Modernizing Control Architectures for Maximum Reliability
and Easy Management with Zero-Touch
Edge Computing
Organizations require a reliable, resilient, and modern computing solution for Monitor & Control applications that are mission-critical to their operations. Zero-Touch Edge Computing provides end users with an optimal platform to quickly modernize legacy control architectures, deploy industry-leading HMI/SCADA software on-machine, at the plant floor, in the control room, or at the operations center, and integrate best-in-class software to improve operational performance. Edge Computing platforms backed by high availability, fault tolerance, and security, ensure these critical applications run with no downtime or data loss.
For over 40 years, Stratus has been developing edge solutions that simplify, protect, and automate the digitally transforming world. By delivering zero-touch Edge Computing platforms that are simple to deploy and maintain, protected from interruptions and threats, and operate autonomously, Stratus ensures continuous availability for mission-critical applications.
The following 12 customer success stories showcase how organizations ranging from Oil & Gas to Specialty Chemical and Pharma leverage Edge Computing to modernize infrastructure, run mission-critical applications without downtime, and build future-proof control architectures for long term success.
-Up to 5,000 I/Os
-Up to 4 virtual machines
-High availability or fault tolerant
-UL Class I Div 2 certified
-100,000+ I/Os
-30+ virtual machines
- Automated uptime layer
-Fault tolerant
Midstream Oil & Gas Company
One of the largest independent liquid petroleum product pipeline operators in the U.S. owns and operates a diversified network of integrated assets providing trusted midstream logistic solutions. With a global terminal network composed of more than 100 liquid petroleum terminals, over 7,000 miles of domestic pipelines, and millions of barrels of tank capacity, the company required a reliable solution to help manage the complex distribution of petroleum-based products.
The company deployed and standardized Stratus Edge Computing running terminal automation software across more than 100 sites replacing legacy PCs and technologies, improving operational efficiency with remote monitor and control capabilities, and reducing costly unplanned downtime.
“As we looked at Stratus, their technologies, and digital transformation, we came to the agreement that we would continue to use their solution and would standardize that across our operational applications within the terminal space.”
Senior Manager of Terminal Operations
Midstream Oil & Gas Company
For the full story, check out How this large Midstream Oil & Gas Company standardized on Stratus Edge Computing Platforms to digitally transform terminal and pipeline automation.
Loginet & Petra Srl
Petra Srl owns and operates one of Italy’s largest oil depots, handling millions of liters of oil and gasoline and loading hundreds of trucks each day. To enable efficiency for depot operations, Petra runs Nuovo Petrol, a next-generation terminal automation solution from an experienced system integrator, Loginet. This solution controls and monitors all terminal procedures and processes – from access control and weigh stations to deliveries in the bays, and paperwork issuances.
With the Loginet solution and Stratus Edge Computing, Petra automated manual processes and integrated disparate terminal systems to reduce risk, enable real-time data, and centralize visibility of operations. The company reduced depot load times by 33% and has experienced zero downtime in a decade using Stratus Edge Computing.
“Petra hasn’t had an unplanned outage in 10 years. They’ve never experienced any business disruption with Stratus as their foundation. When our customers need that extreme level of reliability, we will continue to rely on Stratus for continuous computing.”
Gianluigi Campisano
Automation Engineer
Loginet
For the full story, check out How Stratus Edge Computing eliminated downtime and enabled depot-wide visibility with Loginet’s Next-Gen Terminal Automation Solution at Petra Srl.
