3bdd013090 h en freelance version 2013 - distributed control system for process applications

7/27/2019 3BDD013090 H en Freelance Version 2013 - Distributed Control System for Process Applications

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Freelance Version 2013Distributed control system for processapplications


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Freelance can be installed on any standard computer and

in just five minutes. A quick-start DVD is available, which

allows users to learn at their own pace with detailed

instructional videos. It takes less than a week to learn

since there is just one engineering tool. Pre-engineered,

ready-to-use displays make engineering much easier

than others. Additionally, a single project database makes

archiving or backup very easy to perform. There is also

multiple language support capability.

The Freelance cont rol system combines user-f riendly engineer ing

with an open, modern system architecture. This means: – Only one tool for engineering, commissioning and

diagnostics

– Fieldbus management completely integrated into control

system engineering

– Time and cost savings in engineer ing, commissioning,

testing, service and maintenance

– Assembly close to the field: reduction of field wiring and

space requirements

– Freelance has a convenient cross-reference feature

allowing variables and tags to be found easily in any editor

right up to the graphic display. This makes troubleshooting

and debugging easier, resulting in faster project execution.

Pre-configured components for the operator level

The engineer ing of the Freelance operator level is straight-

forward. The pre-configured visualization components include:

– Faceplates

– Module diagnostics

– Extended troubleshooting capabilities

– Automat ical ly generated sequence diagrams

– Automat ical ly generated system communication

– Event list and alarm line

– Trend displays with long-term archiving

These components can be used straight out of the box,

eliminating time-consuming manual configuration.

Freelance version 2013

After more than 18,000 installations spanning more than

100 countries ABB continues to introduce innovations in its

Freelance distributed control system (DCS). With the latest

new AC 900F controller, Freelance provides more power,

speed and functionality than ever before.

A key feature of Freelance version 2013 is the support of SD

cards for AC 700F and AC 900F controllers. This allows one

to load applications or firmware into the controller without the

need of a terminal program on a computer.

Freelance version 2013: Benefits at a glance

– Compatible with previous versions of Freelance components

– Integrated PROFIBUS line redundancy for AC 900F

– Enhanced engineering tool

– Modbus TCP and IEC 60870-5-104 remote telecontrol

protocol on Ethernet for ABB’s AC 700F, AC 800F, and

AC 900F controllers

– Support of SD Card for application and firmware allows

load and save application and firmware updates without

the need of a computer for AC 700F and AC 900F

– Optional LCD display for AC 900F provides diagnostic

information for maintenance – Highest availability through redundancy with no single point

of failure

– AC 900F has two built -in serial ports and four Ethernet

ports, offering more connectivity.

Freelance is ABB’s user-friendly, cost-effective and robust

solution ideal for nearly all process industries, with the following

benefits:

– Easy to use: It is easy to install, learn, engineer,

commission, back-up, maintain and expand.

– Scalable: Projects can start as small as a few I/Os and

grow to thousands of I/Os controlling the whole plant. – Reliable: It is a proven system with high reliability and

availability providing redundancy options supporting

solutions without any single point of failure.

– Value for your money: Investment goes a long way

because of its small footprint and ability to run on any

standard computer. Together with its ease of use, this

results in savings in installation, engineering,

commissioning and life cycle costs

Easy to use

Freelance value propositions


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Freelance is a well-proven technology that has been

around for about 20 years and is installed in over 18,000

sites globally since its origination in Germany.

There are hardly any maintenance issues encountered after

the system is installed. It has consistently performed well in ABB’s annual customer survey. Existing customers are

staunchly loyal to this product.

High availability

The technology has proven i ts worth in industria l use over

several years and meets the toughest requirements regarding

availability. The hardware can be structured redundantly at all

levels. This includes the redundant fieldbus modules, redun-

dant fieldbus lines as well as network and controller redun-

dancy.

Regulatory complianceWith a view to meeting the requirements of regulatory authorities

such as the American FDA (Food and Drug Administration) or

the EFSA (European Food Safety Authori ty), Freelance provides

a series of features that facilitate the validation procedure.

