ABB upgrades process control systems, cement grinding units in UAE

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

ABB upgraded three grinding units at Star Super Cement in Dubai, UAE, and ensured optimized operations with the Star Cement clinkerization plant in Ras Al Khaimah, UAE, with the installation of ABB Ability System 800xA, a distributed control system (DCS) automation platform.

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.

“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.”

TVS Chidambaram, chief operating officer of Star Cement, added: “It has always been a fruitful experience working with ABB PI team. 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.