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2025年4月24日 BY
IN Industry News

ABB AC800PEC Series controllers: The intelligent core of industrial automation

Ⅰ. Technical Analysis of AC800PEC Series Products

1: Product positioning and market position

The ABB AC800PEC series is a high-end programmable electronic controller for critical process control, specifically designed for heavy industry scenarios such as power, petrochemical, and metallurgy. As a core component of the ABB System 800xA automation system, this series of products has been cumulatively deployed in over 150,000 units worldwide, controlling more than 20% of the supercritical thermal power units and 30% of the ethylene cracking units globally. Its mean time between failures (MTBF) reaches 300,000 hours, and the availability index exceeds 99.9997%.

2. Breakthrough technology architecture
  • Triple Module Redundancy (TMR) design ‌ : enables 50ms-level disturbance-free switching and ensures zero interruption for critical processes
  • Multi-core heterogeneous computing platform ‌ : PowerPC architecture main processor +FPGA coprocessor with computing speed up to 3.5MIPS per instruction
  • Industrial communication network ‌ : Supports 28 protocols including PROFIBUS DP/V1, Modbus TCP, IEC 61850
  • Intrinsically safe design ‌ : In compliance with IEC 61508 SIL3 functional safety standard, fault self-diagnosis coverage ≥99.2%

Ⅱ. ndustry application panorama

1. Power industry
  1. Smart substation control ‌ : Sampling value transmission via IEC 61850-9-2LE protocol, protection action time ≤20ms
  2. Thermal power unit DCS system ‌ : COORDINATE 10,000 + I/O points to complete the closed-loop control of boiler-steam-generator
  3. New energy station management ‌ : Supports group control of photovoltaic inverters and wind pitch synchronization, improving grid adaptability by 15%
2. Petrochemical industry
  1. Ethylene cracking quenching system ‌ : COMPLETE quenching valve group linkage within 100ms, temperature control accuracy ±0.5℃
  2. SIS safety instrument system ‌ : LOPA level protection for HAZOP analysis, response delay ≤100ms
  3. Pipeline SCADA system ‌ : Manage 2000-kilometer oil pipeline network, leak location accuracy up to 50 meters
3. Metallurgical manufacturing
  1. Blast furnace top pressure control ‌ : TRT residual pressure generator set synchronization accuracy 0.02%, annual increase power generation 2.1GWh
  2. Continuous casting machine two cold water control ‌ : Dynamically adjust 5000 nozzles flow rate, cast billet surface temperature difference ≤8℃
  3. Rolling mill thickness automatic control ‌ : Achieve ±0.005mm level accuracy through hydraulic AGC system

Ⅲ. In-depth analysis of Typical application cases

Case 1:1000MW Ultra-supercritical Unit of China Huaneng Yuhuan Power Plant

Project Challenge ‌ :

  • A complex thermal system involving four coal mills and eight stages of feed water pumps needs to be coordinated
  • Achieve deep peak shaving of the unit to 20% of the rated load
  • Meet the environmental protection requirement of NOx emissions ≤30mg/Nm³

AC800PEC solution ‌ :

  • Deploy 12 groups of AC800PEC 01 controllers to construct a distributed architecture
  • The combustion control model is optimized by using the fuzzy PID algorithm
  • Integrate the vibration monitoring module to achieve equipment health early warning

Performance ‌ :

  • The coal consumption for power supply has been reduced to 272g/kWh, and 42,000 tons of standard coal have been saved annually
  • The peak shaving response rate has been increased to 3%/min
  • The operation rate of environmental protection facilities remains at 100%
Case 2: Safety System of Saudi Aramco’s Jazan Refinery

Special requirements ‌ :

  • Corrosive environments for handling sulfur-containing crude oil (H2S concentration ≥500ppm)
  • Achieve millisecond-level response for 2000 ESD interlocking points
  • Meet the explosion-proof certification of ATEX Zone 1

Technical implementation ‌ :

  • The triplet SIS system was constructed by using AC800PEC 03
  • Configure the optical fiber redundant ring network (communication delay ≤2μs)
  • Develop Markov models for reliability verification

Safety benefits ‌ :

