input/output device to interoperate with a virtual controller in communication with the workstation, the virtualized input/output device to be communicatively coupled to a field device in the process control system, the field device to receive a control signal from the virtual controller;   providing, by executing an instruction with the processor circuitry, a remote access user interface for the workstation, the remote access user interface including at least one of an operator interface, a diagnostics interface, or a configuration interface; and   in response to a maintenance action initiated via the remote access user interface, causing, by executing an instruction with the processor circuitry, migration of the workstation to a second physical server in the server cluster different than the first physical server, the workstation to maintain communication with the virtual controller during the migration.   
     
     
         16 . The method of  claim 15 , wherein the causing of the migration of the workstation is accomplished without loss of data and without a communications interruption between the workstation and the virtual controller. 
     
     
         17 . The method of  claim 15 , wherein the causing of the migration of the workstation is accomplished via a redundant back plane that includes a virtualized switch. 
     
     
         18 . The method of  claim 15 , wherein the control signal includes at least one of a 4-20 mA analog input signal, a 4-20 mA analog output signal, a 24 VDC discrete input signal, or a 24 VDC discrete output signal. 
     
     
         19 . The method of  claim 15 , further including:
 providing the remote access user interface via a remote desktop service that stores user information on a storage area network; and   causing transmission of data from the workstation to the storage area network.   
     
     
         20 . The method of  claim 15 , further including launching guest operating systems corresponding to ones of the workstation, the virtual controller, and the virtualized input/output device, at least one of the guest operating systems being a real-time operating system.