ABB A future-proof approach to modernizing industrial automation

Executive summary

Aging automation systems pose significant challenges for industrial plant managers

due to their inability to keep up with technological advancements, leading to inefficiencies,

increased unplanned maintenance costs, and heightened risk of compliance issues.

Traditionally, upgrading these systems involved a costly and disruptive "rip and replace" approach.

However, a more sustainable and cost-effective strategy is now available through modular, phased

upgrades, emphasizing minimal operational disruption.

ABB Ability Symphony Plus SDe introduces a space-fit solution that allows for incremental,  in

place upgrades. This method retains existing infrastructure such as cabinets, cables, and field

wiring, significantly reducing downtime and environmental impact by minimizing hardware

waste. The focus is on replacing or upgrading only the components that add direct value, such as

controllers and I/O modules, which also helps in reducing power consumption and enhancing

energy efficiency.

The transition to a modern Ethernet-based communication backbone in place of proprietary

systems further future-proofs plants, facilitating easier upgrades and integration with other

enterprise systems. This network-centric approach allows for more flexible and scalable plant

operations, adapting to changing needs without extensive re-engineering.

By adopting these innovative solutions, industrial plants achieve a more manageable and cost-

effective upgrade process, maintaining control over their life cycle planning, minimizing risks, and

ensuring continuous improvement in operational efficiency and compliance. This strategy not only

protects the plants' investments in automation but also aligns with broader sustainability and

efficiency goals.