FIELD CONTROL SYTEMS

GEORGIEV BORIS

Faculty of Electrical Engineering and Information Technology, Slovak University of Technology,

SK - 812 19 Bratislava, Ilkovičova 3, ++421260291605, [email protected]

Abstract: This article deals with the field control systems which represent the last evolution phase
of digital control systems. Based on analysis of the evolution defines essential features and
functions of these systems and briefly describes the range of problems which in connection with
these systems are necessary and have to be solved. The article brings in the overview of the main
theme and is intended for wide technical community.

Keywords: intelligent field device, fieldbus, field control system, function block

1 INTRODUCTION
It can be stated from the analysis of the evolution of control system architectures that the
process automation is the most dynamically evolving part of automation and it determines the
direction of control system evolution for several decades. The control system reliability and functional
safety in concert with the ability to assure stability and quality of control are the key requirements for
their operation.
Reliable operation of field instrumentation (transmitters and actuators) is important to satisfy
all requirements mentioned above. Despite the fact that the theory of automatic control omits them, the
field instrumentation and the way of its integration to the control system structure are in the present
the main issues that concern both the suppliers and customers of automation systems. It is about
increasing the amount and quality of information obtained from field devices (for device diagnostic
and maintenance) and from controlled process (for control purpose) as well as making activities
related to field instrumentation within the whole automation system life cycle more effectively.
The need to familiarize with the actual trends in control systems is necessary for each control
engineer. Knowledge of process control system evolution facilitates to understand the meaning of
ongoing changes and at the same time to estimate the trend of automation instruments for control
systems of other application segments of automation (factory, building and vehicle automation).

2 EVOLUTION OF PROCESS AUTOMATION SYSTEMS

The hierarchical distributed control structure is presented by the level model in pic. 1. The set
of tasks performed on each level is one of the criteria for comparing the basic generations of process
instrumentation (GPI).

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 Plant management level

Plant supervisory control level

Process control level

Field level

Controlled process level

Picture 1 - Hierarchical distributed control systems structure

Also the way of performing the functions for information processing is subjected to the
evolution. The transition from pneumatic systems to the recent digitally working functional unit (FU)
was possible as a result of developments in microelectronics.
Several GPI characterized by the significant changes mainly in performing tasks of
information processing, transmission of data and operative control can be distinguished. The evolution
of digital control systems which is symbolically depicted in pic. 2 is characterized by three basic
generation changes:
- DDC – Direct Digital Control with control computers
- DCS - Distributed Control System
- FCS – Field Control System.

DDC DCS FCS OCS

PID

PID
?
PID

Picture 2 - Control system evolution

The usage of control computer (DDC) brought all advantages of digital information processing
(ability to perform difficult algorithms, data archiving, flexible changes of control application etc.). As
the usage of computers was profitable only by the high number of control loops, the control of several
hundreds control loops with single control computer caused low structural reliability of control
system. The other disadvantage was high costs of wires and installation by reason of the single pair of
wires used to interconnect field devices with I/O cards of control computer.
The disadvantages of DDC were partially solved by the first generation of Distributed Control
Systems (DCS). Honeywell TDC 2000 system is regarded as a first DCS. It included digitally working
control units located at the process level (process units), which digitally communicate between each

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other within the one-layer communication system. Each unit performed the function of eight single-
loop controllers and one backup controller. The way of interconnection the field devices with the
control systems was same as in DDC i.e. single pair of wires for each device.
The second generation of DCS, the Field Control Systems (FCS), is in present the last
evolution step of control systems. The hierarchical communication system of FCS enables the digital
communication among devices at the field level (bus interconnection of field devices). Developments
in microelectronics allowed performing functions for information processing used for automatic
control directly in the field devices what leads to increase in structural reliability of control system.
The field device failure in FCS structure causes the shut-down of only one control loop. By using FCS
the compact single-loop controller are no more needed.
Considering the way of performing functions for information processing, the FCS represents
their total functional and area distribution up to implementation in transmitters and actuators. This
implementation is in the pic. 2 shown by the migration of performing PID algorithm. Considering the
way of transmitting information it can be seen the transition from the structure with single pair of
wires for each device with one-way transmission of unified signals (analog and discrete), up to
bidirectional serial transmission of Pulse Code Modulated (PCM) signals over the Field Bus System
(FBS) so-called fieldbus.
Evolution of control systems did not stop at the FCS and continues by defining requests for so-
called Open Control Systems (OCS). These systems should bring the possibility of transporting the
software part of control system and related possibility to choosing the engineering software
independently of used hardware. This should permit separating the design of software part from
selection of automation instruments i.e. to use universal hardware equipments.

