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ABB Ability™ Symphony® Plus HR Series Control and I/O

AlzChem GmbH in Trostberg, a subsidiary of Evonik Industries

AG, produces specialty chemicals products with a wide range

of uses. These chemicals are used, for example, in the production of crop protection products, pigments, dyes, pharmaceuticals and polymers.

In the past, an inverted filter centrifuge in a system for extracting natural substances was PLC-controlled at AlzChem GmbH.

The program code for the PLC, a standard program from the

manufacturer, was not transparent and needed specialists to

make changes. The program was not intuitive and diagnostic

analyses were only available to a very limited extent. In order

to simplify programming and to optimize the process control,

AlzChem thus decided to use the AC 700F controller. This replaced the PLC and was integrated into the existing Freelance

800F system without any problems.

This offers several advantages for AlzChem: The use of one

single engineering tool to configure the entire system simplifies

engineering and saves a significant amount of time during

commissioning. After transferring the program the system is

easy to understand and maintenance is simpler.

During the operating and maintenance phase, the wide range

of diagnostic options (sequence control-, hardware -, interlock

diagnostics), the intuitive graphical user interface and mature

alarm and report management allow costs to be cut. This

reduces downtime of the application and cuts maintenance

Project: System for extracting natural substances,

AlzChem GmbH, Trostberg, Germany

Industry: Chemicals

expenditures. All this improves the efficiency of the entire

system and the slightly higher acquisition costs compared to

a PLC amortize within a very short time.

Hartmut Rohner, Head of Electrical Systems, Instrumentation

and Control at AlzChem, is particularly impressed by the simple

and clear handling of the AC 700F controller and the Freelance

800F system. “It is easy for anyone to learn how to operate

the software and hardware. In contrast, it was practically impossible to understand the standard program supplied by the

manufacturer together with the centrifuge.” Mr. Rohner also

sees clear advantages over other systems when it comes to

maintenance and faultfinding. Whereas with other manufacturers faultfinding is only possible using a handheld device in

the field, Freelance 800F provides extensive analysis options

right in the control room. “Now I look at the status and can

see straight away where the error is. That is not possible that

simply in other systems.” This makes fault finding and maintenance substantially easier.

Northam Platinum Ltd. is based in Johannesburg, South Africa,

and mines and produces precious metals. Convertors are

used to extract platinum from ore. These convertors are driven

using electrical motors. Until now, a PLC controlled the motors’

direct motor starters. This operating mode was not reliable

and efficient enough for Northam, as the motors thus operate

constantly at full output. That reduces the lifespan of the components and causes higher repair and maintenance costs to

increase.

When the application was modernized and converted to frequency converters to increase energy efficiency, the outdated

PLCs were to be replaced. Customer requirements were a

more compact controller, an improved presentation of alarms

and results and an excellent cost/benefits ratio.

Northam opted for the new AC 700F controller when replacing

PLCs for the converters. Northam has been using the Freelance

800F system to control its smelting furnaces and other applications for many years and is convinced by the systems performance.

One AC 700F controller now regulates one variable-speed

drive. The motor output can be adjusted at any time to the

current operating requirements of the application, as frequency

converters can be simply driven by the controller. The adjustment allows up to 50% of energy savings and processes can

be better controlled. The increase in efficiency resulting from

the intelligent speed control can be used in two ways: to increase productivity or to keep production stable while simultaneously reducing energy consumption.

Integration of the AC 700F controller into the existing Freelance

800F system and the easy engineering with just one engineering tool, “Control Builder F” simplify commissioning and maintaining of the entire application. The configuration is particularly

simple as the visualization is also created with Control Builder

F. Separate tools for programming the PLCs and to create

operator images are no longer needed. Technicians now only

need to handle a uniform engineering tool system wide. Production data and information such as signal descriptions,

current and historical data, reports and detailed status information can be recorded over several years in the information

management tool PGIM 800F.

As a result of its positive experience, Northam will modernize

additional converters and other small plants using the AC 700F

controller in the near future.

