OPC UA Inside Out Part 5 - Cloud Connectivity

© Utthunga Technologies Pvt. Ltd. 2020
OPC UA Inside Out
Part 5 – Cloud Connectivity
Utthunga for OPC

Company Overview
Germany
500+
Professionals
USA
Japan 12
HQ & Development Centre
Bangalore India
SERVICES SOLUTIONSFOCUS
Embedded
Software &
Hardware
Product
Engineering
Digital
Services
Application
Software
Engineering
Quality
Engineering
Process &
Factory
Power &
Utilities
IIoT, Cloud &
Big Data
Analytics
Solutions
Data
Connectivity
& Integration
Solutions
Custom
Solutions
Utthunga for OPC

Industry Associations
 Part of various Special Interest Groups (Technical Specifications, Architecture,
Test & Certification and Marketing)
 Involved in reference Application Architecture, Design and Development
 Technology Outsourcing Partner
 PROFIBUS and PROFINET Competency Center
 FDT Test & Certification Center
 Part of Global Expert/Certified Community
Utthunga for OPC

Speakers for Today
About Speaker
 Srivatsa is a seasoned enterprise architect, engineering lead and entrepreneur with a
total of 22 years of experience in various start-ups and established corporates.
 His interest areas are Industrial IoT, Digital Transformation, Artificial Intelligence,
ML/Algorithms, Cloud and Analytics.
 His entrepreneurial, mentoring and innovation-seeking spirit has helped in conceiving,
designing and delivering several products across varied domains like banking,
aerospace, legal, retail and telecom.
 His rich expertise in software architecture, delivery, product management, telecom
network management, system integration, OSS, cloud, mobility, managed
services/XaaS, analytics, AI and IIoT has helped him build strong teams to develop
products leveraging heterogeneous technologies across domains.
Utthunga for OPC
Srivatsa Gorur

Speakers for Today
About Speaker
 Vaageesh is Utthunga’s IIoT specialist with an overall 7+ years in Industrial Automation
and IIoT domain.
 Possessing a strong working knowledge on OPC UA and IIoT, he has been instrumental in
providing cloud solutions to industries in their IIoT/Industry 4.0 journey.
 As an active member of Utthunga's IIoT Platform development, Vaageesh is experienced
in IIOT communication and Industrial protocols like Modbus, DLMS, BACnet, MQTT, etc.
 His software development journey includes providing IIoT solutions like AMR/AMI,
Process Digitization, Productivity Optimization.
Utthunga for OPC
Vaageesh R Bhat

4. OPC Communication Models
3. OPC UA as a standard communication enabler
2. Cloud models & connectivity scenarios
1. Introduction – OPC, IIOT & Cloud
6. Demo of an OPC UA based IIOT Solution
5. Use Cases
Agenda
7. Q & A
Utthunga for OPC

Introduction – OPC, IIOT & Cloud
OPC (Open Platform Communications)
 Original standard in 1996 by Industrial automation task force
 Interface to communicate between like devices on factory floor,
laboratory equipment, test systems/fixtures and
databases/historians
 Primarily a client-server based communication
 Secure and reliable exchange of data for Industrial Automation and
IOT
 Vendor neutral and enables interoperability
 Latest version is OPC Unified Architecture and earlier version is
called OPC Classic
 Classic consists of Data Access (DA), Alarms & Events (AE), Historical
Data Access (HAD) and Data eXchange (DX)
 OPC UA standardized as IEC 62541 and is recommended by RAMI
4.0 for Industry 4.0
Utthunga for OPC
 IEC 62541 defines parts for Address Space Model (IEC 62541-03),
Services (-04), Information Model (-05), Mappings (-06), Profiles (-
07), Data Access (-08), Alarms & Conditions (-09) and Programs (-
10) plus Historical Access (-11), Aggregates (-13) and Device
Integration (-100)
OPC
Client
OPC
Server
Control devicePLC

