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An Open CPPS Automation Architecture based on IEC-61499 over OPC-UA for flexible manufacturing in Oil&Gas Industry
Proceedings of the 20th World Congress The International Federation of Congress Automatic Control Proceedings of the 20th World Available online at www.sciencedirect.com Proceedings of the 20th World Congress Toulouse, France,Federation July 9-14, 2017 The International of Automatic Control The International Federation of Automatic Control Toulouse, France, July 9-14, 2017 Toulouse, France, July 9-14, 2017
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IFAC PapersOnLine 50-1 (2017) 1231–1238
An Open CPPS Automation Architecture based on IEC-61499 over OPC-UA for An Architecture based on An Open Open CPPS CPPS Automation Automation Architecture in based on IEC-61499 IEC-61499 over OPC-UA OPC-UA for for flexible manufacturing Oil&Gas Industry over flexible manufacturing in Oil&Gas Industry flexible manufacturing in Oil&Gas Industry Marcelo V. García*, Edurne Irisarri*, Federico Pérez*, Elisabet Estévez**, Marga Marcos* Marcelo Irisarri*, Federico Estévez**, *University of the Basque Pérez*, Country,Elisabet UPV/EHU, Spain Marga Marcelo V. V. García*, García*, Edurne Edurne Irisarri*, Federico Pérez*, Elisabet Estévez**, Marga Marcos* Marcos* * University of the Basque Country, UPV/EHU, Spain {mgarcia294, edurne.irisarri, federico.perez, marga.marcos}@ehu.eus *University of the Basque Country, UPV/EHU, Spain ** {mgarcia294, federico.perez, marga.marcos}@ehu.eus University of Jaen, Spain {mgarcia294, edurne.irisarri, edurne.irisarri, federico.perez, marga.marcos}@ehu.eus ** of Jaen, Spain **University [email protected] University of Jaen, Spain [email protected] [email protected]
Abstract: The rapid progress of technology such as Big Data, Historians, MES, Intelligent sensors, and Abstract: The rapid rapid progress of companies technologythe such as Big BigtoData, Data, Historians, MES, Intelligentorsensors, sensors, and control systems offersprogress Oil&Gas chance automate high-cost, dangerous, error-prone Abstract: The of technology such as Historians, MES, Intelligent and control systems offers Oil&Gas companies the chance to automate high-cost, dangerous, or error-prone tasks. all these reasons, Industry 4.0 willthe have a profound impacthigh-cost, on Oil&Gas industrialorcompanies in controlFor systems offers Oil&Gas companies chance to automate dangerous, error-prone tasks.years For all alltothese these reasons, Industry 4.0 will will have have profound impact on on Oil&Gasarchitectures industrial companies companies in the come. Low-cost automation promotes profitable reference and new tasks. For reasons, Industry 4.0 aa profound impact Oil&Gas industrial in the years to come. Low-cost automation promotes profitable reference architectures and new development approaches to increase the flexibility and efficiency of production operations in an the years to come. Low-cost automation promotes profitable reference architectures and new development approaches to increase increase the flexibility flexibility and efficiency efficiency of production operations in industrial plant. This has led to the adoption of standards and open network standards for plant-level development approaches to the and of production operations in an an industrial plant. This has led to the adoption of standards and open network standards for plant-level communications. OPC-UA can help industrial companies to integrate into the vision of Industry 4.0, industrial plant. This has led to the adoption of standards and open network standards for plant-level communications. OPC-UA can help industrial companies companies to integrate into the the isvision vision of Industry Industry 4.0, allowing remote OPC-UA access to can plant information, therefore, to vertical integration achieved. The main communications. help industrial integrate into of 4.0, allowing remote access to plant information, therefore, vertical integration is achieved. The main objective of this work is enable vertical integration to become a reality through a CPPS architecture allowing remote access to plant information, therefore, vertical integration is achieved. The main objective of this thisstandard, work is is to to enable vertical integration become aa reality through CPPS architecture and IEC-61499 that allows low-cost access toto in a plant. Using this architecture objective of work enable vertical integration toprocess becomedata reality through aa CPPS and IEC-61499 standard, that allows low-cost access to process data in a plant. Using this architecture along the entire standard, automation system can certainly reduce theinTotal CostUsing of Ownership (TCO) and IEC-61499 that allowsproduction low-cost access to process data a plant. this architecture along the entire entire automation automation system system production production can can certainly certainly reduce reduce the the Total Total Cost Cost of of Ownership Ownership (TCO) (TCO) in the industry. along the in the industry. in industry. © the 2017, IFAC (International Federation of Automatic Control) Hosting by Elsevier Ltd.Enterprise All rights reserved. Keywords: Device integration technologies, Industrial communication protocols, integration, Keywords: Device integration technologies, Industrial communication protocols, Enterprise integration, Cyber-Physical Production Systems (CPPS), Industry 4.0 Keywords: Device integration technologies, Industrial communication protocols, Enterprise integration, Cyber-Physical Production Production Systems Systems (CPPS), (CPPS), Industry Industry 4.0 4.0 Cyber-Physical 1. INTRODUCTION Industry 4.0 is based on Cyber-Physical Production Systems 1. INTRODUCTION Industry on Systems fusion4.0 of is thebased physical and the virtualProduction worlds) CPPS, the 1. INTRODUCTION Industry 4.0 is based on Cyber-Physical Cyber-Physical Production Systems In the Oil&Gas sector, the stakes are high, the conditions (a (a fusion of the physical and the virtual worlds) CPPS, the Industrial Internet of Things(IIoT) and the Internet of In the Oil&Gas sector, the stakes are high, the conditions (a fusion of the physical and the virtual worlds) CPPS, the harsh. Reliable communications and the secure transmission In the Oil&Gas sector, the stakes are high, the conditions Industrial Internet of Things(IIoT) and the Internet of Services, will collectively have a disruptive impact on every harsh. Reliable communications and the secure of business information are critical. information Industrial Internet of Things(IIoT) and the Internet of harsh. Reliable communications andAs themuch secureastransmission transmission Services, will collectively have a disruptive impact on every aspect of manufacturing companies and now we need to of are much technology is very relevant in otherAs fields, it is Services, will collectively have a disruptive impact on every of business business information information are critical. critical. Asindustrial much as as information information aspect of manufacturing companies and now we need introduce these concepts in real industries like Oil&Gas technology is in other it of manufacturing companies and now we need to to highly essential in therelevant Oil&Gas Differentfields, operations technology is very very relevant in industry. other industrial industrial fields, it is is aspect introduce these concepts in real industries like Oil&Gas sector. The 4th industrial revolution, which unlike all others, highly essential in the Oil&Gas industry. Different operations introduce these concepts in real industries like Oil&Gas in the Oil&Gas industry depend solely on information highly essential in the Oil&Gas industry. Different operations sector. The 4th revolution, which unlike is being therefore allowing companies take in depend solely on Thepredicted, 4th industrial industrial revolution, which unlike all alltoothers, others, technology and canindustry only achieve efficiency in the the Oil&Gas Oil&Gas industry depend solelythereof. on information information sector. is being predicted, therefore allowing companies to specific actions before it happens. technology and can only achieve efficiency thereof. is being predicted, therefore allowing companies to take take technology and can only achieve efficiency thereof. actions before it happens. Today’s intelligent oil field is flush with digitally enabled specific specific actions before it happens. Today’s intelligent oil flush with wired equipment, A enabled typical On the other hand, the IEC 61499 standard promotes a model Today’ssystems, intelligent oil field field is isand flushcomponents. with digitally digitally enabled On other 61499 aa model of IEC distributed control promotes systems. Industry wired systems, equipment, and components. A On the thedevelopment other hand, hand, the the IEC 61499 standard standard promotes model production platform can have more than 40,000 data tags, not based wired systems, equipment, and components. A typical typical based development of distributed control systems. Industry 4.0 will allow to model and develop software and hardware production platform can have more than 40,000 data tags, not based development of distributed control systems. Industry all connected or used. Converting this complex flood of data production platform can have more than 40,000 data tags, not 4.0 will model develop software for systems. Theand keyhardware entity in all or Converting complex flood data 4.0 independent will allow allow to todistributed model and andcontrol develop software and hardware into better business operatingthis decisions all connected connected or used. used.and Converting this complexrequires flood of of new, data the for independent distributed control systems. The key in IEC 61499 standard is the Function Block (FB), which into business operating decisions new, for independent distributed control systems. The key entity entity in carefully capabilities data requires manipulation, into better better designed business and and operating for decisions requires new, the IEC 61499 standard is the Function Block (FB), which wraps the control and communication algorithms in different carefully designed capabilities for data manipulation, the IEC 61499 standard is the Function Block (FB), which analysis, and presentation, as well as tools to support decision carefully designed capabilities for data manipulation, wraps the and in programming languages, including IECalgorithms 61131, Java, C++, or analysis, the control control and communication communication algorithms in different different making. analysis, and and presentation, presentation, as as well well as as tools tools to to support support decision decision wraps programming languages, including IEC 61131, Java, or virtually any other programming language. The Service making. programming languages, including IEC 61131, Java, C++, C++, or making. virtually any other programming language. The Service Interface Function (SIFB) is one of the types of FBs In the downstream Oil&Gas operation, corporate virtually any otherBlock