OWS/EWS DCS ABB Retrofit

Problem

The existing ABB System 800xA Distributed Control System (DCS) for Unit 1 and Unit 2 at the 2x30 MW coal-fired power plant had reached significant limitations in performance, software compatibility, operating system support, hardware reliability, and cyber security readiness. Critical infrastructure components including HMI, Operator Workstations (OWS), Engineering Workstations (EWS), servers, and network devices had entered aging and obsolete phases, increasing the risk of operational disturbances, downtime, and maintenance challenges. Internal technical evaluations and consultations with ABB identified the need for a comprehensive retrofit and modernization program to maintain operational reliability and long-term system sustainability.

Approach

Led the end-to-end retrofit and modernization initiative for the boiler DCS control systems across both generating units, including project planning, scope definition, technical evaluation, and procurement management. Coordinated the upgrade strategy for ABB System 800xA covering workstation and server replacement, operating system and software upgrades, historian and connectivity server modernization, network infrastructure upgrades, license management, engineering services, data migration, testing, commissioning, and operator training. The project strategy retained existing ABB AC800M controllers and S800 I/O modules to optimize investment efficiency while ensuring compatibility with the latest ABB System 800xA platform.