Challenges
•Automate terminal operations to improve accuracy, ensure security, maximize safety, gain efficiency, and reduce costs
•Manage 35 tanks for oil-product storage, with approximately 5,000 tons of product shipped daily
•Operational visibility for analysis, alerting, and improvement
Solutions
•Stratus ztC Edge in paired fault tolerant configuration deployed in the control room
•Loginet Nuovo Petrol Terminal Automation System
•Loginet IBIS LT2 Badge Reader
•Loginet GraL Terminal
Benefits
•Reduced filling time by 33%
•Connected real-time operations to ERP and customs reporting
•Enabled depot-wide visibility into operations by unifying systems and ensuring data capture with Edge Computing
•Experience zero unplanned downtime for terminal automation system for 10 years using Stratus Edge Computing platforms
Streamline Innovations
Streamline Innovations develops and operates a proprietary process that removes toxic hydrogen sulfide (H2 S) in Oil & Gas, water, wastewater, landfills, and biogas. To succeed in the competitive oilfield services market, the company developed a visionary solution called the ValkyrieTM Intelligent Platform to bring AI-powered predictive maintenance, remote monitor and control of precise chemical processes and operations, and 99.5% uptime, to remote oilfield equipment.
The ValkyrieTM Intelligent Platform integrates an Ignition HMI/SCADA with Azure Cloud, MS Dynamics ERP, FOG instrumentation, PLC programming, AI/ML software, and more using a single ztC Edge Computing platform with built-in redundancy and virtualization. This offers high-precision process control with “tiered” intelligence to monitor and analyze performance of remote assets.
“We selected the Stratus ztC Edge because it provides redundant processing, high uptime, significant computing power, and virtual machines. This gave us the ability to replicate units across the field, by providing a VM of ignition and VM of the database separately on the same unit.”
Dr. Peter Photos
Chief Technology Officer
Streamline Innovations
For the full story, check out How Streamline Innovations uses Stratus Edge Computing to bring AI-powered predictive maintenance, remote operation, and 99.5% uptime to remote oilfield equipment.
Breton
Italy-based Breton is a leading manufacturer of equipment, machines, and plants that produce and process engineered stone, natural stone (marble, granite, and ornamental), and metals. The company modernized its infrastructure for Industry 4.0 manufacturing environments, where unplanned downtime is not an option and OT useability is critical to unburden IT.
With the goal to innovate their production processes and enhance their business performance, Breton focused on two key objectives: a solution that ensured business continuity and one that was easy for operators to deploy and manage. Partnering with Wonderware Italia, they incorporated Stratus ztC Edge, leveraging its easy-to-support high availability/fault tolerance and built-in virtualization to run AVEVA System Platform, HMI/SCADA, and historian applications.
“Stratus’ unique box of available technology — virtualization, redundancy, protection, security, customizable availability, and industrial interoperability — is a leap forward over traditional IPCs and server configuration.”
Michele Vario OEM and Business Development Director Wonderware Italia
For the full story, check out Breton Next-gen stone processing machines incorporate ztC Edge.
Challenges
• Eliminate unplanned machine downtime to enable business continuity for customers
• Reduce engineering and setup time to speed delivery to customers
• Empower OT with a simple compute infrastructure right on the production floor
Solutions
• Stratus ztC Edge deployed on the manufacturing floor
• AVEVATM System Platform
• System integration by Wonderware Italia
Benefits
• Consolidated four AVEVA applications onto a single ztC Edge compute platform through virtualization
• Improved customer experience by reducing installation and preparation times by eight hours
• Load to add VM images and system upgrades in 20 minutes
Bradbury
The Bradbury Group of manufacturing companies is dedicated to producing high-quality, productivity enhancing metal processing equipment for customers around the world. They needed a solution that readied their customers as well as their own operations for digitalization and efficiency.
By adopting the Stratus ztC Edge platform – running Rockwell Thin Manager® and FactoryTalk® – for their rolling machines, Bradbury Group moved from multiple standalone stations to a centralized distributed visualization platform which reduced costs, resolved downtime issues, and even discovered a new profit-driver for their business providing customer support services.
“ztC Edge is designed to provide remote application management, more rapid and efficient multi-site deployment, improved security, and high availability of critical business operations and applications.”
Craig Resnick Vice President
ARC Advisory Group
To learn more, check out the Bradbury Group case study snapshot.