Examples include:

– Encrypted log and trend data

– Audit trai l functions

– Access rights and user administration (security lock)

Freelance can be easily scaled up from a small system of

a few I/Os to a large system of up to thousands of I/Os.

Expansion can be done with minimal engineering effort.

A Freelance system can consist of one or combination of

several AC 700F, AC 800F and/or AC 900F controllers. It can

be extended with fieldbuses, field devices and remote I/Os.

With AC 800F and AC 900F, you have the option of configuring

your entire system in redundancy.

As shown in the architecture drawing (see pages 8-9), Freelance

can go from a typical OEM offering with an AC 700F controller, a Panel 800 and around 50-100 I/Os. The AC 700F can have

up to eight direct I/O modules connected to it or have remote

I/Os connected via PROFIBUS. Modbus RTU and TCP are also

supported. The Freelance Lite offering can typically have an

AC 700F or AC 900F contro ller and wi ll be in the 250 to 400 I/O

range with possibly a combination license and a few operator

stations. This can ramp up to the Freelance Standard and

Premium offerings with the AC 800F and/or AC 900F, with or

without redundancy. Freelance can go up to thousands of I/Os.

Connections include Foundation Fieldbus, PROFIBUS and

Hart as well. There is also the possibility to connect to super-

visory control stations running on ABB 800xA system.

– The AC 700F controller has a small footpr int that supports

PROFIBUS. It can support up to eight direct I/O modules. The

AC 700F optional ly supports PROFIBUS line redundancy.

– The AC 800F control ler can be equipped with up to four fie ld-

bus modules of type serial, PROFIBUS, FF HSE or Freelance

CAN bus. Optionally, AC 800F supports redundancy.

– The new AC 900F controller also supports PROFIBUS

and truly extends the hardware portfolio of the Freelance

distributed control system. The AC 900F modular controller

offers expanded flexibility via a pluggable SD card, more

Ethernet ports, redundancy options for high availability andpower enough for around 1,500 I/Os per controller. AC

900F can be equipped with either up to 10 direct I/Os or

remote I/Os via PROFIBUS. Optionally, AC 900F supports

redundancy.

All control ler types can be used in combinat ion in a sing le

system. They are suitable both for installation in the control

room and for use in junction boxes directly in the field.

Reliable Scalable

Freelance value propositions



The big advantage of Freelance is the savings it provides

in project engineering.

The easy-to-use features and use of only one tool for configu-

ration of graphics, controllers and field devices allows com-

missioning time to be reduced, resulting in faster start-ups.

Freelance also has a small footprint (comparable to a PLC),

which means less space requirement for cabinets. Since the

system uses intelligent peer-to-peer architecture, there is no

need for expensive server PCs.

Value for your money

In fact, Freelance can run on any standard computer with the

following minimum specifications:

– RAM: 3GB

– Hard disk: > 80GB (or 10GB for Freelance Engineering only)

– CPU speed: > 2GHz

– Operating system: Microsoft® Windows 7 and Windows

2008 Server R1/R2 (32/64 bit) (For OPC Server)

*For older versions, please refer to “Freelance Getting Started Manual” for the

specifications.



Freelance controllers

AC 900F: The core of the Freelance Version 2013

Following years of experience in automation and control

products, ABB is proud to introduce its latest Freelance

controller – the AC 900F. This controller truly extends the

hardware portfolio of Freelance distributed control system.

– SD card support

– Typically around 1,500 I/Os supported

– G3 compliant as standard

– Redundancy option for high availability

– Four (4) built-in Ethernet ports supporting Modbus TCP/IP

or 60870-5-104 telecontrol protocol – Two (2) serial ports supporting Modbus RTU/ASCII or IEC

60870-5-101 telecontrol protocol

– Optional PROFIBUS master modules (up to two) providing

integrated line redundancy

– Direct connection of I/O modules (up to 10), including modules

combining inputs and outputs in just one module can reduce

footprint and costs.

– I/O modules can also be connected remotely via PROFIBUS

AC 800F

– The outstanding feature is i t can be equipped with a set of

fieldbus modules, covering all major fieldbuses used inprocess automation.

