Project code 7508 was about retrofitting of a large control system in a steel complex.
The customer intended to upgrade obsoleted control system of multiple factories in the steel complex due to increasing in cost of maintenance and risk of system failure.
Control systems of Concentration, ore handling, grinding, Crusher, stacker and reclaimer factories all were in scope of this project.
Existing control system architecture includes, central control monitoring and eleven sets of ABB Advant AC450 and MP200 controllers by S100 IO modules, were connected together through a plant bus to process almost 8000 hardwired signals from-to process field devices and electrical system in concentration, grinding and ore handling factories.
Staying on ABB technology and implementing the project in three phases was the best solution through possible options for replacing top-to-bottom of the plant control systems.
At phase one only monitoring system migrate to ABB 800xA to resolve monitoring issues and improve the operation efficiency. A Redundant aspect and three connectivity servers and domain server considered in new monitoring system.
At phase two old Advant AC450 and MP200 controllers replaced by AC800M PM864 controllers to improve function of control systems and solve some issues in maintenance. We rewrote derivated logic of Advant controller that was written by AMPL language in control builder M again.
At phase three all outstanding modules in control system including S100 IO modules replaced by S800 modules.By utilizing phoenix contact interface board we could shorten installation and commission lead time.
Completing this project resolved all the customer issues with old control system, operation efficiency increased due to more flexible operator interfaces, better self-diagnostic and stronger cyber security and production throughput improved, also production and maintenance cost reduced.