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ABEL boasts a wealth of experience and skills in the automation of a multitude of processes across many industry sectors. ABEL software engineers develop code from client FDS (Functional Design Specifications) or from our array of knowledge and experience, past projects or just from holding in depth discussions to ascertain operational and automation needs of plant and machines. Testing of the required solution is often carried out ‘off site’ or prior to commissioning, via fully simulated code. ABEL utilise predominantly Siemens and Rockwell products, but also extend to include ABB and Mitsubishi, Schneider, B&R and OMROM PLC packages.
PLC control panels are one of the staple offerings of ABEL, fully customised, usually with suitable HMI interface, whether it be a stainless steel design for a hygienic process, or mild steel painted type for a switchroom location, high or low IP ratings to suit ingress limits, stand alone or integrated as part of a larger suited system. PLC panels are fully documented with detailed schematics, layout arrangement drawings, power/control field cable scheduling and all developed in conjunction with client specifications and on site requirements. FAT’s are offered as standard to ensure customer satisfaction prior to delivery.
ABEL has, over the years, developed into a leading systems integrator within our markets and for our customers. Our highly experienced engineers and project managers have designed, integrated and managed many turnkey projects with decades of experience. From food processing to power generation, finding and delivering solutions for power, control and automation of multiple processes on a complete project basis is a key offering to our customers.
SCADAs are often required in addition to PLC and HMI’s, integrated into plant network architecture, providing a fully automated graphical representation of the controlled plant, together with alarm logging, trending and diagnostics. Packages such as Wonderware, WinCC and Rockwell are the ABEL preferred standards, having provided such systems nationally and internationally across a multitude of processes and industries on previous projects.
With multi-product solution requirements, many clients require a power and motor control downstream of MV/LV distribution transformers as part of a turnkey offering, providing full power controls and automation. LV MCCs are often required for heavy duty load requirements for such applications as mining and sizing machines. ABEL provide LV MCC solutions fully certified to all relevant IEC and BSEN standards, in forms 1-4 of IEC60439-1 and IEC61439-1 whether fixed pattern compartments of fully withdrawable. With integration skills, solutions often include integrated power distribution equipment and PLC controls, still maintaining the related standards, to ensure a seamless system where only one power source is required.
ABEL Power and Control Systems have a wealth of experience in the design and supply of G59/3 Relay panels, Inverter Power Distribution and Export Limitation. For G59, we offer both Contactor circuit disconnection and Motorised MCCB disconnection options, each with a customised distribution for Inverter connections, and all with generation power meters. The panel design considers either top or bottom entry, Mild Steel or Stainless steel depending on the environmental conditions, and are sized to suit access, dimensional limits, and maximum peak current load. Other facilities can be added, such as test circuits and generator connection interlocks, fire alarm connections and others. For power curtailment, we usually provide a PLC system with a communications interface to the inverters. The export limit can be set at a fixed value or be variable on time of day or year dependant on the DNO's requirements. Note, G59 can be incorporated into other renewable energy schemes, such as wind farms.
Motor starter panels are a more cost effective alternative to fully certified MCCs, still proving the same function for the client, but located in a wardrobe style – requiring less space, however still safely installed within the panel to IP2X protection level, even with certified and insulated busbar systems of needed. PLC controls can be included or if a simpler solution needed the controls can purely be via lamps, switches and pushbuttons. Starter formats can be DOL, soft start, Star/Delta reversing, or VDSs and range from less than a kW up to hundreds of kWs per motor load. Panels and associated equipment are manufactured to all relevant European and International Standards ensure all products achieve the clients requirements both in construction and performance.
In order to ‘house’ electrical power, control equipment and process equipment, ABEL have developed designs for such an application, either using painted mild steel construction or GRP with a steel base. Cable ways are constructed underneath the main construction mounted on the support structure where required. The benefits are significant, as all integrated equipment can be pre-wired and pre-commissioned and avoids expensive civils switchroom construction at site. Secondary benefit is the complete system is shipped ‘as is’, so for overseas plants no export packing is needed. Specialist requirements such as ATEX, (purge pressurised), air conditioning, forced cooling, controlled interlocked heating for cold ambient start ups, smoke / fire detection can all be considered as each solution is custom made to customers, technical standards and country requirements.
With turnkey type projects, many clients require a power, controls and automation solution without having to procure power equipment from alternative suppliers. So alongside our LV and HV Motor Control centres, ABEL provides power distribution transformers and switchgear. Transformers are typically cast resin ANAN type, housed when required, but oil cooled can be provided if required depending on the client specification. Switcboards for Transformer primary and secondary protection is also within the ABEL range, often coupled with our LV/MV switchgear via our certified busbar systems.
With multi-product solution requirements, many clients require a power and motor control upstream of MV/LV distribution transformers as part of a turnkey offering, as well as LV MCC, controls and automation. MV MCC are often required for heavy duty load requirements for such applications as mining and sizing machines. The systems include Arc Protection, power monitoring and management, earthing switches and specialist protection equipment. ABEL provide MV MCC solutions fully certified to all relevant IEC and BSEN standards
ABEL, with over 70 man years of world wide experience in Electrostatic Precipitation, supply a complete range of Redkoh ™ controllers with associated products for minimising air pollution control particulate emissions and with minimal power consumption, in conjunction with the ABEL supply of HV transformer Rectifiers, as well as rapper controls, both for tumble hammer or Migi type. The product range when installed are fully networked and coordinated and often linked to plant DCS, auxiliary equipment PLCs and hardware, i.e a fully integrated solution. Panels and associated equipment are manufactured to all relevant European and International Standards ensure all products achieve the clients requirements both in construction and performance.
ABEL supply transformer rectifiers for delivering DC high voltage and mA to Electrostatic Precipitators (ESPs), typically up to 130kV peak and 2500mA. Designed and built to order, any combination of output voltage and current, coupled with any 2 phase primary voltage at either 50 or 60Hz, can be achieved. Designed for outdoor location to IP65, ONAN cooled, all types of ESP power requirements can be achieved. TRs can be supplied with a range of additional equipment including manual and automatic earthing switches.
ABEL, as an alternative to Electrostatic Precipitator controls, provide PLC controls for Fabric Filters. Whether it be for a waste to energy facility, or a full scale coal fired power plant, ABEL engineers have tailored controls for such applications, including fast acting pulse jet control for bag cleaning, multiple redundancy management, often coupled with pneumatic conveying systems. Panels and associated equipment are manufactured to all relevant European and International Standards ensure all products achieve the clients requirements both in construction and performance.
ABEL engineers have experience over many projects in the Motion Control arena, From a 3 axis positioning system for ultrasonic testing for material flaws, to packaging machines and positioning equipment using servos from such companies as Rockwell, Lenze and Siemens. Using specialist high speed position control motion processors, together with very specific and demanding requirements from customers of this type of system, such as for food processing equipment, ABEL ensures full compliance and accuracy with our control design solutions. Our engineers have good understanding of the associated mechanics, essential for designing control systems for this type of application
A significant number of processes – for example - oil refineries, anaerobic digestion plants and many others, often include the possible presence of flammable gases, hence the need for equipment to ATEX standards, for different gas / level categories such as Zone 1 and Zone 2. ABEL has many years experience of engineering such solutions, whether it be intrinsically safe equipment or a full purged pressurised panel / enclosure, to ensure a gas free positive pressure zone to eliminate explosion risk.