Osby Parca produces high-performance boilers for hot water

and steam. The product range spans from electric boilers with

36 kW through to oil boilers with 16 MW. Osby Parca offers a

wide variety of solutions: for solid fuels, steam, gas, oil, electricity and heat recycling, flue gas cleaning and biomass systems. These boilers are delivered to both small customers and

key accounts - from sole proprietors for pipe installations to

industrial customers and distance heating plants.

In order to control the fully-automated solid fuel boiler Osby

PB2, Osby Parca has been using ABB’s compact Freelance

800F control system for several years. This boiler, with output

of 350 to 3000 kW is used to burn dry wood fuels such as

pellets and briquettes. The control adjusts the combustion to

the current load to ensure that there is a constant inlet temperature. Sensors and actuators regulate the draught in the

firing plant, the movement of the grate and the fuel supply.

Adjusting the draught in the firing plant controls the amount

of air for the combustion process. This allows continuous

control across the entire range of outputs. The combination

of the boiler and the control system allowed Osby Parca to

win several projects and it has equipped various power plants

in Sweden.

The Osby P500 model is a solid-fuel boiler for burning dry

wooden fuels such as pellets, briquettes, peat and wood

chips. The product range comprises four boilers with output

of 100 - 1000 kW. In the past, Osby Parca used a PLC to

control these boilers, as process control technology with

comprehensive features was too expensive for the smaller

models. In the majority of cases, the boilers were independent

sub-sections of a total plant and as a result they were controlled as a “standalone solution”. That is why many users often

decided to use the lowest-priced hardware/software solution

when selecting the automation systems to be used.

This clearly shows the advantages offered by the great scalability of the Freelance 800F system together with the new

AC 700F controller. Osby Parca can now use the wide-ranging

advantages offered by Freelance 800F at a price similar to

PLC + SCADA systems when controlling the smaller boilers.

Compared to PLC + SCADA, a process control system offers

more functionality, for example automatically generated diagnostic information and alarms as well as easy and fast online

optimizations of applications.

In addition, simplified remote diagnostics in central control

rooms is possible, as the control technology automatically

generates system alarms and system diagnostics, which are

available using PC technology.

Osby Parca is very pleased: “The AC 700F Controller combines

the functionality of a control system with the price level of a

PLC with a visualization solution. The uniform tool for configuring the controller and the operator station with automatically

generated faceplates (operator windows) saves time for engineering and commissioning. Time can also be saved in ongoing

operation and for maintaining the application thanks to advanced

diagnostics opportunities and improved alarm handling. This

cuts installation costs and significantly increases the plant’s

economic efficiency.”

Osby Parca is convinced of the opportunities offered by the

Freelance 800F control system and in future it will fit even

more boilers with AC 700F and AC 800F controllers.

At Sasol in Brünsbüttel the AC 700F controller has been installed to control a pneumatic conveyor system for aluminum

oxide powder. This system was controlled using a PLC in the

past. Sasol is a convinced, long-standing user of the compact

control system Freelance 800Fand thus decided to use the

AC 700F Controller when replacing the PLCs. Customer requirements were the transfer of the existing application into

the new controller, the subsequent optimization of process

control through the use of diagnostic features and short setup

and installation times.

In addition, the system was to be configured by one of the

customer’s application engineers, who had never worked with

the Freelance 800F system before. After a short training period

and with ABB’s support during the start-up phase, it was possible to successfully put the project in operation in the shortest

timeframe. The easy-to-learn and intuitive configuration of

Freelance 800F was the crucial factor for Sasol when they

chose the control system.

Thanks to the compact footprint of the AC 700F controller,

the old PLC control could be exchanged without having to

modify the control cabinets - even the existing wiring in the

control cabinet remained unchanged. This allowed considerable advantages to be gained in respect of operation and fault

diagnostics but with minimal outlay. The main advantages of the

compact Freelance 800F system compared to a PLC solution

are the simple configuration, operating the plant from the

control room and the possibility of remote access for maintenance work.

A touch screen operator station replaces the switches and

lights at the control cabinet formerly used as operation elements. This makes it easier for plant operators to control the

equipment locally and also allows all of the other systems

connected to the process control system to be used.

At Sasol, other outdated control cabinets are to be modernized

with the new AC 700F controller in the near future

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