3 FIELD CONTROL SYSTEMS

3.1 Basic terms

„Smart“ field device is device, which internally works digitally (performs function of processing
information) but the transmission of information to / from superior control system is done in analog
way.
Communication can be defined as a process of bidirectional exchange of information between two or
more devices of control system. While the analog communication is based on the transmission of
amplitude modulated (AM) signals, digital communication is characterized by the transmission of
pulse code modulated (digital) data [1].
Field Bus System (fieldbus) provides a serial digital communication among field devices with one
another (horizontal communication) and among field devices and superior control systems (vertical
communication) over single pair of wires.
System device is device with serial digital communication capability with the rest of devices within
the control system structure.
Intelligent field device represent the combination of smart and system device properties i.e. it is device
performing the functions of processing information used in automatic control with ability to
communicate (all digital serial communication) with other devices.

3.2 Field instrumentation

Field devices, performing functions of processing information, and digital communication
system are the basic principles the FCS are based on. The sequence in which they were used in control
systems depends on application segments of automation. For example, while in process control
systems the smart field devices were used before the system device ability was implemented, on the

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contrary in building automation the evolution of process instrumentation goes from system to
intelligent devices [1].
Components of control system (Functional Units – FU) may be decomposed from the point of
performing functions for transmission of information and functions for obtaining, processing and
using information for needs of automatic control into following parts:
- Application Module (AM),
- Communication Module (CM),
which are often centralized in one functional unit (pic. 3) [2].

AM CM
I
FU
CS L

Picture 3 - Decomposition of FU (AM – application module, CM – communication module, FU – functional

unit, L – connecting line, CS – communication system, I – information) [2]

In pic. 4 is shown the basic structure of intelligent transmitter, which comprises of one or several
sensors, A/D converter, microcontroller and communication module.

S1
MUX

S2
ADC

uC CM
Si

FU
L

Picture 4 - Principle structure of intelligent transmitter (S – sensor, MUX – multiplexer, ADC – A/D Converter,
uC – microcontroller, CM – communication module, FU – functional unit, L – connecting line)

The set of functions of processing information performed in microcontroller unit of intelligent

field device was at the beginning limited to solving tasks of primary processing information
(calibration and linearisation of device, compensation of measurements, square root function, totalizer,
counter). Besides these functions are in field devices in the present performed more complex functions
e.g. control functions (PID algorithm), self diagnostic functions and variety of other vendor-specific
functions.

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3.3 Field Bus Systems
The evolution of FBS last for several decades. The works on creation of single standard began
in ‘90s of previous century. There are several reasons why in present exist relatively large amount of
FBS. The main reason is in different requests of each segment of automation. Not small influence on
international standardisation process had the interests of the automation market leaders, which were
developing their own, and in the beginning proprietary i.e. closed and not compatible FBS. Behind the
majority of widely used FBS stood in their beginning leader companies of automation business. Those
companies are now members of interest groups of manufacturers and users of automation systems
supporting the international standardisation as well as the further enhancements of specific FBS.
For example, mainly in Europe used FBS Profibus, was developed and standardized thanks to
initiative of 21 companies and institutes in Germany as national standard DIN 19245 [3]. Then it was
accepted together with other standards as European standard EN 50170. Profibus has been
standardized since 1998 also in IEC 61158 [4]. The further development is initiated and controlled by
the Profibus International (PI) and the site of regional interest groups (PUG – Profibus Users Group or
PNO – Profibus Nutzer Organisation).
To describe the function or to control complex communication system, the seven layer
reference model (ISO 7498, Basic Reference Model for Open Systems Interconnection – OSI) was
developed by ISO (International Standard Organisation). In sense of definition each layer (except. the
1. layer) uses the services of lower layer and its own services (except the 7. layer) provides to upper
layer (pic. 5).

Device 1 Device 2
AM1 AM2

CM1 CM2
application protocol
7. APPLICATION 7. APPLICATION

6. PRESENTATION 6. PRESENTATION

5. SESSION 5. SESSION

4. TRANSPORT 4. TRANSPORT

3. NETWORK 3. NETWORK

2. DATA LINK 2. DATA LINK

physical protocol
1. PHYSICAL 1. PHYSICAL

Picture 5 - Basic Reference Model for Open Systems Interconnection (ISO/OSI model)

To fulfill the basic functions of communication system it is sufficient to realize from these seven
layers only following three [2]:

7. application Defines relation (interface) between user (application program) and

communication functions.
2. data - link Provides organization and control the data transmission, includes MAC (Medium
Access Control) and data security.
1. Physical Defines mechanical, electrical, functional and procedural features of creating,
keeping and discarding the physical connections.