– Option to run controllers either redundantly (CPU redun-

dancy, fieldbus module redundancy) or non-redundantly.

– Fieldbus-compliant components such as remote I/O, field

devices, and network components can be used.

– Optional G3-compliant

– A single controller can typical ly support around 1,000 I/Os

AC 700F

– Typically supports around 300 I/O signals per AC 700F

controller.– This PLC-like controller comes with a very smal l footprint .

Up to eight (8) S700 direct I/O modules can be plugged to

the right of the controller module.

– The connection to the Freelance control network is v ia

Ethernet as for all other controllers. As an alternative to

remote I/Os, AC 700F can be placed directly in the field,

offering a very flexible and cost-effective solution for an

“intelligent” I/O station.

– I/O modules can also be connected remotely via PROFIBUS.

This allows for h igh flex ibi lity in insta llat ion.

– SD card support

AC 900F

AC 700F

AC 800F



Freelance I/Os

Freelance’s PROFIBUS Master module enables connection

of ABB’s remote I/O units such as S700, S800, or S900.

The S700 I/O is meant for bas ic appl ications where traditionally

PLC I/Os have been used. The S800 and S900 are both used

in process automation, with S900 having extended channel

diagnostics and intrinsic safety ideal for areas where explosion

protection is required.

One of the benefits using Freelance in combination with remote

I/Os is that it can be placed in junction boxes in the field instead

of in the control room.

S700

– Can be used as direct I/O for AC 700F and AC 900F

Freelance controllers.

– Can be used as PROFIBUS remote I/O with AC 700F,

AC 800F, AC 900F or other PROFIBUS Masters.

– Small footprint - the modules are featured with a highpacking density, several modules are available with inputs

and outputs mixed in one module. Fourteen (14) different

module types are currently available, covering a wide

variety of applications and giving maximum flexibility.

S800

– A comprehensive, distributed and modular process I/O

system that communicates with controllers via PROFIBUS.

– Installation in the field as remote I/O, close to sensors and

actuators, greatly reduces the installation cost by reducing

the cost of cabling. Ability to exchange modules and

reconfigure the system during operation.– Redundancy options in all areas allow a high degree of

availability.

– For harsh environments, the I/O modules are compliant to

G3 severity level of ISA-S71.04, Environmental Conditions

for Process Measurement and Control Systems.

– A pass-through feature makes it possible to configure and

examine all HART-compliant field devices directly from the

control systems engineering tool.

S900

– Can be installed directly in zone 1 and zone 2 hazardous

areas and modules are compliant to G3.– Communicates with the control system level as remote I/O

using the PROFIBUS standard, therefore reducing marshal-

ling and wiring costs.

– Sturdy, error-tolerant and easy to service.

– Characterized by a compact design, cyclical transmission

of secondary HART variables, parameterization and diag-

nosis of all HART field devices via the fieldbus.

– Redundant Communication ensures maximum availability.

– Integrated disconnection mechanisms allow replacement

during operation, meaning that there is no need to interrupt the

primary voltage in order to exchange the power supply units.

– CB220 Compact box, remote S900 I/O in compact formwith up to four (4) I/O modules for decentralized use in field

housing.

S700

S800

S900



Freelance system overview

Freelance is divided into an operator level and a process level.

The operator level contains the functions for operation and

observation, archives and logs, trends and alarms.

Freelance Operations,

Batch,

Information,

Asset Management

Freelance Engineering

Operator level

Process level

Field

Devices

AC 700F or

AC 900F

Controller with direct I/O

Panel 800

Family

S700 I/O

ControlMaster

Controllers

ScreenMaster

Recorders

P R O F I B U S

M O D B U S

Field

Devices

F o u n d a t i o n

F i e l d b u s

Freelance

Rack I/O

P R

O F I B U S

MODBUS

Field

Devices

Drives

and

Motors

Panel 800 Family

Panel PC

Package Unit

Valve

MODBUS

AC 700F

Controller with direct I/O

Open-loop and closed-loop control functions are processed in

the controllers, and exchange data with actuators and sensors

in the field.

