A DCS is the production memory and nervous system of a plant, expected to run without interruption for years. That is why an installation is an engineering job rather than an equipment list: the process is understood first, the architecture follows from it, and the system goes to site only after it has been proven. With its accumulated experience in installing, assembling and servicing ABB DCS products, ASP Otomasyon runs this chain end to end from one team.

Scope
Architecture and equipment selection, configuration, control application, commissioning
Platforms
ABB System 800xA, Freelance and existing Advant systems
Delivery
A working system, design and test records, backups, training
When
New plant, line extension or system replacement

What does a DCS installation cover?

Every project is different, but the scope usually includes some or all of the items below. We can also support only part of it, depending on what you need.

  • Computer selection: virtual or physical server and client installations.
  • Network equipment and cable selection: control network topology, switches and cabling.
  • Controller and I/O selection: processors, cards and a redundancy structure that fit the process.
  • Field communication cables: cabling standard, termination and fieldbus topology.
  • Actuator and instrument selection: valves, transmitters and drives that suit the system.
  • Configuration: addressing of the selected equipment, network and redundancy settings, users and permissions.
  • Process page standards: screen layout, colours, symbols and alarm presentation that operators read the same way everywhere.
  • Process logic libraries: standard blocks for repeating functions such as motors, valves and PID loops.
Control system layersA five-layer control system architecture running from field instruments through controllers and the control network to operator stations and the enterprise data layer.FieldTransmitters, valves, drives, motor outputsControllers and I/OControl logic, cards and commsNetwork and serversSwitches, servers, redundancyOperator stationsProcess graphics, alarms, trendsData layerOPC, reporting, MES / ERP↑ measurements and status ↓ commands and setpoints
Each layer builds on the one below: measurements flow up, commands flow down.

How we work

  1. Requirements and scopeWe clarify the process, the existing system, I/O counts and expectations together. The scope is written down and the proposal is built on the same scope.
  2. Architecture and equipmentControllers, servers, network and operator stations are selected; redundancy and future expansion are considered from the start.
  3. Panels and site preparationWhere the project needs them, panel design and manufacture, wiring and site preparation run in step with the installation team.
  4. Application softwareControl logic, operator graphics, alarm and trend structure are prepared with standard libraries.
  5. Factory acceptance test (FAT)Before the system goes to site it is verified with simulation and documented test scenarios.
  6. Site installation and commissioning (SAT)The system is brought up on site, loops are verified one by one and an acceptance test is run with the operators.
  7. Training and handoverOperator and maintenance training, backups and documentation go with the system into operation.

Control panels are part of the project

We do not offer panel design and manufacture as a stand-alone service. Where a project needs them, CPU and I/O panels, with redundant power and network equipment, are designed, built and factory-tested as part of the DCS installation. Deriving panel and software from the same I/O list means errors are caught where they are cheapest: in the factory.

Control panel delivery flowA five-step panel delivery flow: from requirements and I/O list to design, manufacture, factory test, shipment and commissioning.Requirementsand I/OProcess, I/O list,environment1DesignLayout,schematics,equipment choice2ManufactureAssembly andwiring3Factory testInspection,insulation andfunction test4Shipment andcommissioningField connection,verification5Each stage leaves records: schematics, bill of materials, test records
Errors are cheapest to find in the factory test; an error found on site costs more and may stop production.

What we pay attention to

  • The I/O list is the single source of truth. Card counts, wiring and software are all derived from the same list; the accuracy of the list is the accuracy of the project.
  • Redundancy is not redundancy until it has been tested. Controller, network and server redundancy are tried with deliberate failures during FAT and SAT.
  • Alarms are designed up front. An alarm structure that floods the operator is one of the hardest things to fix afterwards.
  • The backup and restore plan is part of the handover. The system is delivered with backups taken and the restore tried.

We have detailed articles on each of these: defining DCS project scope, building a useful I/O list, FAT and SAT and alarm management.

Which platforms do we work with?

System 800xAABB's integrated operator environment for process and asset management.Freelance DCSA system that combines PLC compactness with DCS functionality.Advant DCSMaintenance of existing Advant systems and the move to 800xA.

Frequently asked questions

How long does a DCS installation take?

It depends on the number of I/O points and processes, whether the site is ready and when outages are possible. Once the scope is clear, a realistic schedule with milestones, including FAT and SAT, is shared in writing.

Can the installation be done while production continues?

In an existing plant, usually yes: the new system is prepared while the old one runs and is put into service during a short planned outage. See our System Upgrade page for the approach.

Do you build the control panel too?

Yes, where the project requires it: panel design, manufacture and factory testing are carried out within the scope of the DCS installation. We do not offer panel manufacture on its own, separate from a project.

Can I buy part of the service, such as only programming or only commissioning?

Yes. We also support projects where part of the scope is carried out by you or another contractor, by defining the interfaces clearly.

Can I get support after the installation?

Yes. For installed systems our service and maintenance agreements continue with 24/7 remote access and on-site service options.