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Such simplified ISO/OSI model is depicted in pic. 6.

Device 1 Device 2
AM1 AM2

CM1 CM2
application protocol
7. APPLICATION 7. APPLICATION

2. DATA LINK 2. DATA LINK

physical protocol
1. PHYSICAL 1. PHYSICAL

Picture 6 - Simplified model

Several FBS have also specified services of the rest four layers, which brings the possibility
for devices to communicate in large fieldbus networks. According to implementation of individual
layers, the properties and abilities of various FBS can be assessed and compared.
Pic. 7 figures the differentiation of in present widely used FBS. The complexity of
communicating devices (the complexity of transmitted data – bit, byte and block) is on the horizontal
axis. On the vertical axis is the segment of automation (logical control, regulatory control).

Type of Control

FIELDBUS
CONTROL
PROCESS

Profibus PA Foundation
fieldbus

DEVICE BUS

Profibus DP & FMS

Device Net
Lon Works
DISCRETE
CONTROL

Interbus S
SENSOR BUS
WorldFIP

ASi
Seriplex
Interbus loop
Type of De v ice s
Low-end Midrange High-end
bit byte block

SIMPLE COMPLEX
DEVICE DEVICE

Picture 7 - Categorisation of communication systems [5]

Bus systems are according to pic. 7 grouped into three categories (classes):
Sensor bus – FBS for relatively simple field devices, processing mostly binary information (proximity
switches, contactors, buttons)

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Device bus – FBS for devices processing large amount of information (PLC – Programmable Logical
Controllers, RIOS – Remote Input / Output System, operator panels, variable speed
drives)
Fieldbus – (often designated also as Control bus) beside the way of transmission of data defines
also the range of functions and the method of their execution in intelligent field
devices (most appropriate for process control)

3.4 FCS technology

FCS is based on FBS of fieldbus (control bus) class. Despite the fact, that also Profibus PA
(Process Automation) is classified as control bus (pic. 7), in the present only with FBS Foundation
fieldbus (FF) it is possible to achieve structure of FCS often called as „CIF – Control In the
Field“.This leadership of FF is caused by the possibility of horizontal communication i.e. direct
communication between two field devices without the need of third device. This feature of FF is
essential for creating the FCS. While the specification of FF contains in addition to the way of
communication interconnection of field devices also the way of performing the function of processing
information, it can be stated that „FF is more than fieldbus“.
Basics of technology on which the FCS is based will be explained in following on the example
of ratio control of two materials (components). Pic. 8 shows the P&ID (Process & Instrumentation
Diagram) of ratio control. Process variable is the concentration of final product. Manipulated variable
is the flow of component A which is manipulated according to the flow of component B to achieve the
set point value of concentration.

FF FF FF FF
FT FC FY FT
2 3 1 1
FF
FCV
3
Component B

Component A Product

Picture 8 - P&ID of ratio control

Control loop is created from three intelligent field devices:

- FT1 and FT2 designate intelligent flow transmitter
- FC3 is an intelligent final control element with control valve.
As the standard ISO 3511 [6] does not cover functional possibilities of modern field devices
(4th part of standard incorporating control computers was released in 1985), the first problem is with
drawing P&ID diagrams. There is no standardized way how to indicate the function of processing
information performed in the field devices and also their logical communication interconnection.
These functions are in pic. 9 designated with symbol „FF“ (Foundation fieldbus) and their
interconnection is indicated with thin dashed line [5]. Second option is to use conventions for drawing
P&ID diagrams defined by Fieldbus Foundation [7].

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Control loop function from pic. 8 is in pic. 9 transformed to function blocks structure.

Device 1 Device 2

AI AI
T AG T AG
FT 1 FT 2

RA
T AG External Link
FY1 (communicated)