programming language. The Service Interface Function Block (SIFB) is one types of In Oil&Gas corporate allows wrapping and hardware communication is very important order to determine Interface that Function Block (SIFB) is abstracting one of of the the the types of FBs FBs In the the downstream downstream Oil&Gas inoperation, operation, corporate provided provided that allows wrapping and abstracting the hardware communication is very important in order to determine access as well as the resources from the Application efficiency in the various processes. This makes it possible to communication is very important in order to determine provided that allows wrapping and abstracting the hardware access as from the efficiency in This makes to Interface. summary, currently available achieve cost processes. savings and of scale. access as as well well as the the Inresources resources from the Application Application efficiencyenormous in the the various various processes. Thiseconomies makes it it possible possible to Programmer Programmer Interface. In summary, currently available achieve enormous cost savings and economies of scale. technology is mature enough as to achieve the goal of M2M Management has genuine real-time information for its achieve enormous cost savings and economies of scale. Programmer Interface. In summary, currently available technology is mature enough as to achieve the goal of M2M Management has genuine real-time information for its but there is still a gap between technology and real industries decision-making processes. The results of any action taken Management has genuine real-time information for its technology is mature enough as to achieve the goal of M2M but there is still a gap between technology and real industries decision-making processes. The results of any action taken can be directly measured, identified and then corrected as a gap between industries decision-making processes. The results of any action taken but Thethere use is of still standards such astechnology IEC-61499and andreal architectures can measured, identified then as needed. In the short term, even those and aggressively pursuing can be be directly directly measured, identified and then corrected corrected as The use of standards such as IEC-61499 and architectures CPPSuse implies that advance would needed. those aggressively pursuing of standards such in as information IEC-61499 technology and architectures Industry 4.0the willshort haveterm, a mixeven of smart and equipment needed. In In the short term, even thosedevices aggressively pursuing The CPPS implies that advance in information technology would result to the improvement of the Oil&Gas industry as well as Industry 4.0 will have a mix of smart devices and equipment CPPS implies that advance in information technology would with traditional products machines thatandneed M2M Industry 4.0 will have a mixand of smart devices equipment result to the improvement of the Oil&Gas industry as well as every other field of life. This is why lots of intensive with traditional products and machines that need M2M result to the improvement of the Oil&Gas industry as well as communication to guide the process of vertical and horizontal with traditional products and machines that need M2M every other field of life. This is why lots of intensive researches are being carried out on information technology in communication to guide the process of vertical and horizontal every other field of life. This is why lots of intensive integration. communication to guide the process of vertical and horizontal researches are being carried out on information technology in integration. researches are being carried out on information technology in integration. 2405-8963 © 2017, IFAC (International Federation of Automatic Control) Hosting by Elsevier Ltd. All rights reserved. Copyright 2017 responsibility IFAC 1259Control. Peer review©under of International Federation of Automatic Copyright © 2017 IFAC 1259 10.1016/j.ifacol.2017.08.347 Copyright © 2017 IFAC 1259
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the recent time and these have resulted in unimaginable impact on this kind of industry. In previous works of authors (Perez et al. 2015) the general architecture for CPPs was presented. It consists of a modelbased approach identifying the different models needed for achieving vertical integration. This paper contributes to the application of the generic architecture to the special case of oil production industry and to the data collection from field devices using IEC-61499 and OPC-UA protocol for the production process and information supplier devices. The layout of the paper is as follows: Section II shows some related works that have been used as starting point for this research. Section III presents a CPPS Architecture in order to be used in an advanced industrial automation environment. Section IV describes a proposed software implementation using IEC-61499 and OPC UA. Section V proposes a set of SIFB for IEC 61499, describing in detail the configuration XML file for the OPC UA server. In order to validate the work, Section VI shows a case study in Petroamazonas Company where Modbus/TCP and an OPC-UA server into Information Components are implemented. Finally, some conclusions are drawn in Section VI. 2. RELATED WORKS This section reviews related research directly related to the areas of machining and industrial production. It also describes the approach and scope for our research when looking to develop a methodology for agile distributed process planning and adaptable to continuous processes especially in the area of oil & gas Researches about the use and implementation of the IEC61499 function blocks in different control applications have been ongoing for a while. It seems that the absolute majority of these applications are limited to control low-level processes for PLCs, which are not able to handle problems of uncertainty regarding the design layout and process planning in high-level manufacturing systems. According to this literature survey, it seems, they have a limited use of FBs for adaptive processes and control machining/assembly for this reason, the aim of this research is to use FBs architecture in a real continuous process A common application of FB architecture of IEC-61499 is the design of distributed autonomous systems with intelligent control components (Wang et al. 2001), maintenance of distributed control system and engineering web-based (Schwab et al. 2005.), automated verification of industrial control systems based on FB (Völker & Krämer 1999), FBoriented support systems engineering (Thramboulidis & Tranoris, 2001) and reconfigurable concurrent FB models (Brennan et al. 2002) Studies on implementation of IEC 61499 in process control systems are shown (Olsen et al. 2005), an implementation of a distributed control model in real time using a Java-based platform is presented, where a control application is distributed across two devices, supported by a MANAGER FB, capable of providing management services for devices. Real-time execution of IEC 61499 applications, which
describes the elements of execution within a device and different approaches to programming and implementation, is presented by (Zoitl et al. 2005), as well as criticism and solutions, ambiguities concerning the implementation of the norm, leading to different behaviors of execution of the elements in different control devices, (Strasser et al. 2011). The development, implementation and use of an IEC 61499 FB library for embedded closed loop control is presented and demonstrated (Strasser et al. 2004). in a real experiment: a see-saw problem. (Jain et al. 2002), (Yuan & Ferreira 2003) and (Yuan & Ferreira 2004) has developed a system called EMBENCH. This is a design environment simulation and rapid prototyping at different levels of control machining using IEC 61499 for modularization and reuse of services implemented control. The system allows different types of commands to controllers in different layers from the complex flexible manufacturing cell to a single servo binding. An example of how IEC 61499 can be used to model a distributed, flexible and reconfigurable application is demonstrated (Hussain & Frey 2004). But so far, IEC-61499 has only been focused on discrete control processes, this research use IEC-61499 to integrate industrial communication and its use in the monitoring of analog processes. Using the FB for process planning has emerged as an innovative approach in manufacturing systems, mainly since the introduction of the IEC 61499 standard. With the new standard, FBs can be triggered by events to execute internal algorithms in a controlled manner. This feature opens up many new exciting application scenarios. The possibility of handling changes during the generation and execution of process plans as well as the linkage to scheduling for optimal system performance are challenging effects from the distributable and modular nature of the FB technology. FBs applied to assembly process planning are reported in (Wang et al. 2008), in which assembly features (pairs of mating components) are identified and mapped to appropriate assembly FBs. Each FB possesses a set of processing algorithms to determine how to do a specific assembly operation by a robot or a human assembler. In order to facilitate the design of FBs, (Wang et al. 2009) developed an FB designer, crucial to adaptive process plan generation and able to encapsulate generic process plans into FBs for runtime execution. A group-based programming abstraction for CPPS is proposed by Vicaire et. al. (Vicaire et al. 2012). The abstraction model covers sensors and actuators. Heterogeneous devices are supported by this model, that sensors and actuators can be modeled and simulated simultaneously. The abstraction model given in this article is called "Bundle" and is suitable for plant floor devices. However, this kind of models is not addressed to be used with new communications standards such as OPC UA. Stojmenovic (Stojmenovic 2014) considers M2M as a key technology for CPPS. The author identifies the problem that all researches in the field of M2M communication is based on small-scale models and centralized solutions. For this reason,
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a paradigm shift is proposed and suggested where M2M nodes must also make decisions based on local knowledge, rather than just forwarding messages to the central system. By using this new paradigm, M2M could be applied to a larger number of industrial applications. Using this approach on production systems allows an easy linking of plant floor data, from a set of variables that are transmitted safely and where the industrial control is also performed locally. However, the other criteria suggested for the present paper, that is the use of OPC UA combined with multiple protocols, is not analyzed. In this sense, this last approach would allow an easy linking of data, from one set of tags to another, on a processor platform. This aims at a wider range of new M2M applications, supporting also secure supervisory connections.
