This thesis describes how to upgrade existing servers within the customer, whose primary business is the manufacture of cement, into two virtual VMware ESXi 6.0 with associated software. The decision to upgrade was accepted for several reasons. Originally, we wanted to solve costly and unnecessary maintenance with 22 different physical servers, downtime of the production system associated with a failure of any of these servers in the failure reporting systems tied to the server, where previously for the data collection Proficy Historian 3.5 was used. With the failure of the server, where the record of history is held, we are left without data for planned and ongoing consumption, because we were unable to get the balance of the cost for a particular prior period. At once we saved unnecessary costs, associated with the power consumption, caused by earlier servers, a lot of UPS systems and server cabinets cooling. We have also acquired new network connection by decreasing the number of servers required. Since the virtual server is connected via a cluster configuration, in the event of failure of one of the servers, we achieved continuous operation of the system with high availability. Servers are also separated on 2 locations and connected by fiber optic cable. Disk arrays and 10G switching network are duplicated and redundant so that with the failure of ones, the others immediately assume full operability. In this way we ensure a smooth production process, low maintenance costs, facilitate remote management of servers, easier future upgrades, security and reliability of the system, and lower costs of investment in new equipment. With all that is stated above, we cover workflow hardware shortfalls. However, at the software level, it was necessary to configure the switch upon failure of the active SCADA back to the backup. To resolving these problems, we have chosen a provider that has a history of experience with ensuring redundant SCADA system. On the same production side, we have installed servers with the old version of this service provider Proficy HMI/SCADA iFix 3.5, which we decided to upgrade to version 5.8. To facilitate transparency for operators, we decided to increase the resolution from 1280x1040 to 1920x1200 full HD. Instead of 10 physical computer clients we set 6, which access virtual servers via an Ethernet network. Switching between both SCADA systems is solved at the level of the virtual server, so that the operator does not even detect when the turnover between active and backup SCADA on the possible failure occurred. To resolve problems with archiving data on a virtual server, we installed three servers. Two are needed for the latest equipment for data archiving Proficy Historian version 6.0, which now contains a redundancy solution in the package of a Historian server. On one side Historian server and on the other his mirror node. All this is linked to the SQL server, which is installed on a third server. In this way we can make sure that the loss of any of these three servers does not lose the data required for processing. So I took care for all possible distractions to find a solution where the system and manufacturing processes operate smoothly after the failure of any of the above mentioned elements. Nevertheless, nothing can be done in certain situations, such as power loss (during the failure the system it is covered with UPS systems for a certain period of time). I see possibility for improvement mainly on a control unit, as we could order PLCs, which would be redundant to the existing ones and would cover the failure of the control unit. Unfortunately, this solution is economically unjustified and it was not our final decision.
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