Internal Link
Device 3

PID AO
T AG T AG
FC3 FCV3

Picture 9 - Control loop structure in sense of function

Function blocks (FB) are defined by their internal functionality and the set of input, output and
internal parameters. Every FB is through those parameters integrated into the function blocks diagram,
which represents the control application. Basic blocks creating control loop structure are: AI (Analog
Input), PID, AO (Analog Output). Several FB can be performed in a single device. Communication
between blocks within one device is achieved by internal links. Exchange of information between FB
performed in different devices is achieved with external links provided with data transmission over the
fieldbus system.
Block RA (ratio), which is performed in device 1, obtains by internal link information on
component B flow from the AI block (performed in device 1) and by external link information on
component A flow from the AI block (performed in device 2). Calculated actual value of ratio is over
the external link transmitted as a process variable to the PID block (performed in device 3).
Information about the setpoint of manipulated value is transmitted by an internal link to the AO block,
which perform the change of valve stroke i.e. the flow of component A.
Values transmitted between FB are labeled with so-called TAG-s (for example the component
B flow has a tag FT1 ). The access to the communication line of FF, which is controlled at the second
layer of ISO/OSI model, is performed with „Arbitrator – Producer – Consumer“ (A-P-C) method. The
operation of transmission of single parameter (value) can be described on an example in pic. 10 as
follows:
1. device with „Arbitrator“ function according to the time schedule „acclaim“ that the tag FT2 will be
transmitted,
2. one or more devices (Consumers) which process the tag FT2 in their function blocks set themselves
to receive mode,
3. device 2 (Producer), which is the source of FT2 sends the FT2 value to the bus.

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The time sequence of operation of transmitting values and executing function blocks also called as
„control loop micro cycle“ is presented in pic. 10.

Dev ice 2 - AI (FT2)

Loop 1

Dev ice 2 - Producer (FT2)

Dev ice 1 - AI (FT1) and RA (FY1)

Dev ice 1 - Producer (FY1)

Dev ice 3 - PID (FC3), AO (FCV3)

Unscheduled communications

Macrocycle

time
FB execution TAG communication

Picture 10 - Control loop micro cycle

Those slots in which the cyclic communication is not present are intended for unscheduled acyclical
communication (transmission of alarm states, configuration and diagnosis of field devices etc. ).
The device performing the „arbiter“ function is called LAS (Link Active Scheduler). It is
usually the superior control system. In order to increase the reliability of control system can be this
function performed in theoretically any field device (backup LAS) which in case of superior system
malfunction or communication problems with the active LAS take over the LAS function without the
loss of control loops functionality.

3.5 Related tasks

It can be observed that the first stage of international standardisation of fieldbusses, which
brought the answer to the question how to transmit data among FU, was successfully accomplished.
The actual standardisation effort is focused on the features and functions of field devices and the way
of theirs description. In this second stage the meaning of transmitted data is under standardisation i.e.
the question what to transmit. In other words while the first stage dealed with device interoperability
i.e. the ability of devices from different vendors connected to the same bus system to communicate
with each other, the second stage deals with achieving the interchangeability of different vendors
devices.
The range and meaning (type) of values (communication objects), implemented by device
vendor (the set of mandatory and optional parameters which are reachable across the bus), configuring
properties and behaving in particular regimes used by fieldbus system is defined by so-called device
profiles. Profiles are created by previously mentioned non-commercial interest groups e.g. PI for
Profibus.
Standardisation of functions performed in the field devices represented by function blocks is
within the scope of international standardisation solved in standards: IEC 61499 and IEC 61804.
Though function blocks used in FCS with Foundation fieldbus do not correspond to those standards
and as previously mentioned are the part of FF specification.

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 The way of describing the features of field devices is very tightly connected with acquiring the
device interoperability. It can be distinguished in dependence on the range of described features i.e.
communication system basic parameters (e.g. for Profibus the GSD files are used), cyclic and acyclic
data exchange (FDT/DTM or EDDL is used), visualisation of data (EDDL) [8].
To get intelligent field devices and fieldbus systems into the operation in different automation
segments it is necessary to solve problems related mainly with their operation in areas with explosive
atmospheres (FISCO – Fieldbus Intrinsically Safe Concept and FNICO – Fieldbus Non-Incendive
Concept) and to permit the usage of FBS in safety-related control systems. For FF the FF-SIS
(Fieldbus Foundation Safety Instrumented Systems Concept) was defined to facilitate the usage of FF
in accordance with IEC 61508 a IEC 61511 [9, 10].

4 CONTROL OF FBS
Control the fieldbus according to controlled technological process is in the present not very
discussed issue. The fact, that fieldbus systems work in deterministic regime (the maximal time in
which the device is permitted to transmit its data or in which the information from the device reaches
the superior system respectively), doesn’t stimulate discussions about the change in their control,
which could finally result in the increase of reliability, robustness and performance of whole control
system. In present only the question of reliability of alone FBS is solving i.e. the interest is focused
only on process of transmitting data.
Communication systems analysis are mostly focused only on systems with medium access
algorithm like CSMA/CD (Carrier Sense Multiple Access with Collision Detection) or Token Passing
combined with Master – Slave method and the A-P-C method, used in FCS with FF, stays at the
periphery of interests.
The transition from strictly deterministic approach, which is in the present considered as the
most important advantage of FF and Profibus PA, to the adaptive control of communication would
cause the elimination of useless transmission cycles, and as a result either the higher number of
devices would be able to be connected to the bus or it will be possible to transmit larger amount of
data from the field devices e.g. for diagnostic purposes [11].
The last but not the least problem is the reconfiguration of control system structure, as
a reaction to the failure of field devices and the parts of FBS respectively in order to increase the
availability and safety of control system.
First, the creation of formal model of the FBS function is necessary. As the communication
system represents parallel sequential logical system, the description apparatus could be based on e.g.
Petri nets. Applying methods of automatic control to interconnected model of controlled and
communication system would lead e.g. to development of new function blocks in conformity to IEC
61499, which would control the communication on the bus according to controlled process in order to
increase the reliability and robustness of control process.