composed of three different entities: (i) Atomic Services (AS): A set of basic services which perform data acquisition and related issues. (ii) Logical Process Nodes (LPN): LPNs represent a process of the PPM. There is an LPN for process and every LPN refers to the intelligent device where services to access process data are deployed. (iii) CPS Logical Devices (CPSLD): They are the intelligent devices of the PPM where the architecture is deployed
Other research works undertaken by the authors, such as those submitted to ETFA2014 (Garcia et al. 2015) and WFCS2015 (Garcia et al. 2015) international conferences, address low-cost CPPS under IEC 61499. However, this research goes further defining the integration between an OPC-UA server and a particular industrial communication protocol such as Modbus/TCP. It is conceived for an automation system and built upon an XML environment. 3. CPPS ARCHITECTURE The basis architecture for this paper is presented in (Perez et al. 2015). Fig. 1 depicts the general scenario for the monitoring process. This architecture is composed of a set of components that manage a set of models representing the physical world, the information exchange as well as the information to be accessed. The physical world, understood as the production process is called Production Process Model (PPM). This model is composed of the accessible data, generated in the production process (data source), and also of the intelligent devices belonging to the plant that are responsible for communicating the actual data values (data suppliers). The physical plant, including the accessible process variables, is defined by means of the so called Plant Topology Model (PTM). This model collects the physical components of the plant. The PTM represents the layout of the plant. It should be generic enough in order to describe any productive process although it can be customized to fit the interest of the enterprise
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Fig. 1: CPPS General Architecture Finally, the PIM defines the information the user wants to acquire from the process. This information is structured in the socalled Information Components (IC). ICs are the mechanisms to access the plant data. They are composed of a set of atomic services offered by Logical Nodes of the CPS (CPSLD) that handle process data (FD). The user defines ICs by means of configuration services. Once created and launched, an IC offers a unique service (ICS) that is responsible for performing the functionality of the IC. The simplest IC is the minimum access to the plant, for instance, the access to read field data of a process (which is associated to a LPND). This is a user-oriented model, thus the remote client applications are responsible for defining it. As illustrated in Fig. 2, this characterization refers to Field Data belonging to Processes of the PTM, as well as acquisition, pre-processing
The data supplier devices, being process controllers and / or smart devices offering process data and their characteristics are defined in the so called Plant Intelligent Devices Model (PIDM). Furthermore, the Plant Information Model (PIM), corresponds to the user monitoring requirements which can be defined from the PTM specifying the process variables as well as the type of access. Information Exchange Model (IEM), processes the user requirements for monitoring and it is the responsible for accessing the appropriated data process devices. The IEM is
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Fig. 2: IEM Conceptual Structure
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Fig. 3: Oil Crude Process Within oil production field, companies are commonly geographically distributed over the country; consequently, remote access to the process is of vital importance to monitor the whole process or make decisions that can affect different sites. In fact, oil production companies are usually composed of multiple blocks where production surface primary is called Oil Well-pad is a location which houses the wellheads for a number of horizontally drilled wells. The benefit of a drilling pad is that operators can drill multiple wells in a shorter time than they might with just one well per site. Every petroleum well has a downhole sensor that acquires pressure, temperature and vibration measurements for indepth identification, diagnostics and analysis of equipment operating problems and changes in reservoir conditions. Every block has a crude oil extraction module and a three phase based separation module from which oil, gas and water are obtained. Concretely, crude oil is extracted from the bottom of the wells by pumping and once on the surface it is delivered to the manifold. It is here, within the manifold, where the crude oil from all wells constituting a wellpad is collected (See Fig. 3). The extraction process of crude oil finishes when the oil crude is sent to the Production Facilities Center (CPF). The CPF is composed of a tank called crude oil Separator, is a pressure vessel used for separating well fluids produced from oil and gas wells into gaseous and liquid components that collects the crude provided by all wellpads of the block. Besides, the spare oil is sent to be processed to other companies (oil treatment and storage, oil pumping). At the same time, part of the gas is burnt and the rest is ejected by gas pipelines (gas scrubbing). The obtained water is treated and reinjected to wells (water storage, water reinjection) Water Re-Injection Pumps is one of the key technologies oil and gas producers rely on to increase recovery rates, it has proven to be one of the most economical methods for managing reservoirs. This technology can be valuable in helping maintain reservoir pressure, enhancing production of hydrocarbon reserves and reducing the environmental impact
through reinjection of treated and filtered produced water. This process uses centrifugal pumps, control systems with PLCs, pressure transmitters and temperature transmiters 4. PROPOSED IMPLEMENTATION 4.1 IEC-61499 IEC 61499 standard defines a generic model based on function blocks (FBs) for distributed control systems and industrial automation. The four models of the standard models are: FB model, application, resource and device, shown in Fig. 4. FB model is the primary and elementary model of the standard. FB is a functional unit, which has events inputs/outputs; as well as data input/output and has algorithms which are transparent to the user.
Fig. 4: IEC-61499 Function Model FB receives events/data in their input interfaces, internal algorithms processes this information and generates
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events/output data. The order of how input/output events and algorithms run are described in Execution Control Chart (ECC), which is similar to a state machine. The basic FBs can generally be integrated into Sub-Applications or FBs compounds (CFB) that can represent complex functions. Services of communication protocols for data exchange are modelled using Service Interface Function Blocks (SIFBs) In the IEC 61499 architecture, other models can be constructed based on FBs. For example, the application model is built by an FB network, whose nodes are basic FBs, CFBs, or SIFBs, and whose branches are event/data connections. The resource model is comprised of one or more “local application” and communication interfaces. The device model contains one or more interfaces (communication interface or process interface) and one or more resources FBs-based architecture for control devices enables modularization design approach and makes the development process more simple and efficient. However, since the IEC 61499 is a conceptual reference model for general purposes it is necessary to establish a model derived class FBs for a particular application from an object-oriented view 4.2 Combination of two Architectures The model for a CPPS architecture does not specify detailed functions and data types related to those functions, therefore, to get data from different models at CPPS architecture is necessary to use communication protocols. For that reason, OPC UA standard is a promising alternative being a service oriented architecture, offering data security and reliable information model. IEC 61499 model is designed for general purpose and, therefore, needs some modification before being taken in particular applications. Thus, it makes sense to combine the two models to accumulate FB standard for flexible CPPS. As a result, the proposal CPPS architecture can be seen as an integration of standard and reusable components, such as communication services based OPC UA, control algorithms, software etc. FB-based architecture is also desirable to design and develop highly flexible CPPSs profitably. Table 1: Object model mapping between CPPs Architecture and IEC 61499 CPPS ARCHITECTURE IEC 61499 MODEL Server Physical Device Device Logical Device (LD) Resource Logical Process Node (LPN) CFB Information Component (IC) CFB Data Object Basic FB, SIFB Atomic Services FBs, CFB
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directly used in automation systems. OPC UA provides a reliable, robust and high performance communication means, suitable for industrial automation applications and devices, such as those executing CPPS. Classic OPC was not able to properly represent essential issues of today’s connected world such as the types of data, information and relationships between data items and systems. Unlike the classic OPC, OPC UA provides, not only a transport method, but also a modelling mainstay able to support plant floor models. In manufacturing domain, the information technologies have to be integrated with process control engineering. For this purpose, systems must become interoperable, which requires the information exchange. In this sense, the concept of address space in an OPC UA server has to be considered. In particular, under this concept, the set of objects that the server makes available to clients is included. These objects represent the underlying real-time system data. All in all, the address space concept allows representing both real process environment and real-time process behaviour by a unique means, mutually understandable by diverse systems. (Claassen et al. 2011) The OPC UA server may be represented as a model-based system. This approach introduces the model concept for a better adaptation to the needs of modern industrial applications. Typically, a profile is designed for the vertical integration of automation systems. The use of an OPC UA architecture allows a full description of any system data, independently of their complexity. All the options above may not be needed to implement most CPPS. In this sense, the information described in the address space of the OPC UA server may be enough for most industrial systems. 5. SIFB SET FOR IEC 61499 The 4DIAC-IDE framework has been used to create a set of SIFBs, which is based in previous researches (Garcia et al. 2015; Garcia et al. 2015). In this work the new version of the OPC UA server is configured using an information model, implemented using a XML configuration file, which improves the integration with field devices and their process data. In this way, the server includes a driver for Modbus TCP/IP protocol. On the other hand, a subscription mechanism over OPC UA is implemented. 5.1 SIFB STATIC OPCUA_SERVER
4.3 OPC-UA OPC UA is aimed at replacing previous standards such as OPC DA, OPC A&E and OPC HDA. OPC-UA is an evolution of these standards, providing a vendor independent open architecture(Van Der Linden et al. 2011). As its predecessors, OPC-UA follows the client/server paradigm. With regard to portability, the main difference is that the server uses a portable communication stack that may be
This SIFB allows configuring the OPC UA server through a XML file. This file includes all essential parameters for the OPC UA server such as URL address, vendor name, server name, version, etc. Also, this configuration file states the Address Space with their Node Types and Node Instances, among others. Within the configuration two more elements are defined:
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a) Field Devices: This element groups the definition of the devices accessible by the server, characterized by the supported communication and related information. Process data elements (FieldData) supplied for the device are also defined.
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b) Data Mapping: This element defines the existing relationships between DataVariables declared in the address space section of the FieldDevice, and the associated FieldData.
Fig. 7: DINAMIC OPCUA_SERVER 5.3 SIFB OPCUA_CLIENT_READ This SIFB implements an OPC UA client able to read in variables from the OPC UA server. (see Fig. 8)
Fig. 5: Field Device Configuration This SIFB provides common events like INIT, REQ, INITO and CNF (Fig. 6) as well as the following input and output data: −
− − −
Fig. 8: SIFB OPCUA_CLIENT_READ This SIFB includes the following data: −
QI (BOOL): This input data works jointly with INIT to start-up or shut-down the OPC UA server. On INIT event, if QI is TRUE, OPC UA server starts; otherwise, if OI is FALSE, OPC UA server shutdowns. CONFIGFILE (WSTRING): This input data holds the XML configuration filename. QO (BOOL): Informs about the performance of last procedure executed. STATUS (STRING): Reports status information of the server.