Freelance LiteFreelance OEM



System 800xA

Supervisory Operations

ERP

MES

Industrial ethernet (optionally redundant)

ABB and

3rd party

PLC & DCS

Field

Devices

Drives

and Motors

AC 800F

Controller,

ptionally

edundant

S800 I/O

Intelligent

Switchgear

MNS iS

Drives and Motors

S800 I/O

S900 I/O

AC 900F

Controller,

optionally

redundant

P R O F I B U S

Field

Devices

M O D B

U S3rd party PLC

Universal

Motor

Controller

Intelligent

Switchgear

MNS iS

Freelance Standard



Freelance OperationsDigiVis

The Freelance Operations station is a software that runs

on a simple PC-environment under Microsoft Windows.

It installs in five minutes. Freelance Operations supports

dual-monitor operation, which offers the benefit to stay

continuously tuned with essential information like the

alarm list, while inspecting at the same time for example

the progress of a sequential function chart, trend archives,

or the system display with extended diagnostics. In a

plant, several Freelance Operator Workplaces can work

seamlessly together.

The Freelance Operations interface

Freelance Operations meets all standard process control

requirements with regard to operation and observation at an

attractive price. Amongst other things, Freelance Operations

offers the following visualization features:

– Clearly structured faceplates for operator interventions

which can also be combined as required in group displays

– Trend displays including h istorical data and long-term

archiving

– Alarm pages for spec ific plant areas, sequence control

displays, shift logs, event logs and data archiving

– Standardized system display for system hardware diagnostics – Free graphic displays that besides standard graphic elements

are also supported by bitmaps and a 3D macro library

– Dual monitor operation

– Control aspect for interlocking displays

Freelance Operations configuration is fully integrated in

Freelance Engineering. Optional batch and information

packages are also easy to integrate.

FreelanceOperations

Trend display and archiving

1)

Time scheduler display1)

Operator hint list1)

Access control

Formulation and batch

Report

Group display of faceplates1)

Alarm and message list1)

InformationOverview display1)

SFC display1)

1) Pre-engineered and ready-to-use displays

System and device

diagnostics1)



Freelance EngineeringControl Builder F

With Freelance, all engineering work is performed with one

single tool, Freelance Engineering, which works hand in

hand with the visualization and operation tool Freelance

Operations. Configuration of all plant objects – ranging

from process graphics to field devices and operation of

the entire plant – is easy and intuitive to perform.

What’s more, Freelance Version 2013 supports Freelance

hardware dating back to as long as 18 years ago.

Freelance version 2013: Benefits at a glance

– Compatible with former versions – Intuitive auto router in Function Block Diagram (FBD) editor

– Both project tree and editors can be viewed simultaneously

for easier navigation

– Direct copy paste between several editors

– Optimized for efficient engineering, fewer clicks with

auto-accept

– Excel-like filter and sort functions in variable/tag list

– Direct import/export to Microsoft® Excel®

– Graphcical project preview for easier distinction of project

– Direct access to user documentation

The Freelance engineer ing stat ion is used to conf igure and

commission the whole system including the controllers, field

devices and Freelance Operations. Usually, portable equipment

such as laptops, which allow configuration both in the office

and on site, is used. The operator level PCs can also be

used for system engineering. A permanent connection to the

engineering station is not necessary. All five programming

languages specified in IEC 61131-3 are available. Users

especially appreciate how quickly they are able to familiarizethemselves with the tool. Supported by a uniform data basis

throughout the system as well as cross reference functions,

Freelance Engineering enables you to conduct the entire system

configuration quickly and easily, including:

– Configuring and parameterizing the field devices and I/Os

– Setting the bus topology and parameters such as

transmission rates and addresses

FreelanceEngineering

Project tree

Project database

Function Block Diagram Sequential Function Chart Structured Text Instruction List Ladder Diagram

Hardware structure

Configuration of fieldbus

Display process states

Freely configurable

graphic displays

Cross referencing



Freelance Engineering

Freelance Engineering is used with all controller types (AC 700F,

AC 800F and AC 900F) . Freelance supports FDT/DTM and

also user-defined hardware templates for the efficient configu-

ration and maintenance of field devices. This eliminates time-

consuming tasks of integrating device GSD files. In addition

to intuitive graphical parameterization dialogs for intelligent

field devices, a DTM also offers comprehensive diagnosticsfunctions for efficient maintenance.