Introduction – OPC, IIOT & Cloud
Utthunga for OPC
IIOT (Industrial Internet Of Things) & Cloud
 Application of IoT for industrial applications in Agriculture, Oil &
Gas, Manufacturing, Pharmaceuticals, Food & Beverages, Specialty
Chemicals, Iron & Steel, Automobiles, Health Care, Logistics,
Utilities and so on
 Interconnection of computing devices, mechanical and digital
machines to transfer data over a network without requiring human
interaction
 Each object is provided with a unique identifier
 Focuses on Low cost Connectivity, M2M, Sensors, AI/ML, Cloud and
Big Data
 Some of the major challenges to digital transformation are Security,
Interoperability, Data management, Legacy installations,
Significant upfront investment, Lack of skilled staff and Unclear
ROI
IIOT

4. OPC Communication models
3. OPC UA as an open and standard communication enabler
5. Use Cases
Agenda
7. Q & A
Utthunga for OPC

Cloud Models & Connectivity
Utthunga for OPC
OPC UA and ISA 95 model
 OPC foundation has released
OPC UA 95 companion
specification, which adds ISA-95
object model representations of
equipment, personnel, material,
and physical assets
 Low cost connectivity, faster
networks, smarter devices, and
the need for interoperable
software applications are critical
for Industry 4.0. Every node in
this architecture has to expose
information using standard
exchange models.
Level 4
Business Process Information
Network
(ERP, APO, Logistics Systems)
Level 3
Operations Information Network
(MES, LIMS, WMS, CMM)
Level 2
Automation Network
(Batch Systems, HMI, SCADA, DCS, PLC)
Level 1
Discrete & Process Devices
Communication Network
(I/Os, Devices, Sensors, Actuators
Information
Technology
Information
Technology
Operational
Technology
Operational
Technology
Enterprise
Zone
Mfg
Zone

Cloud Models & Connectivity
OPC UA and ISA 95 model
(cont’d)
 Publish/subscribe protocols, such
as those in the OPC UA Part 4
specification and the IEC 62541
standard, and those defined in
ISA-95 Part 6: Message Service
Model eliminate the need for
master-slave polling protocols.
Software applications and
devices become data subscribers.
 Any application or device can
implement functions associated
with multiple activity levels of
ISA-95 model
Level 4
Business Process Information
Network
(ERP, APO, Logistics Systems)
Level 3
Operations Information Network
(MES, LIMS, WMS, CMM)
Level 2
Automation Network
(Batch Systems, HMI, SCADA, DCS, PLC)
Level 1
Discrete & Process Devices
Communication Network
(I/Os, Devices, Sensors, Actuators)
Information
Technology
Information
Technology
Operational
Technology
Operational
Technology
Enterprise
Zone
Mfg
Zone
Utthunga for OPC

Cloud Models & Connectivity – Private Cloud / MPLS / On Premise
Utthunga for OPC
Plant-A Floor Network
OPC client
OPC Server IOT Gateway
Firewall
PLC
Controller
Motor, Analog/Digital, Sensors, Field Devices
Plant-A Operations Network
MES Local Historian
Edge Platform
Firewall
Plant-B Floor Network
OPC client
OPC Server IOT Gateway
Firewall
Controller
Plant-B Operations Network
MES Local Historian
Edge Platform
Firewall
RTDBMS RTDBMS
OT Network
Corporate/IT Network
Corporate/IT Network
ERP
Central Historian
Work Stations
IIoT Platform
Private
Cloud/MPLS,
OPC And
Historian
Enabled Solution
Architecture
Factory
Floor
PLC PLC
PLC PLC PLC
Enterprise
/
Corporate
HQ

