DCS versus FCS

DCS FCS
Definition Definition
DCS = Distributed Control System FCS = Field(based) Control System, an
architecture of FOUNDATION™ Fieldbus (FF)
Control System
DCS Architecture FCS Leaner Architecture

4 Plant
10 M Host Computer:
HSE Fieldbus
3 Control
1M
Power Supplies Linking Device
500 K Control Cards Power Supplies
IO Network
2
Input Cards
Output Cards
Fusing
1.2 K
Marshaling
4-20 mA Termination Field:
Field Cards
1 H1 Fieldbus
P

Proprietary System Network: Open System Network:

1. Field 4~20mA (standard)
2. IO Network (proprietary)
3. Control Network (proprietary)
4. Plant Network (proprietary)
¾ Point-to-point field wiring
¾ Power and communication on the
same pair of wires
¾ Intrinsically safe by point Barrier
¾ One data per wire pair
¾ Unidirectional
¾ Integration by standard 4~20mA
Configured by proprietary engineering tool
Tied to the proprietary vendor for life
¾ FF-H1 (field)
¾ FF-HSE (host)
Both FF-H1 and FF-HSE have the same
protocol for different media allowing bridging
from one to another network. Not only Digital
Communication Protocol, but also
Programming Language for Control
Strategies
¾ Multi-dropped field wiring
¾ Power and communication on the
same pair of wires
¾ Intrinsically safe by fieldbus Barrier
¾ Lot of information per wire pair
¾ Bidirectional
¾ Interoperable with all FF Registered
products
Configured by single open and standard
engineering tool
Not tied to a single vendor

DCS versus FCS page 1

 DCS
Function Blocks resides and executed at
Control / Processor Module
¾ Proprietary Function Blocks
1:16 (typical) Distribution level
Single Loop Integrity by special and
expensive I/O Modules
‘Expandable’ from few loops to many loops
with deteriorated system performance
Mostly use proprietary Device Drivers
Proprietary Operator Workstations
Proprietary Engineering Workstation
Standard 4~20mA, proprietary all the way to
Enterprise level
Limited system view
System
Field
Instruments
FCS
Function Blocks resides and executed in FF
Devices
¾ More than two dozen standard block
types to cover all control and
monitoring functions
¾ Great flexibility to build powerful
control strategies
2:1 (typical) Distribution level. Offers much
more distributed system (32 folds typical)
Single Loop Integrity by FF-H1 segmentation
‘Scalable’ from few loops to many loops
without deteriorating system performance
Utilizing open and standard OPC Servers
Any OPC compliant Operator Workstation
Single Engineering Tool for all FF Registered
Devices
Open all the way from Plant floor to
Enterprise level
Expanded view to field devices
System
DCS versus FCS page 2
 DCS
Sufficient control information but insufficient
management information
Management Information
Control Information
Diagnostics up to I/O modules; alert only on
signal upscale and downscale
Online Plant Asset Management up to I/O
modules, enabling only for ‘predictive’
maintenance
PV Value only:
¾ automatic PID Manual switching by
upscale and downscale signals only
¾ Fail safe actions only mechanically on
output signal or pneumatic source lost
¾ No detail diagnostics
FCS
Slight increase in control information. Vast
increase in management information
Extended Diagnostics up to Field Devices;
Pre-warning alert for field device pre-failure
Online Plant Asset Management up to field
devices, enabling complete ‘proactive’
maintenance.
Status everywhere (PV Value & PV Status):
¾ fully automatic PID Manual switching
on ‘bad’ and ‘uncertain’ PV Status
¾ Fail Safe actions on ‘bad’ and
‘uncertain’ PV Status
¾ Detail diagnostics by Engineering Tool
DCS versus FCS page 3
 DCS FCS
No Data reliability Data Reliability