Challenges
•Increased efficiency and flexibility of machines by adding compute capability
•Reduce development, deployment, and revision update times
•Increase customer uptime with quick replacement hardware, redundancy, and automated system backup
Solutions
•Stratus ztC Edge deployed on the plant floor
•Rockwell Automation ThinManagerTM
• Rockwell Automation FactoryTalk® View Site Edition
Benefits
•Eliminated unplanned downtime
•Used virtualization to consolidate workloads on a single ztC Edge computing platform
•Enabled support services as a new customer offering
•Reduced engineering and maintenance costs
Enginuity Global & QuarterNorth Energy
QuarterNorth Energy, a leading Oil & Gas producer that operates deep water, shallow, and shelf assets in the Gulf of Mexico, needed to modernize infrastructure and process control technology on its Bullwinkle oil platform – a project critical to improve safety and responsiveness, eliminate costly downtime, and drive operational excellence.
QuarterNorth Energy turned to Enginuity Global, an SI with expertise in process automation, control, and field services. In only 45 days, Enginuity upgraded all PLC panels and centralized monitor and control applications by running their Rockwell DCS, including HMI/SCADA and Rockwell Automation Factory Talk® Historian, with SQL Server supporting 6,000 I/Os, on a single, fault tolerant Stratus Edge Computing platform. This resulted in higher yield, improved safety, and a decrease in unplanned downtime.
“The ftServer is a tank. It offers a simplistic approach to a complex system. Part of our motto at Enginuity is, ’We simplify a complex world.’ And so, Stratus servers definitely help reduce some of that complexity. And, we were able to save a substantial amount of money using them.”
Eric Belgard
Lead for Automation and Controls
Enginuity
For the full story, check out How Enginuity Global modernized legacy control systems at QuarterNorth Energy's Bullwinkle Production Platform for operational excellence and safety in 45 days.
• Modernize oil platform’s legacy control systems and infrastructure
• Decentralized control systems
• Outdated servers, workstations, and controllers
• System response time in the tens of seconds slowed reaction time, decision making, and visibility on operations
• Control system/safety system at capacity
• Stratus ftServer deployed in the control room
• Rockwell Automation PlantPAx™ Distributed Control System (DCS) including HMI/SCADA and Factory Talk® historian with SQL Server supporting 6,000 I/Os
• Anti-virus and cluster management software
• System integration by Enginuity Global
• Consolidated 12 applications running on six (6) servers to a single, fault-tolerant Stratus ftServer compute platform
• Centralized monitor and control resulted in higher yield, improved safety, and no downtime for critical applications
• Improved system response time by 1,000%, from more than 20 seconds to milliseconds
Rubberlite
Rubberlite, a materials manufacturer specializing in manufacturing custom-engineered polyurethane foams and flexible composite systems, launched a Supervisory Control Systems Project with the goal of improving overall data quality, starting with standardizing their HMI/SCADA systems.
Running the AVEVA System Platform on a fault tolerant Stratus ftServer allowed Rubberlite to digitalize information, standardize data collection at the source to understand performance, and share that data plant-wide. With critical information and insights, Rubberlite was able to realize an 80% reduction in non-sellable material — critical for customer satisfaction and profit. They also eliminated application downtime and data loss.
Challenges
• Improve product quality for customer satisfaction, enable innovation for growth
• Eliminate downtime for SCADA applications
• Centralize recipe management for manufacturing repeatability
• Modernize compute infrastructure
• Reduce IT maintenance and labor costs
Solutions
• Stratus ftServer deployed in the control room
• Launch Supervisory Control Systems Project
“We have not had a single downtime event since [Stratus ftServer] has been running in March 2016.”
Process Automation Engineer
For the full story, check out How Stratus Edge Computing enabled Rubberlite to eliminate downtime, lower IT costs by 50%, and reduce non-sellable material by 80%.
• AVEVA™ System Platform on ftServer® for fully integrated DCS and data historian
Benefits
• Experienced no downtime since implementation in 2016
• Reduced non-sellable material production by 80%
• Increased sales by 25%
Rubberlite
Synthomer
London-based multinational specialty chemicals company, Synthomer, produces additives and raw materials for creating coatings, paper, textiles, and health and protection products. Previously, the company’s production facility in Piedmont, Italy was controlled by PLCs from different manufacturers operating independently in siloes. These islands of automation were difficult and expensive to maintain and operate.