With Freelance version 2013, ABB introduces new technologies

in the Freelance engineering tool to optimize workflow.

Freelance leverages the familiar Microsoft® environment to

allow easy navigation. For instance, different function block

diagrams can be displayed and copied, and tag or variable

list can be sorted and filtered similar to Excel spreadsheets.

Both lists can be easily exported to or imported from a

Microsoft® Excel® spreadsheet.

Freelance Engineering offers the following features for configuration, parameterization and commissioning:

– A single software tool for conf iguration of the automation

functions, the operator interface with displays and logs,

and fieldbus parameters.

– Graphical configuration with powerful editors according to

IEC 61131-3 in any of the following programming languages:

Function block diagram (FBD); Instruction List (IL);

Ladder diagram (LD); Sequential function chart (SFC) and

Structured text (ST).

– A function b lock l ibrary with more than 220 tried and tested

functions, greatly exceeding the basic ones outlined in

IEC 61131-3. – An extensive macro library containing more than 200 graphic

symbols, which can be extended by the user.

– A project t ree for flexible program generation and transparent

program structuring.

– Verification of automation funct ions, wi th the chance to find

and remove errors quickly and easily.

– Convenient cross-reference function allowing variables and tags

to be found easily in any editor right up to the graphic display.

– Importing and exporting of programs, displays, variables,

tags and parts of the project tree.

– Password protection to prevent unauthorized project

modification.

– Password protection for user-defined function blocks.

– Uniform and auto-generated system-wide graphical docu-

mentation of the entire user program, system communi-

cation and all field device parameters. – Integrated online help.

– Project file (application) backup on any data medium (hard

disk, CD, memory stick, etc.). The project file includes the

complete project with all p rograms, graphics, controllers,

and field device parameters.

– Testing and simulation of user programs (e.g. interlocks)

even without connected hardware using the controller

emulator.

– Bulk data manager allows to import signal lists from planning

tools via Excel and fast duplicating of typical solutions.

Versatile communication You can use the following as required: OPC, Ethernet, TCP/IP,

PROFIBUS, FOUNDATION Fieldbus, MODBUS or HART. In

addition, use audio instructions to obtain a solution in the

event an alarm, video integration or internet connection.

The structure of the field level

ABB offers an extens ive selection of devices that are f ine-

tuned to meet the needs of the relevant area of use. Thanks

to established communication standards, integration into

Freelance is quite simple. Using PROFIBUS together with the

controllers, intelligent field devices can be integrated into the

system directly or via remote I/Os.

The choice of fieldbus type

In accordance with the concept of plug-and-produce, Freelance

allows the integration of all common fieldbuses – providing the

user the freedom to choose the fieldbus type. Various types of

fieldbus can be operated in parallel in a single controller.

Bus Type AC 700F AC 800F AC 900F

PROFIBUS-DPV1 Yes Yes Yes

FOUNDATION Filedbus No Yes No

HART via remote I/O Yes Yes Yes

MODBUS Master and Slave Yes Yes Yes

MODBUS TCP Yes Yes Yes

CAN for Freelance Rack I/O No Yes No

Telecontro l protocol IEC 60870-5 Yes Yes Yes



Freelance technology management

Cyber Security

Software Security Management

– ABB reviews, tests and va lidates monthly Microsoft

securityupdates and third-party virus scanner software for

compatibility with Freelance system software. A monthly

qualification reportis provided to subscribers of Automation

Sentinel.

– User authentication and access control based on user, role

and location

– Backup / restore function to backup changes to the appli-

cation and allow restoration against attacks

Batch Management

Freelance Formulation

– Freelance Formulation is an essential Recipe Management

component for single product or multi-grade product process

cells, controlled by Freelance DCS. The Control Recipes

are executed on a single Sequential Function Chart (SFC)

and only one Control Recipe can run on an SFC at any

time.

