More than fifteen years of DCS support at a chemical plant

The challenge

A chemical producer runs its plant on an ABB Freelance distributed control system. Over the years the plant kept adding process units, retiring old I/O and tightening its safety documentation. It needed one partner who knew the system end to end: someone to design and build panels, write and change the DCS logic, support start-ups and shutdowns, and keep the software supported.

What we did

• Panel design and build (2009 onward). Engineering and CAD redesign of existing control panels, plus new I/O panels built in our shop:
  • ABB Freelance AC 800F controllers with Ethernet and fieldbus modules;
  • ABB S800 I/O (digital and analog input and output modules on extended termination units) linked over PROFIBUS through CI801 interfaces.
• I/O modernization. A wireless I/O integration on site (2010), then a staged upgrade from the original rack-style Freelance I/O to S800 I/O (2013–2014), with DCS programming, start-up and commissioning support.
• New process areas. Over the years our engineers designed, programmed or integrated controls for:
  • a spray-dryer panel and its automation design, from functional description to start-up (2016–2017);
  • an enzyme plant;
  • acid, solvent and flash tanks;
  • an air dryer and seal water;
  • a centrifuge PLC integration;
  • bulk-bag and packaging lines;
  • steam condensate;
  • unloading-point receivers.
• Data and operations. We set up the interface between the DCS and the plant historian, supplied and licensed operator and engineering stations, and rebuilt servers. In 2025 we worked with ABB to specify a Freelance OPC server license for the station that feeds the plant historian.
• Safety and turnarounds. On-site programming and support during planned shutdowns, programming changes from process hazard analysis (PHA) reviews, and interlock documentation (2020–2021).
• Training. On-site ABB DCS training for plant staff, including training on the receiver system.
• Support agreements. A three-year ABB Freelance care agreement (2022–2024), followed by a new three-year industry care contract that runs from 2026.

The result

The plant has one engineering partner that has worked on its control system since 2009. Work has spanned new hardware, software, programming, start-up, shutdown and training, and support continues under a care contract running from 2026.

What it shows: long-term ownership of a process-plant DCS, in panel building, I/O migration, Freelance programming, shutdown support and safety documentation, as one supplier.

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