Cloud Models & Connectivity – Public Cloud & Wireless for Remote Sites
Utthunga for OPC
IOT Gateway
OPC Server
IOT Gateway
Firewall
Controller
Plant-A Operations Network
MES Local Historin
Firewall
RTDBMS
Private/ Public Cloud
Cloud Solution
Architecture
with Wired and
Wireless
communication
from plants
MQTT Message Broker
OPC Server Controller
IOT Gateway
IOT Gateway
IIoT Cloud Platform
ERP
3G/4G
Factory
Floor
Enterprise
/
Corporate
HQ
OPC client
Plant-B Operations Network
PLC PLC PLC
PLC PLC PLC

Cloud Models & Connectivity – OPC UA for Large Deployments
Utthunga for OPC
Large Multi-
Site,
Regional/Zon
al and
Enterprise
Deployment
Sites
Production
Zones / Regions
Corporate
Command Control
Center
Enterprise
Region X
Site 1
Site 2
Region Y Site 3
Plants
Plant A
Plant B
Plant C
Plant D
Public / Private Cloud LAN, Field NWsWAN/LAN, Field NWsWAN, Pub/Pri Cloud
O
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DMZSecure
ERP

Cloud Models & Connectivity – OPC UA & Cloud Security
Security in OPC UA
 Is secure by design and specifications provided in Part-
2 (Security Model), Part-4 (Services), Part-6 (Service
Mappings), Part-7 (Profiles) and Part-12 (Discovery)
 Allows different levels of security
 Is flexible and extensible
OPC UA Security Model
 Application Authentication
 User Authentication
 User Authorization
 Availability
 Auditability
Utthunga for OPC
Confidentiality
Integrity
CIA
Availability

Cloud Models & Connectivity – OPC UA & Cloud Security
Security in Public Cloud
 Leverages security built and managed by the Cloud Provider
 Up to date as vendors have a focus on latest Security events
 Cost effective, can Scale quickly
 More suitable for SaaS applications that do not store user
confidential and sensitive data
 Application security still lies with companies hosting them
 Less flexible for specific customizations
Security in Private Cloud/On Premise
 Local ownership including infrastructure security
 Staying up-to-date with hardware, hypervisors, virtualization
software and operating systems and patches
 Comparatively higher OpEX and CapEx
 More Secure for sensitive data
 Flexible for customized security whether it is for specific
business or compliance
Utthunga for OPC
Migrating to Cloud
 Choosing a right vendor based on requirements, sizing
and business model
 Adhering to Industry defined Security best practices
 Establishing a proper process and cloud governance
 Enforcing strict access control policies and real time
tracking for violations and vulnerabilities
 Auditing of computing devices, networks, services, APIs
and so on periodically
 Deployment of appropriate security software to protect
data and applications
 Using Automation and AI/ML techniques for identifying
intrusions and protecting data
 Restricting user sensitive and confidential data on cloud
 Security education and training for employees

4. OPC Communication models
5. Use Cases
Agenda
7. Q & A
Utthunga for OPC

OPC UA as a standard communication enabler
Utthunga for OPC
Challenge for Industry 4.0/IIoT
 Secure and standard data exchange between devices and service
 Heterogenous network of devices on the shop floor
 Machine manufacturers' proprietary communication protocol
 In 2015, RAMI 4.0 recommended IEC 62541 standard OPC UA for
implementing IIOT communication layer
Vendor A Vendor B
HART
Driver
Modbus
Driver
Profibus
Driver
OPC Server
OPC Client OPC Client OPC Client

OPC UA as a standard communication enabler
Utthunga for OPC
Why OPC UA for Industry 4.0 journey?
 Independence of Protocol, Platform, Manufacturer for data exchange
 Comprehensive Information Modeling
 Enable once, use forever
 Enables autonomous Horizontal and Vertical secured communication
 Transport Level Security
 User Level Security
 Application Level Security
 Scalability
 Adaption
 Independence from physical transport medium and the transport
protocol as key differentiator between OPC UA and other IOT
protocols
Source: OPC Foundation