In 2018, Synthomer modernized the plant’s disparate monitor and control system with an ftServer running Rockwell Automation PlantPAx® DCS, including HMI/SCADA, with the help of system integrator, Progecta. The project drove a considerable increase in production and revenue at the plant by creating a simple, standardized, and resilient system.
Challenges
• Centralize control of siloed PLC systems from different manufacturers
• Solve the expense and complexity of operating disparate PLCs
• Migrate to a distributed control system without shutting the plant down
Solutions
• Stratus ftServer deployed in the control room
• Rockwell Automation PlantPAx DCS
• System integration by Progecta
“Redundancy at the compute level matched with PlantPAx DCS redundancy at the control level, is a formidable combination for downtime prevention for mission-critical applications. By partnering with Rockwell Automation to characterize this joint solution, we’re delivering a massive leap forward for operations.”
Frank Hill Director Rockwell
Automation, Strategic Alliance at Stratus
To learn more, check out How Synthomer centralized and optimized operations with a Rockwell Automation DCS using Stratus ftServer.
Benefits
• 99.999% uptime with the fault-tolerant ftServer
• Vast availability of data empowers operators and fuels analytics
• 30% increase in production at the Piedmont facility
RoviSys
A leading life sciences company that manufactures cell biology, DNA, RNA, and protein analysis products needed to eliminate downtime and data loss to avoid costly disruptions and ensure regulatory compliance. In one week, RoviSys, a global system integrator specializing in automation, deployed Stratus Edge Computing platforms running Rockwell Automation PlantPAx®, including HMI, for three manufacturing sites.
The new production monitor and control architectures provided fault tolerance, simplified validation, converged OT and IT, and reduced TCO by 15-20% compared to a cluster solution. The life sciences company has experienced no downtime and is able to service the Stratus platforms without dedicated IT support.
Challenges
• Eliminate downtime and data loss in batch manufacturing for three sites of a life sciences company
• Ensure data reliability for FDA regulation, GMP, and VCAP
• Enable manufacturing operations team to maintain and support compute infrastructure without high-level IT support
Solutions
• Stratus ztC Edge deployed on the production line
• Stratus ftServer deployed in the control center
“With Stratus’ longevity and durability, and streamlined FAT/SAT verification, our customer has a top-performing, high-availability solution for the long haul.”
Network Engineer
RoviSys
For the full story, check out How RoviSys deployed Stratus Edge Computing to eliminate downtime and data loss, converge OT/IT, and reduce FAT/SAT from weeks to days for a life sciences company.
• Rockwell PlantPAx software for campus-wide production control
Benefits
• Eliminated downtime and consolidated software workloads
• Reduced FAT/SAT from weeks to hours; completed full validation in one week
• Reduced TCO by 15-20% and increased compute infrastructure lifespan to 15 years
DC Water
DC Water treats water and wastewater for 1.6 million people in the District of Columbia, as well as for neighboring counties in Maryland and Virginia. The company has the largest facility of its kind in the world, treating an average of nearly 290 million gallons per day, with a peak capacity of nearly 1 billion gallons per day. By operating one of the largest water utilities, it’s no surprise that a strong HMI/SCADA system is a non-negotiable requirement.
DC Water relies on the AVEVA System Platform running on a Stratus Edge Computing platform for secure, real-time automation, operations, and control of its water pumping stations, storage facilities, sewage pumping stations, stormwater pumping stations, and fabridams on the Potomac River. To provide continuous service on a massive scale, DC Water deployed a novel fault-tolerant Edge Computing architecture built on four Stratus ftServers spread across multiple locations to run their sophisticated SCADA systems.