  • The availability of the SIL3 certification interlock system reaches 99.9999%
  • The number of accident shutdowns decreased by 83%
  • The security audit passed the API 780 standard

组合图

Ⅳ. Core product model and technical parameters

1. AC800PEC 01 (Basic Type)
Parameter item Technical indicators
Processor architecture PowerPC e500mc dual-core @1.2GHz
Memory configuration 512MB DDR3 + 8GB Flash
Redundant switching time ≤50ms (hardware hot standby)
I/O processing capacity Supports 4096 points of digital quantity /2048 points of analog quantity
Communication interface 4× Ethernet, 2×RS485, 1×CANopen
Working temperature -40℃ to +70℃ (industrial wide-temperature type)
Protection grade IP41 (expandable to IP65)

ABB GFD233A103 3BH022294R0103 AC800PEC Rectifier control module

Control system PPD113B01-23-111000 AC800PEC 3BHE023784R2330

AC800PEC series excitation controller PCD235B1101 3BHE032025R1101

PCD232 PCD232A 3BHE022293R0101 PEC80-CIO Industrial process control

AC 800 PEC GFD563A102 3BHE046836R0102 low-speed process control

2. AC800PEC 02 (Safety Type)
Parameter item Technical indicators
Security certification IEC 61508 SIL3/ISO 26262 ASIL D
Diagnostic coverage rate ≥99.3% (Hardware fault diagnosis)
Voting mechanism 2003D dynamic redundancy architecture
Event sequence recording The resolution of SOE is 0.1ms
Secure communication Profisafe V2.3/CIP Safety
MTTR ≤15 minutes (modular replacement design)
3. AC800PEC 03 (High-performance Type)
Parameter item Technical indicators
Computing performance 4-core PowerPC@2.0GHz + FPGA acceleration
Control cycle Configurable from 1ms to 100ms
Motion control Supports 8-axis synchronization (±1μs level interpolation)
Storage expansion Dual SD card slots (maximum support 512GB)
Real-time database Sampling rate of 10,000 points per second
Virtualization support It can run dual systems of VxWorks and Linux

PPD539A102 3BHE039770R0102 High performance controller丨AC 800PEC PP D539

Made by ABB丨UAD149A0001 3BHE014135R0001 AC 800PEC controller

Ⅴ. Technological Evolution and Ecological Construction

ABB is promoting the AC800PEC series to develop in three major directions:

  1. Edge Intelligence ‌ : Integrated AI inference chip for device anomaly detection (accuracy ≥95%)
  2. Digital Twin Integration ‌ : Connected to ABB Ability™ platform via OPC UA over TSN protocol
  3. Quantum Secure communication ‌ : Using NIST-certified post-quantum encryption algorithm (CRYSTALS-Kyber)

As a benchmark product in the field of industrial control, the AC800PEC series continuously empowers global industrial upgrading through its outstanding reliability, open architecture design and deep industry integration. In the pursuit of millisecond-level protection in power systems, precise interlocking control in petrochemical plants, and extreme precision in metallurgical production lines, the AC800PEC is driving industrial automation towards a new era of autonomous decision-making with its intelligent control core. With the deepening of Industry 4.0, this control platform will continue to lead the digital transformation wave of critical infrastructure.
2025年4月18日 BY
IN Industry News

GE Turbine Controllers and Gas Turbines: Innovation Drives the Future of Energy

Ⅰ. Overview of GE Gas Turbine and Turbine Controller Technology

1: The core position of GE gas turbines

General Electric (GE), as a world-leading industrial equipment manufacturer, has continuously led industry transformation with its gas turbine technology over the past century. GE gas turbines cover multiple product lines including the 7HA series heavy-duty machines and the LM series aviation-modified machines, with single-unit power ranging from 30MW to 827MW. The combined cycle efficiency has exceeded 64%, representing the highest technical level in the current gas power generation field.

As the central nervous system of the unit, the GE turbine controller adopts an advanced closed-loop control algorithm. By real-time monitoring of data from thousands of sensors (including parameters such as temperature, pressure, rotational speed, and vibration), it achieves a millisecond-level response speed, ensuring the unit operates under the optimal working conditions. Its control system has a redundancy rate as high as 99.9999%, ensuring over 15,000 safe start-stop operations worldwide each year.

