Unlocking intelligent, flexible, future-ready industrial operations
Automation plays a key role in the safe, efficient operation of factories, refineries and processing facilities. Stefan Basenach, Senior Vice President, Automation Technology at ABB, introduces ABB’s Automation Extended program that streamlines the evolution of industrial plant owners’ Distributed Control Systems while minimizing impact on production.
From oil refineries to paper mills, food and beverage, power generation and water treatment plants, automation systems keep industrial operations running smoothly, efficiently and safely.
In process plants and other industrial facilities, operations have traditionally been orchestrated by Distributed Control Systems (DCS). These automate various steps in batch or continuous processing, with the objective of maintaining reliable plant operation and consistently high-quality output. Efficiencies realized by the DCS also help plant owners reduce energy consumption and minimize waste.
Addressing the challenges of a changing world
The commercial challenges confronting industrial operators have multiplied since the first DCS deployments in the 1970s. The consequences of global competition, changing demand and rising material costs are compounded by stringent regulation, tighter safety standards and the mandate to decarbonize through greater energy efficiency and lowered emissions.
Like all organizations, plant operators must safeguard themselves against a growing spectrum of cyber security threats. Meanwhile they are dealing with the realities of changing workforce demographics, where traditional heavy engineering skills are giving way to a new generation of digital native workers.
In a changing world these pressures on efficiency and profitability mean plant owners and automation suppliers must ensure their control systems are modular, secure, future ready and capable of fully harnessing the opportunities that digitalization brings.
Tech trends including Artificial Intelligence and Machine Learning (ML), cloud and edge computing are extending the scope of today’s industrial automation systems beyond their original role of deterministic real-time process control. Increasingly smart applications can unearth powerful business insights from the deluge of data generated by connected field devices in a modern plant. Similarly, advanced data analytics can inform preventative maintenance strategies to minimize unplanned shutdowns and extend asset lifespan.
Integrating these new capabilities into heritage automation systems can deliver valuable dividends in terms of greater process efficiency, reliability, safety and sustainability. However, the need for stability can conflict with ambitions to innovate. Plant owners are often reluctant to embrace the opportunities offered by the latest technology when business continuity is an overarching priority. Modernizing process automation systems has traditionally been a major undertaking that requires major shutdowns. And every hour of lost production in even a modestly sized factory or processing plant can potentially run to hundreds of thousands of dollars in lost revenues.
Introducing Automation Extended
As a pioneer in process automation and a global leader in distributed control systems, ABB is responding to the changing demands of industrial organizations with its Automation Extended program.
Reflecting ABB’s longstanding leadership in Distributed Control Systems and its extensive installed base across multiple sectors, Automation Extended allows plant owners to capitalize on new automation capabilities with minimal disruption. The overarching goal of Automation Extended is to preserve system integrity while providing the efficiency and agility needed for the next era of industrial operations. Building on ABB’s proven automation platforms and based on open technology standards, Automation Extended provides a smart, secure and readily scalable modular automation ecosystem that allows innovation to flourish without jeopardizing reliable daily operation.
Separating control and digital environments
Central to ABB’s Automation Extended program is the concept of a “separation of concerns”. This frames the automation ecosystem as a future-ready, cyber-secure architecture comprising two distinct yet securely interconnected environments, each optimized for its own purpose.
The first of these two architectural elements is the control environment. This is a software‑defined domain that oversees robust, reliable and deterministic real-time control of critical processes. Prioritizing safety and reliability, this control environment reflects the traditional purpose and strengths of the DCS in dependably automating day-to-day plant operation.
Securely connected to this control layer, a second digital environment enables advanced applications, edge intelligence and real‑time analytics. Leveraging Artificial Intelligence and Machine Learning to augment human decision making, this digital environment lets plant owner progressively introduce new capabilities without disturbing proven control structures. Crucially, this separate space allows new applications and tools to be introduced, updated or patched without impacting on core control functions.
Despite this separation of concerns, these two domains nevertheless form a single common ecosystem, united by common information models and communication standards, shared engineering principles and a unified user experience. Reinforcing rather than replacing the value of human workers, Automation Extended also provides an intuitive environment augmented by visualization tools and decision-support systems. As well as supporting quicker, better-informed decision making, this allows engineers to shift their focus from overseeing daily operations to performing higher value strategic tasks.
Similarly, separating control and digital domains simplifies the task of minimizing exposure to rapidly evolving cyber threats while assuring compliance with evolving regulations.
Enabling innovation with continuity
This separation of concerns provides a clear, low-risk path to modernization of existing automation systems, allowing new technologies to be integrated at a comfortable pace without threatening the integrity and stability of day-to-day operations. Protecting and extending the life of industrial operators’ existing DCS investments, Automation Extended offers increased flexibility, scalability and efficiency for the next era of industrial operations.
The DCS represents a significant long-term investment for industrial operators. Core control systems can frequently remain in service for 20 years or more before technology obsolescence makes replacement necessary. With Automation Extended, plant owners can continue to rely on their proven process automation solutions such as ABB Ability™ System 800xA®, ABB Ability™ Symphony® Plus and ABB Freelance that are tried and trusted across multiple industries. Adding new capabilities to these systems can be performed incrementally, with security, safety and interoperability always at the core.
A stable platform for modernization with continuity
For industries looking to modernize and protect their long-term investments, ABB’s Automation Extended program delivers modular, cyber-secure and future-ready automation that boosts efficiency, enhances stability and accelerates time to market.
Unlike traditional rip-and-replace approaches, Automation Extended enables seamless evolution of industrial operators’ existing DCS infrastructures. Rather than being locked into inflexible upgrade cycles, plant owners can benefit from an integrated automation ecosystem where innovation does not have to compromise reliability.
With Automation Extended, commercial returns on decades-old DCS investments can be extended by leveraging modern technologies, helping plant owners adapt, scale and stay profitable while they embrace new commercial opportunities.