OPC Communication Models – Client : Server Model
Utthunga for OPC© Utthunga Technologies Pvt. Ltd. 2020
Server
Client
Client
Client
Server
TCP based Request/Response
 Connection/session context required (peer-
to-peer)
 Save transport, acknowledgement of every
message
 Polling for “DataChange”
 Keep alive subscription for each client
 Higher resource consumption
 Gateway can be used to convert and send
machine data to cloud middleware

OPC Communication Models – Publisher : Subscriber Model
Utthunga for OPC
UDP based Pub/Sub
 Connection-less, broadcast-style
communication
 Fire and forget transportation (data loss)
 “Public” subscription, same data for all clients
 Low resource consumption
 Cyclic publish of “all” data (deterministic via
TSN support)
 Chip manufacturing
 Eliminates lag in time-critical application in
manufacturing facilities
 Enables direct connectivity to cloud middleware
via MQTT, AMQP
Publisher
Subscriber
Broker
Publisher
Subscriber

4. OPC Publisher-Subscriber model
1. Introduction – IIOT & OPC
5. Use Cases
Agenda
7. Q & A
Utthunga for OPC

Use Case 1: Production monitoring through OEE in Discrete Manufacturing
Utthunga for OPC
Challenges:
• Inconsistent Production quality
• Under utilization of the equipment
• Not meeting planned production
• Machine Controllers from multiple OEMs
Solution
• Data extraction from Controllers via OPC UA
• Continuous reading of production data from Controllers
• Data getting published to IIOT platform
• Live OEE
Benefits:
• Single communication protocol OPC UA for multiple
vendor machine controllers
• Live OEE helps identifying production issues
• Alarms for below expected OEE goal
• Greater equipment Availability
• Helps improving productivity as necessary actions taken
based on OEE monitoring Machine 2Machine 1 Machine 3
Controller1 Controller3Controller2
OPC UA Client
MQTT
IIOT Cloud Platform
REST API
OPC UA Server

Use Case 2: KPI Monitoring and Analytics for Oil & Gas refinery
Utthunga for OPC
Challenges:
• Management wanted to drive their operations through continuous
KPI Monitoring
• Data Analysis in multiple dimensions such as Reference Tracking
• Working with Heterogeneous systems containing multiple data
sources and historians
Solution
• IIOT Platform on cloud with customizable KPI manager
• Hierarchical KPIs and drill down to the last KPI in the Hierarchy
covering the entire span of requirements of CXO to Devices.
• Heterogeneous system through OPC Stack and Edge connectors
for systems which were not compliant with OPC UA
• AI Processing engine using latest AI/ML models and algorithms
to perform predictive analytics
Benefits:
• Near Real-time tracking and monitoring of KPI’s for Production,
Quality, Maintenance and Remote Operations
• Tracking with respect to production, cost & revenue
• Single view real time metrics data from different plant floor
systems to derive useful relations affecting plant operations
• Understand impact of reactive and proactive maintenances on
the production, equipment and labor and build knowledge base
Machine 2Machine 1 Machine 3
Controller1 Controller3Controller2
MQTT
IIOT Cloud Platform
REST API
OPC UA Client
OPC UA Server
OPC DA-UA Modbus-UA

Webinars : Up-Coming
5. OPC UA Inside Out Part 5 - Cloud Connectivity – 25th June, 2020
4. OPC UA Inside Out Part 4 - Tunneller – 11th June, 2020
3. OPC UA Inside Out Part 3 - Edge Gateway – 28th May, 2020
2. OPC UA Inside Out Part 2 - Embedded & constrained devices – 14th May, 2020
6. OPC UA Inside Out Part 6 - Green Field and Brown Field – 09th July, 2020
1. OPC UA Inside Out Part 1 - Introduction and Playing Field – 30th April, 2020
Utthunga for OPC

Utthunga Technologies Pvt. Ltd.
No. 8, 27th Cross, 2nd Stage,
Banashankari, Bangalore – 560 070
Phone: +91-80-68151900
Mail: contact@utthunga.com

OPC UA Inside Out Part 5 - Cloud Connectivity

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