− − − −
URLSERVER (WSTRING): URL of the OPC UA server. DATANAME (WSTRING): Name of the variable data available from the OPC UA server. RD (ANY): Data provided by the OPC UA server to which the client is connected. The type of this parameter is ANY to improve reuse. SOURCETIMESTAMP (DATE AND TIME): Timestamp associated to the source resource item. SERVERTIMESTAMP (DATE AND TIME): Timestamp associated to the OPC UA server item.
5.4 SIFB OPCUA_CLIENT_WRITE This SIFB provides variable writing service, having as parameters (Fig. 9): − Fig. 6: SIFB STATIC OPCUA_SERVER
−
5.2 SIFB DINAMIC OPCUA_SERVER This SIFB provides OPC UA communication using FORTE CommLayer. The network interface is designed to be as flexible as possible. The basis for the network interface is the implementation of the layer design pattern. The function block class and the layer classes are interacting by the following functions; a detailed description is given in this section (Fig. 7): −
− −
ID (WSTRING): Connection identifier to OPC UA protocol, it has parameters like; Server name [o] – svr:; Configuration file [m] – cnf:; Field device [o] – fd:; Process Tag [o] – tg[num]: SD (ANY): Data value to be written; parameter (memory tag) [o] – sd[num]: RD (ANY): Data provided by the OPC UA server; parameter (memory tag) [o] – rd[num]:
TYPE (WSTRING): Data type for the value to be written. SD (ANY): Data value to be written. Again, the type of this parameter is ANY in order to increase generality.
Fig. 9: SIFB OPCUA_CLIENT_WRITE 5.5 SIFB OPCUA_CLIENT_SUBSCRIBE This SIFB implements a single subscription to monitor variables in OPC UA servers. The subscription maintains a local copy of the parameters for the monitored item. These local copies can be altered by updating their properties without affecting the state on the server. This SIFB input and output parameters are: (see Fig. 10)
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− − −
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MODE (WSTRING): three monitoring modes are supported: “Reporting”, “Sampling” and “Disabled”. PERIOD (ULINT): Set the sampling period in millisecond for sampled monitored items. RD (ANY): Value of the monitored item provided by the OPC UA server.
Fig. 12: Communication system for separation and extraction modules
Fig. 10: SIFB OPCUA_CLIENT_SUBSCRIBE 6. CASE STUDY: PETROAMAZONAS EP The case study is focussed on Petroamazonas EP Oil Company of Ecuador. Concretely, the Block18. In this Block, there are 4 wellpads which are made up by 30 wells. The example is focused on the extraction of crude oil from one well (PAA-01 of Fig. 11). The PAA-01-01 wellhead has been enriched with two transmitters: TIT-WPA01-01 which indicates the temperature and PIT-WPA01-01 that indicates the pressure. There is also a production emergency valve (SDV-WPA01-01). On the other hand, in relation with the Electric Submersible Pumping system (BESPA1), the following elements should be considered: i) two pressure transmitters: PT-BESPA1-01 for input pressure (intake) and PT-BESPA1-02 for output pressure (exhaust); ii) three temperature transmitters: TTBESPA1-01 for the temperature of the fluid, TT-BESPA1-02 for the temperature of the motor and TT-BESPA1-03 for the temperature of the output fluid; iii) a sensor for the current of the motor (CT-BESPA1-01); iv) VT-BESPA1-01 which provides the voltage of the motor
Fig. 11: P&ID ESP and oil crude production system Additionally, the core of the ESP is composed of motor (MWPA01-1), pump (P-WPA01) and VSD (VSD-WPA01). Fig. 12 shows the current communication system where OPC UA Server under IEC 61499 is located.
The design and development of an ICs is a stepwise but simple process with the following steps: Step 1) Decompose the required application function to a degree of granularity of the existing FBs. Step 2) Select corresponding FBs from the FB library for all the decomposed sub-functions, then create instances of the selected FBs, set their parameters, and connect these FBs with data flow and event flow. Step 3) Validate the whole IC model to avoid errors. Step 4) Integrate physical components to IC using OPC UA FBs and perform comprehensive testing. As an example, the design of a IC using standard FBs developed in this research is given. Fig. 12 shows the FB architecture of the IC. The IC consists of three main modules: i) OPC UA Static Server with XML configuration; ii) create dynamically new tags using OPC UA Server and use FBs of Atomics services (Logging Data, Report Data, Read Data, etc) and iii) communication services integration using OPC UA FBs for the process bus. 7. CONCLUSIONS This work presents an approach for accessing field data in automation systems using OPC UA servers in CPPS architecture using IEC 61499 applications running over FORTE runtime. The use of this kind of systems helps to introduce new CPPS concepts within the Industry 4.0 paradigm. This architecture provides a M2M infrastructure for plant floor communications. A set of SIFBs is proposed to be used for implementing OPC UA servers and clients, including subscription mechanisms. The use of FBs for designing ICs has many obvious and potential benefits. Perhaps the simplest but most important one is that the same IC is applicable for different function installations by means of software reconfiguration. It is also feasible to add, remove, and replace some functions of an IC on service when application requirements change. Another significant advantage is simplicity of design and development since it is possible to construct a software system with existing reusable software components. Modularization design and visual programming can be adopted to further expedite the development process. In addition, the reliability of the software system is also guaranteed when using software components containing mature algorithms. Future works focus on developing new functionalities such as
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Figure 13: Information Component Well PAA001 integrating OPC UA models with other industrial standards like ISA 95 or AML that will improve CPPS integration. ACKNOWLEDGMENT This work was financed in part by the University of the Basque Country (UPV/EHU) under project DPI2015-68602R (MINECO/FEDER,UE) and GV/EJ under recognized research group IT914-16, and Government of Ecuador through grant SENESCYT-2013. REFERENCES Brennan, R.W. et al., 2002. A Reconfigurable Concurrent Function Block Model and Its Implementation in Real-time Java. Integr. Comput.Aided Eng., 9(3), pp.263–279. Available at: http://dl.acm.org/ citation.cfm?id=1275687.1275693. Claassen, A., Rohjans, S. & Lehnhoff Member, S., 2011. Application of the OPC UA for the Smart Grid. In 2011 2nd IEEE PES International Conference and Exhibition on Innovative Smart Grid Technologies. IEEE, pp. 1–8. Available at: http://ieeexplore.ieee.org/lpdocs /epic03/wrapper.htm?arnumber=6162627. Garcia, M. V. et al., 2015. Building industrial CPS with the IEC 61499 standard on low-cost hardware platforms. 19th IEEE International Conference on Emerging Technologies and Factory Automation, ETFA 2014. Garcia, M. V. et al., 2015. Developing CPPS within IEC-61499 based on low cost devices. IEEE International Workshop on Factory Communication Systems - Proceedings, WFCS, 2015–July. Hussain, T. & Frey, G., 2004. Developing IEC 61499 compliant distributed systems with network enabled controllers. In IEEE Conference on Robotics, Automation and Mechatronics, 2004. IEEE, pp. 507–512. Available at: http://ieeexplore.ieee.org/document/1438972/. Jain, S., Yuan, C. & Ferreira, P., 2002. EMBench: A Rapid Prototyping Environment for Numerical Control Systems. In Dynamic Systems and Control. ASME, pp. 7–13. Available at: http://proceedings.asme digitalcollection.asme.org/proceeding.aspx?articleid=1580998. Van Der Linden, D. et al., 2011. An OPC UA interface for an evolvable ISA88 control module. IEEE International Conference on Emerging Technologies and Factory Automation, ETFA. Olsen, S. et al., 2005. Contingencies-based reconfiguration of distributed factory automation. Robotics and Computer-Integrated Manufacturing, 21(4–5), pp.379–390. Perez, F. et al., 2015. A CPPS Architecture approach for Industry 4.0. IEEE International Conference on Emerging Technologies and Factory Automation, ETFA, 2015–Octob. Schwab, C., Tangermann, M. & Ferrarini, L., 2005. Web based methodology for engineering and maintenance of distributed control systems: the TORERO approach. In INDIN ’05. 2005 3rd IEEE International Conference on Industrial Informatics, 2005. IEEE, pp. 32–37. Available at: http://ieeexplore.ieee.org/document/1560348/.