– Multiple Control Recipes may run on different SFCs at the

same time.

– The database used to store the recipes can be shared

among several Freelance Formulation workstations. – The Free lance Formulation database support up to 50 SFCs

with 30 Master Recipes for each and 30 Control Recipes per

Master Recipe. Each recipe can have up to 300 parameters

and report items.

– Once a Control Recipe has been executed, Freelance

Formulation will run a simple batch report based on

Microsoft Excel.

– The user has one tool to conf igure recipes, organ ize

parameters and schedule control recipes. It provides all the

information the operator needs to schedule batches in one

simple application, easily integrated into user graphics.

– Little or no knowledge of a batch manager software packet

is required to use the Formulation tool. Less time learning a

tool, more time to focus on the process.

– Ideal for procedures where multiple formulations apply to

one Master Procedure (SFC).

Freelance Batch

– Batch Operation integrated in Freelance Operation

– From standard batch reports up to FDA-compliant batch

documentation

– Unit management module with alarm management

– Automat ic reading of report values f rom the cont rolle r

– Transfer of Cont rol (TOC) and “Stop Phase” functionali ty atbatch level

– Easy equipment engineering

– Versioning on recipe level

– Instantiation on recipe level

– Easy licensing

Extended Automation Batch Management

– Used in Extended Automation solution with Freelance

Controllers

– Scheduling, monitoring and controlling batches and

campaigns

– Recipe control and operation – Resource management

– Redundancy

– Reporting, material tracking and history

– Traceabi lity of actions, the process, and deviations of the

process

– ISA 88.01 flexible batch management for simple, accurate

and repeatable reuse

Freelance History and information

Today, Freelance comes wi th a historian included wi th the

basic software licence. It is possible to view trends, signal

sequence logs and Excel reports, all with the standardFreelance operations software (DigiVis) software.

Freelance Information is an optional package that offers

enhanced visualization and reports, giving operators a more

powerful information management system along with a server

redundancy option.



Freelance lifecycle services

A comprehensive customer service is worth its weight in gold

Service means a profitable investment in continually maximizing

and optimizing the availability, performance, quality and security

of a plant. ABB’s support covers the following areas:

– Customer Support Services

– Training

– Spare Parts & Logistics, Repair Shops – Process, Application & Consulting Services

– Service agreements

– Extensions, upgrades and retrofits

Through the resulting specialization of our employees, we

guarantee maximum competence for each task we perform.

Whether it’s more traditional service support such as commis-

sioning and maintenance or individual consulting services – the

result is measurable customer benefits.

Our comprehensive Life Cycle Services enable us to increase

the value of your plant over its entire lifetime. The conventional, reactive service can reduce production downtimes, while

the use of new technologies offers an increased number of

capabilities for preventive service measures to identify and avoid

cost-intensive faults at an early stage. Proactive services such

as asset management or ongoing modernization increase the

value of our customers’ plants and give them a distinct

competitive edge.

Life cycle management

Automat ion Sentinel is ABB’s control system life cycle manage-

ment and support program. With this program, you can keep

your control system up-to-date and maintain a flexible path to

new technology. Automation Sentinel helps manage automation

software assets with timely delivery of the latest Freelance

releases, thus providing you with better productivity, lower

support cost and simpler software management. Migration from

traditional control systems to Freelance enables ease-of-use

and lower maintenance cost.

One valuable service of the Automation Sentinel program is the secure, web-based platform My Control System. It provides

detailed information about your installed software, as well as

operational data such as alerts and reports (including health

status, performance, safety, and security reports) and all that

in a single location.

My Control System presents, in dashboard format, important

information about the control system’s subscriptions and

software licenses in terms of content, expiry dates, tools and

license key downloads. All this data is available with just a few

clicks. For convenience, the ABB local service contact infor-

mation is listed on the starting page.

Using My Control System to access pre-filtered information

dedicated to your installed control system can help you lowering

your total support cost and reduce after-hours support or

service calls.