2.Technological breakthroughs and industry contributions
  • FlexEfficiency technology ‌ : achieves high thermal efficiency within 30%-100% load range through dynamic adjustment of the combustion chamber
  • DLN2.6+ combustion system ‌ : Nitrogen oxide emissions are less than 15ppm, meeting the world ‘s most stringent environmental protection standards
  • Hydrocarbon fuel adaptability ‌ : Can handle more than 20 forms of energy including LNG, syngas and high hydrogen fuel
  • Digital Operations ‌ : With the Predix platform, fault prediction accuracy has increased by 40% and maintenance costs have decreased by 25%

Ⅱ. Analysis of Typical Application Cases

Case 1: The Nishi-Nagoya Power Plant of Chubu Electric in Japan

1: Project size ‌ : A 1.3GW combined cycle power station consisting of three GE 7HA.02 gas turbines
2:Technical highlights ‌ :
  • The Mark VIe control system realizes the collaborative scheduling of the three machines
  • The integrated thermal management system (ITM) increases the cooling efficiency by 18%
  • The fuel flexibility design enables rapid switching to liquefied hydrogen fuel
3.Performance ‌ :
  • The annual power generation reaches 10.5TWh and the power supply efficiency is 64.1%
  • Reduce CO₂ emissions by 1.3 million tons annually
  • The peak shaving response speed reaches 88MW/ minute

Case 2: Self-owned Power Station of the Yanbu Oil Refinery in Saudi Arabia

1：Special requirements ‌ :
  • Refinery tail gas (containing 40% hydrogen) needs to be treated.
  • All-weather stable operation in desert environments
  • Meet the anti-corrosion standard of ISA 71.04 G3 grade
2.GE Solutions ‌ :
  • The LM6000 gas turbine is equipped with a dedicated controller
  • The dual-fuel nozzle design realizes the mixed combustion of hydrogen
  • The three-redundant control system ensures an availability rate of 99.97%
3.Economic benefits ‌ :
  • The annual treatment capacity of refinery waste gas is 230 million cubic meters
  • The power generation cost has been reduced to $0.028/kWh
  • The MTBF (Mean Time Between Failures) of the equipment exceeds 100,000 hours

Ⅲ. Analysis of the Core Module of GE Turbine Controller

1.Mark VIe Digital Control System

Architecture Innovation ‌ :

  1. Triple Module Redundancy (TMR) architecture
  2. IEC 61508 SIL3 Safety Certification
  3. Support 12 kinds of industrial protocols such as OPC UA and Modbus TCP

Key features ‌ :

  1. Combustion pulsation Monitoring (CPM) module
  2. Modeling of temperature field in blade path
  3. Active Clearance Control (ACC) algorithm

Application scenario ‌ : HA-class heavy-duty gas turbine, combined cycle power station

GE Electric丨IS220UCSAH1A PAMC Acoustic Monitor (processor)，Mark VIe GE IS420UCSBH3A‌ Turbine control module

Industrial Ethernet switch IS420ESWBH3A Mark VIe security control system，Mark VIe GE IS420UCSBH3A‌ Turbine control module

Mark VIe series controllers IS420UCSBH4A，IS220PTURH1A Input/output module for turbine design

Mark VI IS220PDIOH1B Discrete input/output (I/O) modules，IS420YDOAS1B Discrete Output I/O Pack丨Simplex or TMR

2. Speedtronic™ Mark V

Technical features ‌ :

  1. 32-bit RISC processor, 0.5ms control cycle
  2. Embedded Vibration Monitoring Module (BN3500)
  3. The response time of the gas turbine protection system is less than 50ms

Typical configuration ‌ :

  1. 16-channel analog input module (AIM12)
  2. Digital Servo Control Unit (DSCU)
  3. Gas Valve Group Controller (GVCP)
3. LM Controller series

Aero Engine technology transfer ‌ :

  1. Derived from the FADEC system of the CFM56 aero engine
  2. Supports ultra-high-speed control above 15,000 RPM
  3. Integrate surge prediction and active suppression functions

Core module ‌ :

  1. Fuel Metering Unit (FMU)
  2. Lubricating Oil System Health Monitoring (LOHM)
  3. Gas Path Performance Analysis (GPA) software package