Stojmenovic, I., 2014. Machine-to-Machine Communications with Innetwork Data Aggregation, Processing and Actuation for Large Scale Cyber-Physical Systems. IEEE Internet of Things Journal, PP(99), pp.1–1. Available at: http://ieeexplore.ieee.org/lpdocs/epic03/ wrapper.htm?arnumber=6766661. Strasser, T. et al., 2011. Design and Execution Issues in IEC 61499 Distributed Automation and Control Systems. IEEE Transactions on Systems, Man, and Cybernetics, Part C (Applications and Reviews), 41(1), pp.41–51. Available at: http://ieeexplore.ieee.org/ document/5571034/. Strasser, T., Auinger, F. & Zoitl, A., 2004. Development, implementation and use of an IEC 61499 function block library for embedded closed loop control. In 2nd IEEE International Conference on Industrial Informatics, 2004. INDIN ’04. 2004. IEEE, pp. 594–599. Available at: http://ieeexplore.ieee.org/document/1417415/. Thramboulidis, K. & Tranoris, C., 2001. An architecture for the development of function block oriented engineering support systems. In Proceedings 2001 IEEE International Symposium on Computational Intelligence in Robotics and Automation (Cat. No.01EX515). IEEE, pp. 536–542. Available at: http://ieeexplore.ieee.org/document/101 3258/. Vicaire, P.A. et al., 2012. Bundle : A Group-Based Programming Abstraction for Cyber-Physical Systems. , 8(2), pp.379–392. Völker, N. & Krämer, B.J., 1999. Automated verification of function block based industrial control systems. Electronic Notes in Theoretical Computer Science, 25(July 1999), pp.97–110. Wang, L. et al., 2001. Realizing Holonic Control with Function Blocks. Integr. Comput.-Aided Eng., 8(1), pp.81–93. Available at: http://dl.acm.org/citation.cfm?id=1275723.1275730. Wang, L., Keshavarzmanesh, S. & Feng, H.Y., 2008. Design of adaptive function blocks for dynamic assembly planning and control. Journal of Manufacturing Systems, 27(1), pp.45–51. Available at: http://dx.doi.org/10.1016/j.jmsy.2008.06.003. Wang, L., Song, Y. & Gao, Q., 2009. Designing function blocks for distributed process planning and adaptive control. Engineering Applications of Artificial Intelligence, 22(7), pp.1127–1138. Available at: http://dx.doi.org/10.1016/j.engappai.2008.11.008. Yuan, C. & Ferreira, P., 2004. An Integrated Environment for the Design and Control of Deadlock-Free Flexible Manufacturing Cells. In Manufacturing Engineering and Materials Handling Engineering. ASME, pp. 471–481. Available at: http://proceedings.asmedigital collection.asme.org/proceeding.aspx?articleid=1652663. Yuan, C. & Ferreira, P., 2003. An Integrated Rapid Prototyping Environment for Reconfigurable Manufacturing Systems. In Materials. ASME, pp. 737–744. Available at: http://proceedings.asmedigitalcollection.asme .org/proceeding.aspx?articleid=1571334. Zoitl, A. et al., 2005. Executing real-time constrained control applications modelled in IEC 61499 with respect to dynamic reconfiguration. In INDIN ’05. 2005 3rd IEEE International Conference on Industrial Informatics, 2005. IEEE, pp. 62–67. Available at: http://ieeexplore. ieee.org/document/1560353/.
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An Open CPPS Automation Architecture based on IEC-61499 over OPC-UA for An Architecture based on An Open Open CPPS CPPS Automation Automation Architecture in based on IEC-61499 IEC-61499 over OPC-UA OPC-UA for for flexible manufacturing Oil&Gas Industry over flexible manufacturing in Oil&Gas Industry flexible manufacturing in Oil&Gas Industry Marcelo V. García*, Edurne Irisarri*, Federico Pérez*, Elisabet Estévez**, Marga Marcos* Marcelo Irisarri*, Federico Estévez**, *University of the Basque Pérez*, Country,Elisabet UPV/EHU, Spain Marga Marcelo V. V. García*, García*, Edurne Edurne Irisarri*, Federico Pérez*, Elisabet Estévez**, Marga Marcos* Marcos* * University of the Basque Country, UPV/EHU, Spain {mgarcia294, edurne.irisarri, federico.perez, marga.marcos}@ehu.eus *University of the Basque Country, UPV/EHU, Spain ** {mgarcia294, federico.perez, marga.marcos}@ehu.eus University of Jaen, Spain {mgarcia294, edurne.irisarri, edurne.irisarri, federico.perez, marga.marcos}@ehu.eus ** of Jaen, Spain **University [email protected] University of Jaen, Spain [email protected] [email protected]
Abstract: The rapid progress of technology such as Big Data, Historians, MES, Intelligent sensors, and Abstract: The rapid rapid progress of companies technologythe such as Big BigtoData, Data, Historians, MES, Intelligentorsensors, sensors, and control systems offersprogress Oil&Gas chance automate high-cost, dangerous, error-prone Abstract: The of technology such as Historians, MES, Intelligent and control systems offers Oil&Gas companies the chance to automate high-cost, dangerous, or error-prone tasks. all these reasons, Industry 4.0 willthe have a profound impacthigh-cost, on Oil&Gas industrialorcompanies in controlFor systems offers Oil&Gas companies chance to automate dangerous, error-prone tasks.years For all alltothese these reasons, Industry 4.0 will will have have profound impact on on Oil&Gasarchitectures industrial companies companies in the come. Low-cost automation promotes profitable reference and new tasks. For reasons, Industry 4.0 aa profound impact Oil&Gas industrial in the years to come. Low-cost automation promotes profitable reference architectures and new development approaches to increase the flexibility and efficiency of production operations in an the years to come. Low-cost automation promotes profitable reference architectures and new development approaches to increase increase the flexibility flexibility and efficiency efficiency of production operations in industrial plant. This has led to the adoption of standards and open network standards for plant-level development approaches to the and of production operations in an an industrial plant. This has led to the adoption of standards and open network standards for plant-level communications. OPC-UA can help industrial companies to integrate into the vision of Industry 4.0, industrial plant. This has led to the adoption of standards and open network standards for plant-level communications. OPC-UA can help industrial companies companies to integrate into the the isvision vision of Industry Industry 4.0, allowing remote OPC-UA access to can plant information, therefore, to vertical integration achieved. The main communications. help industrial integrate into of 4.0, allowing remote access to plant information, therefore, vertical integration is achieved. The main objective of this work is enable vertical integration to become a reality through a CPPS architecture allowing remote access to plant information, therefore, vertical integration is achieved. The main objective of this thisstandard, work is is to to enable vertical integration become aa reality through CPPS architecture and IEC-61499 that allows low-cost access toto in a plant. Using this architecture objective of work enable vertical integration toprocess becomedata reality through aa CPPS and IEC-61499 standard, that allows low-cost access to process data in a plant. Using this architecture along the entire standard, automation system can certainly reduce theinTotal CostUsing of Ownership (TCO) and IEC-61499 that allowsproduction low-cost access to process data a plant. this architecture along the entire entire automation automation system system production production can can certainly certainly reduce reduce the the Total Total Cost Cost of of Ownership Ownership (TCO) (TCO) in the industry. along the in the industry. in industry. © the 2017, IFAC (International Federation of Automatic Control) Hosting by Elsevier Ltd.Enterprise All rights reserved. Keywords: Device integration technologies, Industrial communication protocols, integration, Keywords: Device integration technologies, Industrial communication protocols, Enterprise integration, Cyber-Physical Production Systems (CPPS), Industry 4.0 Keywords: Device integration technologies, Industrial communication protocols, Enterprise integration, Cyber-Physical Production Production Systems Systems (CPPS), (CPPS), Industry Industry 4.0 4.0 Cyber-Physical 1. INTRODUCTION Industry 4.0 is based on Cyber-Physical Production Systems 1. INTRODUCTION Industry on Systems fusion4.0 of is thebased physical and the virtualProduction worlds) CPPS, the 1. INTRODUCTION Industry 4.0 is based on Cyber-Physical Cyber-Physical Production Systems In the Oil&Gas sector, the stakes are high, the conditions (a (a fusion of the physical and the virtual worlds) CPPS, the Industrial Internet of Things(IIoT) and the Internet of In the Oil&Gas sector, the stakes are high, the conditions (a fusion of the physical and the virtual worlds) CPPS, the harsh. Reliable communications and the secure transmission In the Oil&Gas sector, the stakes are high, the conditions Industrial Internet of Things(IIoT) and the Internet of Services, will collectively have a disruptive impact on every harsh. Reliable communications and the secure of business information are critical. information Industrial Internet of Things(IIoT) and the Internet of harsh. Reliable communications andAs themuch secureastransmission transmission Services, will collectively have a disruptive impact on every aspect of manufacturing companies and now we need to of are much technology is very relevant in otherAs fields, it is Services, will collectively have a disruptive impact on every of business business information information are critical. critical. Asindustrial much as as information information aspect of manufacturing companies and now we need introduce these concepts in real industries like Oil&Gas technology is in other it of manufacturing companies and now we need to to highly essential in therelevant Oil&Gas Differentfields, operations technology is very very relevant in industry. other industrial industrial fields, it is is aspect introduce these concepts in real industries like Oil&Gas sector. The 4th industrial revolution, which unlike all others, highly essential in the Oil&Gas industry. Different operations introduce these concepts in real industries like Oil&Gas in the Oil&Gas industry depend solely on information highly essential in the Oil&Gas industry. Different operations sector. The 4th revolution, which unlike is being therefore allowing companies take in depend solely on Thepredicted, 4th industrial industrial revolution, which unlike all alltoothers, others, technology and canindustry only achieve efficiency in the the Oil&Gas Oil&Gas industry depend solelythereof. on information information sector. is being predicted, therefore allowing companies to specific actions before it happens. technology and can only achieve efficiency thereof. is being predicted, therefore allowing companies to take take technology and can only achieve efficiency thereof. actions before it happens. Today’s intelligent oil field is flush with digitally enabled specific specific actions before it happens. Today’s intelligent oil flush with wired equipment, A enabled typical On the other hand, the IEC 61499 standard promotes a model Today’ssystems, intelligent oil field field is isand flushcomponents. with digitally digitally enabled On other 61499 aa model of IEC distributed control promotes systems. Industry wired systems, equipment, and components. A On the thedevelopment other hand, hand, the the IEC 61499 standard standard promotes model production platform can have more than 40,000 data tags, not based wired systems, equipment, and components. A typical typical based development of distributed control systems. Industry 4.0 will allow to model and develop software and hardware production platform can have more than 40,000 data tags, not based development of distributed control systems. Industry all connected or used. Converting this complex flood of data production platform can have more than 40,000 data tags, not 4.0 will model develop software for systems. Theand keyhardware entity in all or Converting complex flood data 4.0 independent will allow allow to todistributed model and andcontrol develop software and hardware into better business operatingthis decisions all connected connected or used. used.and Converting this complexrequires flood of of new, data the for independent distributed control systems. The key in IEC 61499 standard is the Function Block (FB), which into business operating decisions new, for