Integrating a Hazardous-Area Scrubber Expansion into an Existing ABB 800xA Control System

Expanding a manufacturing facility often brings a familiar challenge: how do you integrate new process equipment without disrupting an established control system?

A process manufacturing client was expanding its scrubber system and needed additional hazardous-area field instrumentation integrated into its existing ABB System 800xA Distributed Control System (DCS). The solution needed to fit seamlessly within the current architecture while maintaining strict separation between intrinsically safe (IS) and non-intrinsically safe circuits, supporting future expansion, and arriving on site fully tested and ready for commissioning.

The client wasn’t looking to replace their existing control platform, they needed a solution that would extend its capabilities while minimising project risk.

Integrating hazardous-area instrumentation into an operational manufacturing environment requires more than simply connecting additional devices.

The project demanded:

• Safe integration with an existing ABB 800xA system.

• Compliance with hazardous-area wiring requirements.

• Reliable communication via Profibus DP.

• High availability through separate UPS and mains supplies.

• Comprehensive testing before installation to reduce commissioning risk.

Without a carefully engineered solution, the project risked increased commissioning time, unnecessary disruption and greater complexity during installation.

Integrating hazardous-area instrumentation into an operational manufacturing environment requires more than simply connecting additional devices.

The project demanded:

• Safe integration with an existing ABB 800xA system.

• Compliance with hazardous-area wiring requirements.

• Reliable communication via Profibus DP.

• High availability through separate UPS and mains supplies.

• Comprehensive testing before installation to reduce commissioning risk.

Without a carefully engineered solution, the project risked increased commissioning time, unnecessary disruption and greater complexity during installation.

BONNER’s Engineering Solution

We designed, built and factory-tested a complete two-bay safe-area remote I/O interface panel, providing a fully integrated solution that connected the new scrubber instrumentation into the client’s existing control architecture.

The solution included:

• A two-bay Rittal modular enclosure assembly.

• ABB S800 Remote I/O integration.

• Profibus DP communications.

• Pepperl+Fuchs intrinsic safety barriers for hazardous-area field loops.

• Segregated intrinsically safe and non-IS wiring in accordance with BS EN 60079-14.

• Dual power supplies using separate UPS and mains incomers.

• Thermal management, surge protection, service power and internal lighting.

• Comprehensive factory acceptance testing against the ABB 800xA platform before delivery.

Every aspect of the project,from electrical design and panel manufacture through to documentation and testing, was delivered by BONNER’s automation and electrical engineering team.

Delivering a Single-Source Engineering Package

Rather than coordinating multiple contractors, the client benefited from a single engineering partner responsible for the entire project.

BONNER delivered:

• Electrical design and documentation.

• Hazardous-area interface design.

• Panel manufacture and wiring.

• ABB S800 and Profibus integration.

• Inspection and testing.

• Factory Acceptance Testing (FAT).

• Full documentation, including CE and UKCA declarations.

This single-source approach reduced interface risk and ensured every stage of the project was delivered to a consistent engineering standard.