5 CONCLUSION
Field Control Systems represents so far the last evolution step of control systems. Intelligent
field devices and digital communication systems, which are the basis for FCS, are in the present in the
center of interest of the world of automation. Their implementation causes cardinal changes in all
engineering activities within the life cycle of the control system and changes processes at the all levels
of the control system of the factory. The development of these systems together with the international
standardisation still continues and leads to open systems. Open systems at the present state of
economical globalisation and following concentration of automation systems vendors are essential for
achieving the effectivity in process industry.

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Abbreviations

AI Analog Input
AM Application Module
Amplitude Modulation
AO Analog Output
A-P-C Arbitrator – Producer – Consumer
CIF Control In Field
CM Communication Module
CSMA/CD Carrier Sense Multiple Access with Collision Detection
DCS Distributed Control System
DDC Direct Digital Control
EDDL Electronic Device Description Language
FB Function Block
FBS Fieldbus System
FCS Field Control System
FDT/DTM Field Device Tool / Device Type Manager
FF Foundation fieldbus
Fieldbus Foundation
FF-SIS Fieldbus Foundation Safety Instrumented Systems Concept
FISCO Fieldbus Intrinsically Safe Concept
FNICO Fieldbus Non-Incendive Concept
FU Functional Unit
GPI Generations of Process Instrumentation
GSD Gerate Stamm Daten
Generic Station Description
IEC International Electrotechnical Commission
ISO International Standard Organisation
LAS Link Active Scheduler
OCS Open Control System
OSI Open Systems Interconnection
P&ID Process & Instrumentation Diagram
PA Process Automation
PCM Pulse Code Modulation
PI Profibus International
PLC Programmable Logical Controllers
PNO Profibus Nutzer Organisation
PUG Profibus User Group
RIOS Remote Input / Output System

Overview of related standards

IEC 61131: Programmable controllers

IEC 61158: Digital data communications for measurement and control - Fieldbus for use in industrial
control systems.
IEC 61499: Function blocks for industrial-process measurement and control systems.
IEC 61508: Functional safety of electrical/electronic/programmable electronic safety-related systems.
IEC 61511: Functional safety instrumented systems for the process industry.
IEC 61784: Digital data communications for measurement and control.
IEC 61804: Function blocks for process control.
ISO 3511: Process measurement control functions and instrumentation -- Symbolic representation

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References

[1] GEORGIEV, B.; Jurišica, J. Systémové a inteligentné čerpadlá v riadiacich systémoch

vykurovania (System and intelligent pumps in heating control systems). TZB Haustechnik,
2004, No. 2, Pg. 10.
[2] GEORGIEV, B. Digitálna komunikácia v riadiacich systémoch vykurovania (Digital
communication in heating control systems). In. 12. Medzinárodná konferencia
VYKUROVANIE 2004, 1. – 5.3.2004 Tatranské Matliare, SSTP, Pg. 363.
[3] Profibus Nutzer Organisation. www.profibus.com
[4] IEC 61158: Digital data communications for measurement and control - Fieldbus for use in
industrial control systems.
[5] www.plantwebuniversity.com
[6] ISO 3511: Process measurement control functions and instrumentation - Symbolic
representation
[7] Fieldbus Foundation. Function Block Capabilities in Hybrid / Batch Applications.
www.fieldbus.org.
[8] IEC 61804 - 2: Function blocks (FB) for process control - Part 2: Specification of FB concept
and Electronic Device Description Language (EDDL)
[9] IEC 61508: Functional safety of electrical/electronic/programmable electronic safety-related
systems.
[10] IEC 61511: Functional safety instrumented systems for the process industry.
[11] RAKŠÁNY, P. Adaptívny prenos dát v systémoch riadenia technologických procesov
(Adaptive transmission of data in process control systems). Kandidátska dizertačná práca
(Ph.D dissertation work). Bratislava: EF STU, 1993.

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