independent distributed control systems. The key entity entity in carefully capabilities data requires manipulation, into better better designed business and and operating for decisions requires new, the IEC 61499 standard is the Function Block (FB), which wraps the control and communication algorithms in different carefully designed capabilities for data manipulation, the IEC 61499 standard is the Function Block (FB), which analysis, and presentation, as well as tools to support decision carefully designed capabilities for data manipulation, wraps the and in programming languages, including IECalgorithms 61131, Java, C++, or analysis, the control control and communication communication algorithms in different different making. analysis, and and presentation, presentation, as as well well as as tools tools to to support support decision decision wraps programming languages, including IEC 61131, Java, or virtually any other programming language. The Service making. programming languages, including IEC 61131, Java, C++, C++, or making. virtually any other programming language. The Service Interface Function (SIFB) is one of the types of FBs In the downstream Oil&Gas operation, corporate virtually any otherBlock programming language. The Service Interface Function Block (SIFB) is one types of In Oil&Gas corporate allows wrapping and hardware communication is very important order to determine Interface that Function Block (SIFB) is abstracting one of of the the the types of FBs FBs In the the downstream downstream Oil&Gas inoperation, operation, corporate provided provided that allows wrapping and abstracting the hardware communication is very important in order to determine access as well as the resources from the Application efficiency in the various processes. This makes it possible to communication is very important in order to determine provided that allows wrapping and abstracting the hardware access as from the efficiency in This makes to Interface. summary, currently available achieve cost processes. savings and of scale. access as as well well as the the Inresources resources from the Application Application efficiencyenormous in the the various various processes. Thiseconomies makes it it possible possible to Programmer Programmer Interface. In summary, currently available achieve enormous cost savings and economies of scale. technology is mature enough as to achieve the goal of M2M Management has genuine real-time information for its achieve enormous cost savings and economies of scale. Programmer Interface. In summary, currently available technology is mature enough as to achieve the goal of M2M Management has genuine real-time information for its but there is still a gap between technology and real industries decision-making processes. The results of any action taken Management has genuine real-time information for its technology is mature enough as to achieve the goal of M2M but there is still a gap between technology and real industries decision-making processes. The results of any action taken can be directly measured, identified and then corrected as a gap between industries decision-making processes. The results of any action taken but Thethere use is of still standards such astechnology IEC-61499and andreal architectures can measured, identified then as needed. In the short term, even those and aggressively pursuing can be be directly directly measured, identified and then corrected corrected as The use of standards such as IEC-61499 and architectures CPPSuse implies that advance would needed. those aggressively pursuing of standards such in as information IEC-61499 technology and architectures Industry 4.0the willshort haveterm, a mixeven of smart and equipment needed. In In the short term, even thosedevices aggressively pursuing The CPPS implies that advance in information technology would result to the improvement of the Oil&Gas industry as well as Industry 4.0 will have a mix of smart devices and equipment CPPS implies that advance in information technology would with traditional products machines thatandneed M2M Industry 4.0 will have a mixand of smart devices equipment result to the improvement of the Oil&Gas industry as well as every other field of life. This is why lots of intensive with traditional products and machines that need M2M result to the improvement of the Oil&Gas industry as well as communication to guide the process of vertical and horizontal with traditional products and machines that need M2M every other field of life. This is why lots of intensive researches are being carried out on information technology in communication to guide the process of vertical and horizontal every other field of life. This is why lots of intensive integration. communication to guide the process of vertical and horizontal researches are being carried out on information technology in integration. researches are being carried out on information technology in integration. 2405-8963 © 2017, IFAC (International Federation of Automatic Control) Hosting by Elsevier Ltd. All rights reserved. Copyright 2017 responsibility IFAC 1259Control. Peer review©under of International Federation of Automatic Copyright © 2017 IFAC 1259 10.1016/j.ifacol.2017.08.347 Copyright © 2017 IFAC 1259
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the recent time and these have resulted in unimaginable impact on this kind of industry. In previous works of authors (Perez et al. 2015) the general architecture for CPPs was presented. It consists of a modelbased approach identifying the different models needed for achieving vertical integration. This paper contributes to the application of the generic architecture to the special case of oil production industry and to the data collection from field devices using IEC-61499 and OPC-UA protocol for the production process and information supplier devices. The layout of the paper is as follows: Section II shows some related works that have been used as starting point for this research. Section III presents a CPPS Architecture in order to be used in an advanced industrial automation environment. Section IV describes a proposed software implementation using IEC-61499 and OPC UA. Section V proposes a set of SIFB for IEC 61499, describing in detail the configuration XML file for the OPC UA server. In order to validate the work, Section VI shows a case study in Petroamazonas Company where Modbus/TCP and an OPC-UA server into Information Components are implemented. Finally, some conclusions are drawn in Section VI. 2. RELATED WORKS This section reviews related research directly related to the areas of machining and industrial production. It also describes the approach and scope for our research when looking to develop a methodology for agile distributed process planning and adaptable to continuous processes especially in the area of oil & gas Researches about the use and implementation of the IEC61499 function blocks in different control applications have been ongoing for a while. It seems that the absolute majority of these applications are limited to control low-level processes for PLCs, which are not able to handle problems of uncertainty regarding the design layout and process planning in high-level manufacturing systems. According to this literature survey, it seems, they have a limited use of FBs for adaptive processes and control machining/assembly for this reason, the aim of this research is to use FBs architecture in a real continuous process A common application of FB architecture of IEC-61499 is the design of distributed autonomous systems with intelligent control components (Wang et al. 2001), maintenance of distributed control system and engineering web-based (Schwab et al. 2005.), automated verification of industrial control systems based on FB (Völker & Krämer 1999), FBoriented support systems engineering (Thramboulidis & Tranoris, 2001) and reconfigurable concurrent FB models (Brennan et al. 2002) Studies on implementation of IEC 61499 in process control systems are shown (Olsen et al. 2005), an implementation of a distributed control model in real time using a Java-based platform is presented, where a control application is distributed across two devices, supported by a MANAGER FB, capable of providing management services for devices. Real-time execution of IEC 61499 applications, which
describes the elements of execution within a device and different approaches to programming and implementation, is presented by (Zoitl et al. 2005), as well as criticism and solutions, ambiguities concerning the implementation of the norm, leading to different behaviors of execution of the elements in different control devices, (Strasser et al. 2011). The development, implementation and use of an IEC 61499 FB library for embedded closed loop control is presented and demonstrated (Strasser et al. 2004). in a real experiment: a see-saw problem. (Jain et al. 2002), (Yuan & Ferreira 2003) and (Yuan & Ferreira 2004) has developed a system called EMBENCH. This is a design environment simulation and rapid prototyping at different levels of control machining using IEC 61499 for modularization and reuse of services implemented control. The system allows different types of commands to controllers in different layers from the complex flexible manufacturing cell to a single servo binding. An example of how IEC 61499 can be used to model a distributed, flexible and reconfigurable application is demonstrated (Hussain & Frey 2004). But so far, IEC-61499 has only been focused on discrete control processes, this research use IEC-61499 to integrate industrial communication and its use in the monitoring of analog processes. Using the FB for process planning has emerged as an innovative approach in manufacturing systems, mainly since the introduction of the IEC 61499 standard. With the new standard, FBs can be triggered by events to execute internal algorithms in a controlled manner. This feature opens up many new exciting application scenarios. The possibility of handling changes during the generation and execution of process plans as well as the linkage to scheduling for optimal system performance are challenging effects from the distributable and modular nature of the FB technology. FBs applied to assembly process planning are reported in (Wang et al. 2008), in which assembly features (pairs of mating components) are identified and mapped to appropriate assembly FBs. Each FB possesses a set of processing algorithms to determine how to do a specific assembly operation by a robot or a human assembler. In order to facilitate the design of FBs, (Wang et al. 2009) developed an FB designer, crucial to adaptive process plan generation and able to encapsulate generic process plans into FBs for runtime execution. A group-based programming abstraction for CPPS is proposed by Vicaire et. al. (Vicaire et al. 2012). The abstraction model covers sensors and actuators. Heterogeneous devices are supported by this model, that sensors and actuators can be modeled and simulated simultaneously. The abstraction model given in this article is called "Bundle" and is suitable for plant floor devices. However, this kind of models is not addressed to be used with new communications standards such as OPC UA. Stojmenovic (Stojmenovic 2014) considers M2M as a key technology for CPPS. The author identifies the problem that all researches in the field of M2M communication is based on small-scale models and centralized solutions. For this reason,
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a paradigm shift is proposed and suggested where M2M nodes must also make decisions based on local knowledge, rather than just forwarding messages to the central system. By using this new paradigm, M2M could be applied to a larger number of industrial applications. Using this approach on production systems allows an easy linking of plant floor data, from a set of variables that are transmitted safely and where the industrial control is also performed locally. However, the other criteria suggested for the present paper, that is the use of OPC UA combined with multiple protocols, is not analyzed. In this sense, this last approach would allow an easy linking of data, from one set of tags to another, on a processor platform. This aims at a wider range of new M2M applications, supporting also secure supervisory connections.