Asset Management

If you want to keep your production plant up and running in

the long term, you need information about the availability and

degree of wear and tear of your equipment. All of the information

necessary for this is available; integrated and included in the

basic software package of the Freelance control system. Asa result, several customers have been able to avoid making

investments that appeared essential but were in fact unneces-

sary. Freelance allows the use of modern asset management

methods for more efficient maintenance and optimization –

helping for instance to make optimum use of plant capacity.

For more information about Automation Sentinel please refer

to the Automation Sentinel Datasheet (3BUS095075).



Freelance applications ABB’s Freelance has helped thousands of customers from diverse industries across the globe. This compilation of

success stories, ranging from simple process operations to highly complex industrial applications, is a demonstration

of Freelance’s ability to meet challenging requirements in terms of robustness, scale and reliability.

Case study 1: Oil and gas industry – The customer, a gas plant in the United States, wanted to upgrade

their pneumatic controls with minimum downtime during switch-over.

Results: The Freelance DCS system provided the ability to quickly turn the control of the DCS over to theplant personnel for modifications and additional enhancements after initial commissioning.

Case study 2: Chemicals industry – The customer, a major Chinese chemicals company, wanted to

expand their melamine production.

Results: The plant was able to increase its melamine production by 30,000 tons to 100,000 tons p.a.,

with the Freelance DCS system, and add new nodes in the future to expand the installation.

Case study 3: Wastewater industry – The customer, a wastewater treatment plant in Thailand, wanted

to evolve its wastewater treatment process from being a manual task, to one that is fully automated.

Results: They saw increased effic iency in the filt rat ion and backwashing operations due to improved

control and monitoring processes with Freelance DCS. It can now also be fully backed up in case of new

system failure.

Case study 4: F & B industry – The customer in Poland, one of the country’s largest sugar factories,

wanted to modernize the pneumatic control system for its diffusion, evaporators, raw juice filtration and

boilers.

Results: This technological advancement using Freelance DCS system enabled the sugar manufacturer

to increase capacity by up to 70%, or 12,200 tons/day.

Case study 5: Pulp & paper industry – The customer, a Brazilian pulp and paper company, wanted to

improve productivity with entry-level solutions, and without a huge capital outlay.

Results: With the Freelance DCS controlling the mixing pump, the number of paper breaks in the paper

machine was greatly reduced, thereby generating savings and profitability.

Case study 6: Power industry – The Germany-based customer, which generates 760 million Kwh of

power for Germany and Switzerland, wanted to upgrade their Contronic P control system using a

multiphase migration strategy.

Results: The plant now has unmanned operations, the integration of remote alarm functionality, ease of

spare parts procurement, while cost-effectively migrating a Contronic P to a Freelance DCS.

Case study 7: Cement industry – The Chinese customer wanted the latest control technology that supports

Ethernet, TCP/IP, standard fieldbus, and integrates transmitters, sensors, etc. from different vendors.

Results: Even though there were nine Freelance controllers, the system variables and tag values from

the different process segments can still be shared across the system by the controllers and the operator

stations. A Chinese version of the system software was also available, including engineering tools,

operator interface, help function and all menus.

Case study 8: Glass industry – The customer, a leading German packaging business, produces

approximately 25 billion containers annually. They wanted to upgrade the batch control system for their

glass making processes.

Results: The customer found Freelance Engineering easy, using just one tool for configuration. The

customer was also able to retain I/O channels, including having visualization and intervention capabilities.

Case study 9: Boiler manufacturing – The customer, a Swedish manufacturer of high-performance

boilers for hot water and steam wanted a system to control their fully automated solid fuel boiler.

Results: The customer found that the Freelance DCS is very user-friendly and rarely malfunctions.

Furthermore, it supports easy and quick modifications to meet specific product specifications.

Case study 10: Mining industry – The customer, a South-Africa-based mining company wanted to

replace the PLC that controlled the direct motor starters of conveyors that extract p latinum from ore.

Results: With intelligent speed control from Freelance DCS, the customer was able to realize up to 50%

in energy savings, as well as increased productivity.



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