IV. Future Technological Evolution Directions

GE is promoting technological innovation through three major paths:

  1. Hydrogen transition ‌ : Development of 100% hydrogen fuel combustion chambers, expected to be commercialized by 2025
  2. Digital Twin ‌ : Creating digital models for the entire life cycle of gas turbines boosts maintenance efficiency by 60%
  3. Hybrid System ‌ : Integrate battery energy storage with gas turbine control to build a virtual power plant with minute response

GE gas turbines and their control systems are reshaping the global energy landscape through continuous innovation. From the efficiency records set by HA-class units to the intelligent control achieved by the Mark VIe system, GE has always been committed to creating quantifiable value for customers. In the wave of energy transition, these technologies will help the world achieve a reliable, clean and efficient energy future. If you have a GE product that requires a quote, please contact us more at…….
2025年4月17日 BY
IN Industry News

Technical Analysis and Industry Practice of ABB ACS6000 Medium Voltage Frequency Converter

Ⅰ.ACS6000 Medium Voltage Frequency Converter: Core Technology and Design Innovation

The ABB ACS6000 series medium-voltage frequency converters are core equipment specially designed for industrial high-voltage motor drives, covering voltage levels of ‌3.3kV-6.9kV ‌ and power range of ‌0.5MW-40MW ‌. Adopting a modular architecture and advanced semiconductor technology, they have become key power control solutions in heavy industries such as mining, petroleum, and power.

1：Technical architecture and core components
  • Rectifier unit ‌ : Based on ‌, three-level neutral point clamped (NPC) topology ‌, supports 12-pulse or 18-pulse rectification, input current harmonic distortion rate (THDi) is less than 4%, meets IEEE 519 standard ‌.
  • Inverter unit ‌ : With ‌RC-IGCT (reverse conduction integrated gate commutation thyristor) ‌, switching frequency up to 500Hz, efficiency up to 98.5%, loss 30% less than traditional GTO devices ‌.
  • Cooling system ‌ : Optional water-cooled or air-cooled solution, water-cooled model power density up to 120kW/m³, suitable for closed Spaces such as offshore platforms ‌
2：Model matrix and adaptation scenarios
  1. ACS6000-07‌ : Basic type, power range 0.5-5MW, suitable for fan and pump loads
  2. ACS6000-C6‌ : Compact, 40% less footprint, for space-constrained underground mining ‌
  3. ACS6000-MV‌ : Offshore explosion-proof, ATEX/IECEx certified, salt spray resistant

Ⅱ.Industry application scenarios and typical cases

1. Oil and gas: Compressor drive for long-distance pipelines
  • Project Background ‌ : Siberia-China gas Pipeline booster station
  • Scheme configuration ‌ : 4 ACS6000-MV (6.6kV/12MW) drive centrifugal compressors

Technical highlight

  1. The RC-IGCT device is adopted to achieve 0.1ms level fault current blocking, protecting the system from the impact of power grid fluctuations
  2. The risk of compressor surge is reduced by 92% through the DTC (Direct Torque Control) algorithm

Economic benefits ‌ : Electricity savings of 15 million kWh per year, equivalent to carbon reduction of 12,000 tons ‌4

2.Power frequency regulation: Black start of gas turbine combined cycle units
  1. Project background ‌ : 420MW gas turbine at Rabigh II power plant in Saudi Arabia
  2. Technical solution ‌ : ACS6000-07 (6.9kV/28MW) as static variable frequency starter
  3. Core value
  • The gas turbine started smoothly from 0 to 3000rpm within 8 minutes, and the current impact was reduced by 60%
  • Integrated predictive maintenance module, critical component life assessment error <3%‌

 

Ⅲ.RC-IGCT technology: The revolutionary core of medium-voltage frequency converters

1. Device structure and performance advantages

RC-IGCT integrates reverse diodes on the basis of traditional GCT (Gate commutation thyristor) to form a monolithic package structure, achieving:

  • Reduced conduction loss ‌ : 45% less than GTO, rated current density up to 100A/cm²
  • Switching Speed boost ‌ : Off time is only 3μs, supports higher frequency PWM modulation
  • Enhanced reliability ‌ : Wire-free bonding design, 5 times better vibration resistance