composed of three different entities: (i) Atomic Services (AS): A set of basic services which perform data acquisition and related issues. (ii) Logical Process Nodes (LPN): LPNs represent a process of the PPM. There is an LPN for process and every LPN refers to the intelligent device where services to access process data are deployed. (iii) CPS Logical Devices (CPSLD): They are the intelligent devices of the PPM where the architecture is deployed
Other research works undertaken by the authors, such as those submitted to ETFA2014 (Garcia et al. 2015) and WFCS2015 (Garcia et al. 2015) international conferences, address low-cost CPPS under IEC 61499. However, this research goes further defining the integration between an OPC-UA server and a particular industrial communication protocol such as Modbus/TCP. It is conceived for an automation system and built upon an XML environment. 3. CPPS ARCHITECTURE The basis architecture for this paper is presented in (Perez et al. 2015). Fig. 1 depicts the general scenario for the monitoring process. This architecture is composed of a set of components that manage a set of models representing the physical world, the information exchange as well as the information to be accessed. The physical world, understood as the production process is called Production Process Model (PPM). This model is composed of the accessible data, generated in the production process (data source), and also of the intelligent devices belonging to the plant that are responsible for communicating the actual data values (data suppliers). The physical plant, including the accessible process variables, is defined by means of the so called Plant Topology Model (PTM). This model collects the physical components of the plant. The PTM represents the layout of the plant. It should be generic enough in order to describe any productive process although it can be customized to fit the interest of the enterprise
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Fig. 1: CPPS General Architecture Finally, the PIM defines the information the user wants to acquire from the process. This information is structured in the socalled Information Components (IC). ICs are the mechanisms to access the plant data. They are composed of a set of atomic services offered by Logical Nodes of the CPS (CPSLD) that handle process data (FD). The user defines ICs by means of configuration services. Once created and launched, an IC offers a unique service (ICS) that is responsible for performing the functionality of the IC. The simplest IC is the minimum access to the plant, for instance, the access to read field data of a process (which is associated to a LPND). This is a user-oriented model, thus the remote client applications are responsible for defining it. As illustrated in Fig. 2, this characterization refers to Field Data belonging to Processes of the PTM, as well as acquisition, pre-processing
The data supplier devices, being process controllers and / or smart devices offering process data and their characteristics are defined in the so called Plant Intelligent Devices Model (PIDM). Furthermore, the Plant Information Model (PIM), corresponds to the user monitoring requirements which can be defined from the PTM specifying the process variables as well as the type of access. Information Exchange Model (IEM), processes the user requirements for monitoring and it is the responsible for accessing the appropriated data process devices. The IEM is
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Fig. 2: IEM Conceptual Structure
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Fig. 3: Oil Crude Process Within oil production field, companies are commonly geographically distributed over the country; consequently, remote access to the process is of vital importance to monitor the whole process or make decisions that can affect different sites. In fact, oil production companies are usually composed of multiple blocks where production surface primary is called Oil Well-pad is a location which houses the wellheads for a number of horizontally drilled wells. The benefit of a drilling pad is that operators can drill multiple wells in a shorter time than they might with just one well per site. Every petroleum well has a downhole sensor that acquires pressure, temperature and vibration measurements for indepth identification, diagnostics and analysis of equipment operating problems and changes in reservoir conditions. Every block has a crude oil extraction module and a three phase based separation module from which oil, gas and water are obtained. Concretely, crude oil is extracted from the bottom of the wells by pumping and once on the surface it is delivered to the manifold. It is here, within the manifold, where the crude oil from all wells constituting a wellpad is collected (See Fig. 3). The extraction process of crude oil finishes when the oil crude is sent to the Production Facilities Center (CPF). The CPF is composed of a tank called crude oil Separator, is a pressure vessel used for separating well fluids produced from oil and gas wells into gaseous and liquid components that collects the crude provided by all wellpads of the block. Besides, the spare oil is sent to be processed to other companies (oil treatment and storage, oil pumping). At the same time, part of the gas is burnt and the rest is ejected by gas pipelines (gas scrubbing). The obtained water is treated and reinjected to wells (water storage, water reinjection) Water Re-Injection Pumps is one of the key technologies oil and gas producers rely on to increase recovery rates, it has proven to be one of the most economical methods for managing reservoirs. This technology can be valuable in helping maintain reservoir pressure, enhancing production of hydrocarbon reserves and reducing the environmental impact
through reinjection of treated and filtered produced water. This process uses centrifugal pumps, control systems with PLCs, pressure transmitters and temperature transmiters 4. PROPOSED IMPLEMENTATION 4.1 IEC-61499 IEC 61499 standard defines a generic model based on function blocks (FBs) for distributed control systems and industrial automation. The four models of the standard models are: FB model, application, resource and device, shown in Fig. 4. FB model is the primary and elementary model of the standard. FB is a functional unit, which has events inputs/outputs; as well as data input/output and has algorithms which are transparent to the user.
Fig. 4: IEC-61499 Function Model FB receives events/data in their input interfaces, internal algorithms processes this information and generates
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events/output data. The order of how input/output events and algorithms run are described in Execution Control Chart (ECC), which is similar to a state machine. The basic FBs can generally be integrated into Sub-Applications or FBs compounds (CFB) that can represent complex functions. Services of communication protocols for data exchange are modelled using Service Interface Function Blocks (SIFBs) In the IEC 61499 architecture, other models can be constructed based on FBs. For example, the application model is built by an FB network, whose nodes are basic FBs, CFBs, or SIFBs, and whose branches are event/data connections. The resource model is comprised of one or more “local application” and communication interfaces. The device model contains one or more interfaces (communication interface or process interface) and one or more resources FBs-based architecture for control devices enables modularization design approach and makes the development process more simple and efficient. However, since the IEC 61499 is a conceptual reference model for general purposes it is necessary to establish a model derived class FBs for a particular application from an object-oriented view 4.2 Combination of two Architectures The model for a CPPS architecture does not specify detailed functions and data types related to those functions, therefore, to get data from different models at CPPS architecture is necessary to use communication protocols. For that reason, OPC UA standard is a promising alternative being a service oriented architecture, offering data security and reliable information model. IEC 61499 model is designed for general purpose and, therefore, needs some modification before being taken in particular applications. Thus, it makes sense to combine the two models to accumulate FB standard for flexible CPPS. As a result, the proposal CPPS architecture can be seen as an integration of standard and reusable components, such as communication services based OPC UA, control algorithms, software etc. FB-based architecture is also desirable to design and develop highly flexible CPPSs profitably. Table 1: Object model mapping between CPPs Architecture and IEC 61499 CPPS ARCHITECTURE IEC 61499 MODEL Server Physical Device Device Logical Device (LD) Resource Logical Process Node (LPN) CFB Information Component (IC) CFB Data Object Basic FB, SIFB Atomic Services FBs, CFB
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directly used in automation systems. OPC UA provides a reliable, robust and high performance communication means, suitable for industrial automation applications and devices, such as those executing CPPS. Classic OPC was not able to properly represent essential issues of today’s connected world such as the types of data, information and relationships between data items and systems. Unlike the classic OPC, OPC UA provides, not only a transport method, but also a modelling mainstay able to support plant floor models. In manufacturing domain, the information technologies have to be integrated with process control engineering. For this purpose, systems must become interoperable, which requires the information exchange. In this sense, the concept of address space in an OPC UA server has to be considered. In particular, under this concept, the set of objects that the server makes available to clients is included. These objects represent the underlying real-time system data. All in all, the address space concept allows representing both real process environment and real-time process behaviour by a unique means, mutually understandable by diverse systems. (Claassen et al. 2011) The OPC UA server may be represented as a model-based system. This approach introduces the model concept for a better adaptation to the needs of modern industrial applications. Typically, a profile is designed for the vertical integration of automation systems. The use of an OPC UA architecture allows a full description of any system data, independently of their complexity. All the options above may not be needed to implement most CPPS. In this sense, the information described in the address space of the OPC UA server may be enough for most industrial systems. 5. SIFB SET FOR IEC 61499 The 4DIAC-IDE framework has been used to create a set of SIFBs, which is based in previous researches (Garcia et al. 2015; Garcia et al. 2015). In this work the new version of the OPC UA server is configured using an information model, implemented using a XML configuration file, which improves the integration with field devices and their process data. In this way, the server includes a driver for Modbus TCP/IP protocol. On the other hand, a subscription mechanism over OPC UA is implemented. 5.1 SIFB STATIC OPCUA_SERVER
4.3 OPC-UA OPC UA is aimed at replacing previous standards such as OPC DA, OPC A&E and OPC HDA. OPC-UA is an evolution of these standards, providing a vendor independent open architecture(Van Der Linden et al. 2011). As its predecessors, OPC-UA follows the client/server paradigm. With regard to portability, the main difference is that the server uses a portable communication stack that may be
This SIFB allows configuring the OPC UA server through a XML file. This file includes all essential parameters for the OPC UA server such as URL address, vendor name, server name, version, etc. Also, this configuration file states the Address Space with their Node Types and Node Instances, among others. Within the configuration two more elements are defined:
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a) Field Devices: This element groups the definition of the devices accessible by the server, characterized by the supported communication and related information. Process data elements (FieldData) supplied for the device are also defined.
