ABB upgrades process control systems and cement grinding units in UAE for increased uptime and uniformity across multiple sites

ABB upgrades process control systems and cement grinding units in UAE for increased uptime and uniformity across multiple sites

  • ABB installs state-of-the-art distributed control system (DCS) automation platform at Star Super Cement cement grinding plants in UAE
  • Upgrade to central processing units brings uniformity across Star Cement clinkerization plant as well as Star Cement grinding plants in the Middle East to lower maintenance downtime
  • ABB has also installed the latest generation automation controllers for high availability of control applications at the Ultratech Cement subsidiaries

Global technology company ABB has installed ABB Ability™ System 800xA®, the market-leading distributed control system (DCS) automation platform, to upgrade three grinding units at Star Super Cement in Dubai, UAE, and ensure optimized operations with the Star Cement clinkerization plant in Ras Al Khaimah, UAE.

Star Cement and Star Super Cement are subsidiaries of Ultratech Cement, India and operate a 3 million tons per annum (tpa) clinkerization unit at Ras Al Khaimah, four cement grinding units of 2.2 million tpa unit at Jabel Ali, 1.4 million tpa unit at Abu Dhabi and 1.1 million tpa unit at Ajman in UAE as well as a 1 million tpa grinding unit in Bahrain.

ABB was the electrical and automation partner for the Star Cement clinkerization plant ten years ago and had deployed ABB’s DCS for three cement grinding units when these plants were installed. Each grinding unit had a different generation of DCS depending on the plant commissioning period. All grinding units have now been upgraded to ABB Ability System 800xA which can implement advanced process control methods and is ranked by the ARC advisory group as the world’s #1 DCS platform over the last 22 years.

Star Cement can benefit from advanced process control methods through ABB's latest upgrades
Star Cement can benefit from advanced process control methods through ABB's latest upgrades

“Star Cement will benefit from improved operator visibility, easier maintenance and minimum downtime with the new upgraded systems and uniformity across the various clinkerization and grinding unit locations,” said Max Tschurtschenthaler, Global Cement Lead, ABB Process Industries. “We are pleased to have built on our longstanding relationship. The successful upgrade of three different systems to the latest platform will ensure overall interoperability and ease of operations.”

“It has always been a fruitful experience working with ABB PI team,” said TVS Chidambaram, Chief Operating Officer of Star Cement. “The DCS upgrade project handled by ABB ran very smoothly and barely disturbed the organization’s ongoing activities. Well planned engineering and installation works during a holiday period helped us to continue our sales without any disturbance. We’re now in a much better position for future operations.”

The scope of work undertaken by ABB included the upgrade of all previously installed central processing units (CPUs) and controllers to the latest version of ABB Ability System 800xA. The project also involved the complete erection and installation for the new panels while keeping the field wiring intact. Minerals libraries were introduced to the system. Project panels were manufactured and delivered locally.

ABB (ABBN: SIX Swiss Ex) is a leading global technology company that energizes the transformation of society and industry to achieve a more productive, sustainable future. By connecting software to its electrification, robotics, automation and motion portfolio, ABB pushes the boundaries of technology to drive performance to new levels. With a history of excellence stretching back more than 130 years, ABB’s success is driven by about 105,000 talented employees in over 100 countries.

ABB Process Automation is a leader in automation, electrification and digitalization for the process and hybrid industries. We serve our customers with a broad portfolio of products, systems, and end-to-end solutions, including our #1 distributed control system, software, and lifecycle services, industry-specific products as well as measurement and analytics, marine and turbocharging offerings. As the global #2 in the market, we build on our deep domain expertise, diverse team and global footprint, and are dedicated to helping our customers increase competitiveness, improve their return on investment and run safe, smart, and sustainable operations.


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