DCS FCS

TAG = LIC-012
VALUE = 70.34
UNIT = m3
15.3 mA
STATUS= GOOD
ALARM = Y/N

TRANSMITTER TRANSMITTER

¾ Only Process Variable (PV) Data scaled ¾ PV Data in Engineering Unit

in 4~20mA transmitted as digital signal
¾ Engineering Unit conversion done at ¾ Scaling in Engineering Unit executed
Operator Workstation at FF devices as calibrated
¾ Analog signal conversion at field ¾ Engineering Unit transmitted together
device with PV value
¾ Analog to Digital conversion at I/O ¾ TagID transmitted together with PV
module to raw counts value
¾ PV Status transmitted together with
PV value
¾ PV Alarm status transmitted together
with PV value
Non integrated system database Single integrated system database
¾ Changing range and engineering unit ¾ Changing range and engineering units
of field device require Operator also change the display
Workstation reconfiguration ¾ Minimize configuration error
¾ Error due to wiring error of I/O point ¾ FF device configuration means
could not be detected configuring the entire system
¾ Multiple configuration required for
each subsystem
Redundancy at: Redundancy at all level
¾ CPU Increases Safety and Availability
¾ Power Supply everywhere at every level
Redundant
¾ I/O Modules OPC server
Redundant UPS
¾ Control Network
Host
Redundant Workstations Power Level

¾ I/O Network
Network
Single Node Host Network
Segments Level
HUB HUB Redundant
Redundant Bridge / Link Linking
Hub & Power Level

Redundant Redundant Minimum

Controller Power I/O Modules
Redundant Field
Isolated Loops
Power Level
by segmentation
Network
Active
Junction Box Backup
Redundant LAS Automatic
Transmitters Shutdown
Field
Level

Redundant
Sensors

DCS versus FCS page 4

Proper implementation of FF Technology
Is Hybrid System (DCS with FF capability) an ‘open’ system?
DCS with FF Capability NO! Foreign System
are they ‘Open System’? are not interoperable
at most of system level

Proprietary and Dedicated Software

Proprietary and Dedicated Network

with Proprietary Drivers
(Proprietary Layer + TCP/IP + Ethernet)

Proprietary Functionality, Control

Function and I/O-Bus
FF Gateway

Two different type of field

communication,
i.e. 4~20mA and FF-H1

4~20 ma Devices FF-H1

Does Hybrid System (DCS with FF capability) have FCS Architecture

(with its features and benefits)?
DCS with FF Capability NO! It is still DCS
with capabilities to
Do they have FCS connect to FF Devices
Architecture?

FF
Configuration
FF Configuration have to be
done by dedicated FF
Configuration Tool connected
directly to FF-H1 or FF Gateway

No Linking Device
No FF-HSE
FF Gateway

Fieldbus H1 Network (31.25 Kbps)

4-20 ma Devices

Proper implementation of FF Technology page 1

Does all Manufacture design to have FCS architecture?

ƒ Other Solution ƒ True FCS Architecture

Linking Device
Proprietary on Ethernet & IP,
ControlNet or others HSE Fieldbus

NOT a Linking Device Single integrated unit

PCF F
SPBB PS
U
I I I I
H1 Fieldbus
H1 Fieldbus

Does all FF System have Standard Open Network?

Standard Open Host-Level Network

„ Proprietary Control Network; „ HSE as Open Host-level Network;

Proprietary Controller Linking Device must be
interoperability registered device
OSI Model

“User”
HSE
Application
. Registered
Proprietary Ethernet HSE Fieldbus

PCF F NOT Registered Transport UDP/TCP

SPBB Network IP
U
Data Link H1 Fieldbus
Ethernet
Physical
H1 Fieldbus

Proper implementation of FF Technology page 2

How would FF Enterprise Automation look like?
FF Enterprise Automation
AssetView WS
Internet
PIMS WebHMI
CMMS ERP Server @ Intranet

Printer Printer
Workstation Server Workstation Server Workstation Workstation

Enterprise LAN/WAN - Intranet

OWS - ProcessView AssetView WS
EWS - SYSCON AssetView Srv

OPC
Printer
Workstation Workstation Workstation

FOUNDATION™ Fieldbus HSE

Workstation Printer
Workstation Workstation

Server
Server Server

Firewall

ÅLinking DeviceÆ

FF FF FF FF
H1 H1 H1 H1

MobileHMI √
Å FF Devices Æ

Proper implementation of FF Technology page 3