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b) Data Mapping: This element defines the existing relationships between DataVariables declared in the address space section of the FieldDevice, and the associated FieldData.
Fig. 7: DINAMIC OPCUA_SERVER 5.3 SIFB OPCUA_CLIENT_READ This SIFB implements an OPC UA client able to read in variables from the OPC UA server. (see Fig. 8)
Fig. 5: Field Device Configuration This SIFB provides common events like INIT, REQ, INITO and CNF (Fig. 6) as well as the following input and output data: −
− − −
Fig. 8: SIFB OPCUA_CLIENT_READ This SIFB includes the following data: −
QI (BOOL): This input data works jointly with INIT to start-up or shut-down the OPC UA server. On INIT event, if QI is TRUE, OPC UA server starts; otherwise, if OI is FALSE, OPC UA server shutdowns. CONFIGFILE (WSTRING): This input data holds the XML configuration filename. QO (BOOL): Informs about the performance of last procedure executed. STATUS (STRING): Reports status information of the server.
− − − −
URLSERVER (WSTRING): URL of the OPC UA server. DATANAME (WSTRING): Name of the variable data available from the OPC UA server. RD (ANY): Data provided by the OPC UA server to which the client is connected. The type of this parameter is ANY to improve reuse. SOURCETIMESTAMP (DATE AND TIME): Timestamp associated to the source resource item. SERVERTIMESTAMP (DATE AND TIME): Timestamp associated to the OPC UA server item.
5.4 SIFB OPCUA_CLIENT_WRITE This SIFB provides variable writing service, having as parameters (Fig. 9): − Fig. 6: SIFB STATIC OPCUA_SERVER
−
5.2 SIFB DINAMIC OPCUA_SERVER This SIFB provides OPC UA communication using FORTE CommLayer. The network interface is designed to be as flexible as possible. The basis for the network interface is the implementation of the layer design pattern. The function block class and the layer classes are interacting by the following functions; a detailed description is given in this section (Fig. 7): −
− −
ID (WSTRING): Connection identifier to OPC UA protocol, it has parameters like; Server name [o] – svr:
TYPE (WSTRING): Data type for the value to be written. SD (ANY): Data value to be written. Again, the type of this parameter is ANY in order to increase generality.
Fig. 9: SIFB OPCUA_CLIENT_WRITE 5.5 SIFB OPCUA_CLIENT_SUBSCRIBE This SIFB implements a single subscription to monitor variables in OPC UA servers. The subscription maintains a local copy of the parameters for the monitored item. These local copies can be altered by updating their properties without affecting the state on the server. This SIFB input and output parameters are: (see Fig. 10)
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− − −
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MODE (WSTRING): three monitoring modes are supported: “Reporting”, “Sampling” and “Disabled”. PERIOD (ULINT): Set the sampling period in millisecond for sampled monitored items. RD (ANY): Value of the monitored item provided by the OPC UA server.
Fig. 12: Communication system for separation and extraction modules
Fig. 10: SIFB OPCUA_CLIENT_SUBSCRIBE 6. CASE STUDY: PETROAMAZONAS EP The case study is focussed on Petroamazonas EP Oil Company of Ecuador. Concretely, the Block18. In this Block, there are 4 wellpads which are made up by 30 wells. The example is focused on the extraction of crude oil from one well (PAA-01 of Fig. 11). The PAA-01-01 wellhead has been enriched with two transmitters: TIT-WPA01-01 which indicates the temperature and PIT-WPA01-01 that indicates the pressure. There is also a production emergency valve (SDV-WPA01-01). On the other hand, in relation with the Electric Submersible Pumping system (BESPA1), the following elements should be considered: i) two pressure transmitters: PT-BESPA1-01 for input pressure (intake) and PT-BESPA1-02 for output pressure (exhaust); ii) three temperature transmitters: TTBESPA1-01 for the temperature of the fluid, TT-BESPA1-02 for the temperature of the motor and TT-BESPA1-03 for the temperature of the output fluid; iii) a sensor for the current of the motor (CT-BESPA1-01); iv) VT-BESPA1-01 which provides the voltage of the motor
Fig. 11: P&ID ESP and oil crude production system Additionally, the core of the ESP is composed of motor (MWPA01-1), pump (P-WPA01) and VSD (VSD-WPA01). Fig. 12 shows the current communication system where OPC UA Server under IEC 61499 is located.
The design and development of an ICs is a stepwise but simple process with the following steps: Step 1) Decompose the required application function to a degree of granularity of the existing FBs. Step 2) Select corresponding FBs from the FB library for all the decomposed sub-functions, then create instances of the selected FBs, set their parameters, and connect these FBs with data flow and event flow. Step 3) Validate the whole IC model to avoid errors. Step 4) Integrate physical components to IC using OPC UA FBs and perform comprehensive testing. As an example, the design of a IC using standard FBs developed in this research is given. Fig. 12 shows the FB architecture of the IC. The IC consists of three main modules: i) OPC UA Static Server with XML configuration; ii) create dynamically new tags using OPC UA Server and use FBs of Atomics services (Logging Data, Report Data, Read Data, etc) and iii) communication services integration using OPC UA FBs for the process bus. 7. CONCLUSIONS This work presents an approach for accessing field data in automation systems using OPC UA servers in CPPS architecture using IEC 61499 applications running over FORTE runtime. The use of this kind of systems helps to introduce new CPPS concepts within the Industry 4.0 paradigm. This architecture provides a M2M infrastructure for plant floor communications. A set of SIFBs is proposed to be used for implementing OPC UA servers and clients, including subscription mechanisms. The use of FBs for designing ICs has many obvious and potential benefits. Perhaps the simplest but most important one is that the same IC is applicable for different function installations by means of software reconfiguration. It is also feasible to add, remove, and replace some functions of an IC on service when application requirements change. Another significant advantage is simplicity of design and development since it is possible to construct a software system with existing reusable software components. Modularization design and visual programming can be adopted to further expedite the development process. In addition, the reliability of the software system is also guaranteed when using software components containing mature algorithms. Future works focus on developing new functionalities such as
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Figure 13: Information Component Well PAA001 integrating OPC UA models with other industrial standards like ISA 95 or AML that will improve CPPS integration. ACKNOWLEDGMENT This work was financed in part by the University of the Basque Country (UPV/EHU) under project DPI2015-68602R (MINECO/FEDER,UE) and GV/EJ under recognized research group IT914-16, and Government of Ecuador through grant SENESCYT-2013. REFERENCES Brennan, R.W. et al., 2002. A Reconfigurable Concurrent Function Block Model and Its Implementation in Real-time Java. Integr. Comput.Aided Eng., 9(3), pp.263–279. Available at: http://dl.acm.org/ citation.cfm?id=1275687.1275693. Claassen, A., Rohjans, S. & Lehnhoff Member, S., 2011. Application of the OPC UA for the Smart Grid. In 2011 2nd IEEE PES International Conference and Exhibition on Innovative Smart Grid Technologies. IEEE, pp. 1–8. Available at: http://ieeexplore.ieee.org/lpdocs /epic03/wrapper.htm?arnumber=6162627. Garcia, M. V. et al., 2015. Building industrial CPS with the IEC 61499 standard on low-cost hardware platforms. 19th IEEE International Conference on Emerging Technologies and Factory Automation, ETFA 2014. Garcia, M. V. et al., 2015. Developing CPPS within IEC-61499 based on low cost devices. IEEE International Workshop on Factory Communication Systems - Proceedings, WFCS, 2015–July. Hussain, T. & Frey, G., 2004. Developing IEC 61499 compliant distributed systems with network enabled controllers. In IEEE Conference on Robotics, Automation and Mechatronics, 2004. IEEE, pp. 507–512. Available at: http://ieeexplore.ieee.org/document/1438972/. Jain, S., Yuan, C. & Ferreira, P., 2002. EMBench: A Rapid Prototyping Environment for Numerical Control Systems. In Dynamic Systems and Control. ASME, pp. 7–13. Available at: http://proceedings.asme digitalcollection.asme.org/proceeding.aspx?articleid=1580998. Van Der Linden, D. et al., 2011. An OPC UA interface for an evolvable ISA88 control module. IEEE International Conference on Emerging Technologies and Factory Automation, ETFA. Olsen, S. et al., 2005. Contingencies-based reconfiguration of distributed factory automation. Robotics and Computer-Integrated Manufacturing, 21(4–5), pp.379–390. Perez, F. et al., 2015. A CPPS Architecture approach for Industry 4.0. IEEE International Conference on Emerging Technologies and Factory Automation, ETFA, 2015–Octob. Schwab, C., Tangermann, M. & Ferrarini, L., 2005. Web based methodology for engineering and maintenance of distributed control systems: the TORERO approach. In INDIN ’05. 2005 3rd IEEE International Conference on Industrial Informatics, 2005. IEEE, pp. 32–37. Available at: http://ieeexplore.ieee.org/document/1560348/.
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