“In our line of work, we need responsive support, and Stratus’s engineers are right alongside us on every issue. Even if it’s a non-urgent issue, they will call me to follow up until the issue is resolved. They’re very responsive and diligent — and that’s just what we want.”
Karen Green SCADA Manager
DC Water
To learn more, check out How DC Water architected Stratus Edge Computing platforms to provide double redundancy and reduce system failover time by 90%.
Challenges
•Deploy SCADA applications on resilient, fault-tolerant platform
•Provide reliable automated instrumentation for dozens of sites and facilities throughout the DC Water system
•Create real-time data for analysis and executive/ regulatory reporting
Solutions
•Stratus ftServer deployed in the control center
•AVEVA System Platform, InTouch, and Historian
•Rockwell PLC
•Schneider Electric PLC
Benefits
•Reduced system failover time for entire network to two minutes (90% less)
•Enabled fast access to timely data for KPI analysis and regulatory reporting
•No system downtime in six years, resulting in uninterrupted water supply to 1.6 million consumers
Quantum Solutions and St. Louis Airport
As a major transportation hub for 30 years, St. Louis Lambert International Airport is pursuing digital transformation initiatives to bring Industry 4.0 to aviation. Such modernization projects are critical for consumer experience and stakes are high.
Previously, projects had been piecemeal and disconnected, and limited to improving one area of the facility at a time. St. Louis Airport leveraged the expertise of Quantum Solutions, a system integrator, and installed Stratus Edge Computing running AVEVA software – including HMI/SCADA and Historian – integrating the different islands of automation into a complete and centrally connected facilities and building management system. This replaced their aging and disparate systems, accelerating digitalization at the airport.
“High availability is a big thing. When you're talking about moving an entire airport with multiple legacy siloed solutions over into one centralized system then you can't afford to have downtime.”
Jeremy Meahl
Regional Sales Engineer and Owner
Quantum Solutions
To learn more, check out Unified Operations Center powers successful digital transformation at St. Louis Lambert International Airport.
Challenges
• Modernize a decades-old operation, the largest and busiest airport in Missouri
• Deploy and scale compute infrastructure to optimize operations of more than 190,000 daily aircraft operations on four active runways, two terminals, and five concourses
• Support 15.6 million passengers and 74,000 tons of cargo per year
Solutions
• Stratus ftServer deployed in the control center
• AVEVA System Platform
• System integration by Quantum Solutions
Benefits
• Enabled situational awareness and unified operations center backed by easy-to-use fault tolerant computing
• Continuous availability for critical business applications
• Open and scalable software architecture
Dogfish Head
Dogfish Head is an award-winning microbrewery located in Milton, Delaware, that produces 262,000 barrels of beer in 12 varieties annually. The company had automated its unique hop-dosing process, but their solution became obsolete, resulting in unplanned shutdowns and cybersecurity risks.
Dogfish Head partnered with Stratus to ensure continuous availability for a new manufacturing execution system, fueling business growth and future-proofing the plant. With 24/7/365 monitoring and automated processes, such as predictive health alerts online parts replacement, the company has enhanced computing flexibility to keep growing in the brewing sector.
“With the solution that ProLeiT and Stratus have provided, we’re no longer limited by our automation system; we’re able to grow and the sky’s the limit.”
Liz Stairs
Process Improvement Specialist
Dogfish Head
For the full story, check out Dogfish Head Craft Brewery: International brewer makes downtime a thing of the past whilst preparing for the future.
Modernize
Your Monitor & Control Applications at the Edge
Stratus develops Edge Computing platforms that allow teams to capture critical data from edge locations and deploy multiple software applications in a single, purpose-built compute device with redundancy for reliability.
For mission-critical operations, leveraging benefits such as workload consolidation, operational resilience, downtime protection, and standardization ensures a more powerful, efficient, and secure monitoring and control solution.
For over 40 years, we have provided reliable and redundant zero-touch computing, enabling global Fortune 500 companies and small-to-medium sized businesses to turn data securely and remotely into actionable intelligence at the Edge, cloud, and data center – driving uptime and efficiency.