DCS upgrade for a UK Paper Mill

At the request of a pulp & paper manufacturer, iconsys were tasked with integrating 36 Profibus controlled ABB ACS850 Drives into the existing ABB 800xA DCS system. iconsys were required to provide a solution using the existing DCS system with master Bus 300 network and newly installed ABB800xA IIT system. Currently the existing system is split between two Advant AC450 controllers and a recently installed AC800M controller for QCS.

Additionally, iconsys tasked to supply remote I/O panels controlled via Profibus interface which will be used for various site services during the commissioning of the paper mill to enable integration into the new 800M controller for the fan and pump drives into the ABB 800xA DCS.

Our Solution

As the paper mill already has version 6.0 ABB 800xA IIT system up and running we recommended installing an ABB DCS Controller type AC800M. It is the latest technology which is easy for trouble shooting and commissioning. It allows for future expansion, works well with Profibus and Profinet and is ready for use when the existing paper machine drive system requires an upgrade. Additionally, it integrates easily into ABB 800xA IIT system platform.

We also installed a new AC800M controller, CI854 Profibus card and CI855 MB300 network card to read/write data from the old Advant DCS controllers. We proposed 3 CI801 remote panels IP66 rated with comms mode with various I/O cards.

Scope of supply:
• Project Management
• Installation of new equipment
• Hardware and software system design
• ABB 800xA IIT system
• ABB ACS580
• AC800M controllers
• ABB S800 remote I/O
• Profinet interface with to safety systems
• Site Installation
• Commissioning & testing

Results

• Upgrade of obsolete machinery
• Reduced machinery downtime
• Future expansion catered for
• Easier trouble shooting