Recommended models of RC-IGCT:

ABB RC-IGCT 5SHX 1960L0006, 91MM GVC736BE101 3BHB016120R0002 3BHE019719R0101，IGCT MODULE GVC736BE101 5SHY 3545L0016, 4500V, 91MM 3BHB020720R0002 3BHE019719R0101，5SHX06F6010 5500V 520A IGCT，5SHX08F4510 4500V 630A IGCT，5SHX10H6010 5500V 900A IGCT，5SHX14H4510 4500V 1100A IGCT，5SHX19L6010 5500V 1800A IGCT，5SHX19L6020 5500V 1800A IGCT，5SHX26L4510 4500V 2200A IGCT，5SHY35L4510 4500V 4000A IGCT，S-073N 3BHB009884R0021 S-093H 3BHB009885R0004，S-113H 3BHB018008R0003

2. Engineering innovation in ACS6000
  • Current sharing control ‌ : When multiple RC-IGCTs are running in parallel, the current imbalance is controlled within ±2% through gate drive synchronization technology
  • Thermal Management Breakthrough ‌ : 3D cooling channel design based on ANSYS simulation, chip junction temperature fluctuation range compressed to ±5 ° C
  • Fault ride-through capability ‌ : Can run continuously for 500ms when grid voltage drops by 50%, ensuring uninterrupted critical loads ‌
3. Technology Spillover and Industry Popularization

RC-IGCT has been expanded to multiple ABB high-end frequency converters:

  1. ACS5000‌ : Special frequency converter for ship propulsion, single unit drive power up to 45MW
  2. ACS8000‌ : 10kV class frequency converter for speed regulation of large water pumps in hydropower plants

Industry data show that the penetration rate of RC-IGCT in the global medium voltage inverter market reached 38% in 2025 and is expected to exceed 60%‌ in 2030

Ⅳ：Frontier exploration and ecological synergy

ABB and Infineon jointly launched the ‌SiC-RC-IGCT‌ research and development project, which combines silicon carbide material with RC-IGCT, with the aim of achieving:

  • The switching frequency has exceeded 2kHz, making it suitable for more precise servo control scenarios
  • The power density has been raised to 200kW/m³, driving a revolution in the miniaturization of frequency converters

The pilot project has achieved phased results in CRRC high-power locomotive traction converters, with efficiency increased to 99.1%‌

HONG KONG SAUL ELECTRICAL LIMITED. has deeply laid out in the field of industrial automation. Its core products and solutions have been successfully applied in key scenarios such as intelligent control of metallurgical blast furnaces, digital gathering and transportation of oil and gas fields, precise temperature control of glass melting furnaces, and energy-saving optimization of aluminum electrolytic cells. Covering 15 core industrial fields such as energy, manufacturing and environmental protection. From servo drives in automotive production lines to intelligent aeration systems in sewage treatment plants, from relay protection in ultra-high voltage substations to frequency conversion energy-saving renovations for textile machinery, the company, relying on its cross-industry technology integration capabilities, continuously provides high-reliability equipment and customized services to Fortune 500 companies and leading local customers.

As a strategic-level partner of 38 international industrial giants such as ABB, Honeywell and Yokogawa Electric, HONG KONG SAUL ELECTRICAL LIMITED. has constructed a full-stack product matrix covering the control layer (TRICONEX safety instrument system), the execution layer (Woodward governor), and the perception layer (Bentley vibration monitoring). The company not only holds the exclusive debugging and certification qualification of GE Fanuc numerical control systems in the field of aerospace precision processing, but also deeply integrates Emerson DeltaV intelligent factory platform with HIMA safety barrier technology, achieving 99.99% system availability in benchmark projects such as Sinopec’s intelligent pipeline network and CATL’s extreme manufacturing production line. This dual-wheel drive model of “international top hardware + localized in-depth services” continuously consolidates the enterprise’s technological discourse power and industry benchmark position in the wave of Industry 4.0 transformation.
2025年4月17日 BY
IN Industry News

Analysis of ABB Distributed Control System (DCS) Technology and Industry Practice

1：Core architecture and functions of ABB’s Distributed Control System (DCS)

