ABB implements first AbilityTM Distributed Control System in Pakistan

ABB has successfully implemented ABB AbilityTM System 800xA as part of an upgrade at Bulleh Shah Packaging (Pvt) Limited in Pakistan

Bulleh Shah Packaging (Pvt.) Limited, a Packages Group Company, is the market leader in corrugated packaging, the largest renewable packaging facility and the only liquid packaging board providing facility in Pakistan.

The packing company was facing challenges with their previous automation systems and hardware, and they were running into bottlenecks in their day-to-day production activities. “The customer complained about the slow performance of their system, overloading of field controllers and difficulties in handling the 16 server machines and 25 operator stations. The outdated hardware and server room environment was badly affecting the hardware of the servers and operating stations,” said Zeeshan Ullah Chaudhary, Project Manager, ABB.  

There was a high expectation from customer’s side as they were keen to see a dramatic improvement in their key performance indicators (KPIs), which are remotely monitored. ABB’s solution to this problem was to introduce an 800xA Smart Client solution for plant management, to view and develop different dashboards for quick plant overviews and also conduct management trainings, so managers can develop their own dashboards.

“This example became the first one where the customer put their trust on the local ABB unit for such a large upgrade project. They trusted our competency and skillfulness and we were able to meet the biggest challenge of installation; testing and upgrade of two paper machines, one coater machine and a 41 MW power plant within 48 hours,” added Zeeshan.

The upgrade involved paper machines, power house, coater machines and stock areas adding up to a total business of 800,000 USD in value. This project strengthens ABB’s position in the paper industry. ABB also pitched the idea of virtualizing with standby fall-over server and SAN storage server. The virtual machine technology replaced 16 redundant physical hardware units with two virtual servers and 25 workstations. 

Being a first of its kind virtualized solution in Pakistan, it is a step forward for ABB in the country. The virtual solution has helped the customer make sweeping changes such as increased energy efficiency, reduction in hardware costs and work space thanks to the minimized dependencies on hardware.

 “We are a continuous process industry with Pakistan’s biggest DCS control network comprising of 29 field controllers, 1,900 graphical aspects and over 20,000 tags. What we required at the time of upgrade was a team that could upgrade our swiftly aging system with the latest solution providing 100% reliability. Our first inclination was towards ABB Italy, who were our main system implementation team, but ABB in Pakistan ensured and guaranteed us of their technical competence and professionalism for implementing this massive upgrade. They eventually did meeting the tough timelines provided to them for completion of this upgrade”  Jahanzeb Khan, Technical Manager, BSPL Paper & Board. 

ABB (ABBN: SIX Swiss Ex) is a pioneering technology leader in electrification products, robotics and motion, industrial automation and power grids, serving customers in utilities, industry and transport & infrastructure globally. Continuing a history of innovation spanning more than 130 years, ABB today is writing the future of industrial digitalization and driving the Energy and Fourth Industrial Revolutions. As title partner of Formula E, the fully electric international FIA motorsport class, ABB is pushing the boundaries of e-mobility to contribute to a sustainable future. ABB operates in more than 100 countries with about 136,000 employees.

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