ABB’s distributed control system (DCS) takes ‌ modular design ‌ and ‌ networked control ‌ as its core, and realizes centralized management and decentralized control of industrial processes through a hierarchical architecture. A typical example is ‌ The ABB 800xA system ‌, which integrates process control, production management and asset management and supports full-chain digital integration from field equipment to enterprise-level management ‌

1：The system architecture is stratified
  1. Field layer ‌ : Comprising devices such as sensors and actuators, it communicates with the controller in real time via fieldbus protocols such as Profibus and Modbus ‌.
  2. Control layer ‌ : Logic operations are performed by controllers such as AC700F, AC450, etc. It supports complex algorithms such as PID control and batch control. A single controller can manage 8 I/O modules and expand remote I/O units ‌.
  3. Operation layer ‌ : Human-machine interaction is realized through software such as WinHMI, providing process flow visualization, real-time data monitoring and alarm management functions ‌.
2：Technological advantage
  1. High reliability ‌ With redundant design and SIL3 safety certification, the system can run even if a single node fails ‌.
  2. Openness ‌ : Compatible with third-party devices and OPC UA protocol, supports seamless integration with ERP and MES systems ‌.
  3. Energy and Carbon Synergy ‌ : Integrate iCE600 energy and carbon management platform to monitor production energy consumption in real time and generate optimization strategies ‌.

2：Mainstream products and models of ABB DCS

ABB offers a DCS product matrix covering the demands of multiple industries. The following are typical representatives:

1. Large-scale industrial-grade system: ABB 800xA

Applicable scenarios ‌ : Continuous production industries such as petrochemicals, power energy, pharmaceuticals, etc

Core component

  1. AC800M controller ‌ : Supports 1000+ I/O points, processing power up to 1ms
  2. S800 I/O module ‌ : provides analog, digital and safety I/O to meet SIL3 certification requirements
  3. Asset Vista Asset Management Suite ‌ : Predictive maintenance accuracy increased to 92%‌

The AC800M controller is ‌ :

PM866AK01 controller unit 3BSE076939R1
PM866AK02 Redundant controller Unit 3BSE081637R1
PM891K01 controller Unit 3BSE053241R1
PM864K01 controller unit 3BSE018150R1
PM864AK01 controller unit 3BSE018161R1
PM864AK02 Redundant controller Unit 3BSE018164R1

2.Mid-sized flexible plan: Freelance 800F

Core model ‌ : AC700F controller

  1. Support Profibus-DP and Ethernet communication
  2. The maximum expansion is 8 local I/O modules, and it is compatible with the ABB COM600 communication gateway
  3. Typical applications: food and beverage production lines, water treatment plants ‌
3.Teaching and lightweight System: HT600 series
  • Hardware configuration ‌ : all-in-one controller +WinConfig Engineer station
  • Teaching function ‌ : Emulator controller Emulator supports IEC61131-3 standard programming training
  • Industry applications ‌ : Automation laboratories in colleges and universities; technological transformation projects in small manufacturing enterprises ‌

3：Industry application cases

1.Petrochemical industry: Digital Upgrade of Beihai Oilfield
  • System configuration ‌ : ABB 800xA + AC450 controller

Implementation effect

  1. Integrate 12 control nodes of offshore drilling platforms and reduce the frequency of manual inspections by 60%
  2. Data intercommunication with headquarters SCADA system via OPC UA protocol, decision response speed increased by 50%‌
2：Electric power energy: Cluster control of photovoltaic power stations in South Africa
  • Technical solution ‌ : Freelance 800F + COM600 communication gateway
  • Functional highlight
  1. Remote control of the 300MW photovoltaic inverter has optimized the power generation efficiency by 12%
  2. Integrated weather prediction algorithm to achieve dynamic adjustment of charge and discharge strategy of energy storage system ‌

4：Technological evolution and ecological layout

ABB is promoting the deep integration of DCS with AI and edge computing. Version 6.1 of ‌800xA, released in 2025 ‌, adds an AI energy consumption prediction module that can generate carbon emission optimization paths based on historical data ‌. Meanwhile, ABB, in collaboration with Tsinghua University and other institutions, has piloted the “DCS+5G” industrial Internet, enabling 20ms delay remote control of the rolling mill control system at Baowu Steel ‌

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