Automating Processes.
Optimizing the Future.
We Automate Processes.
We Optimize the Future.
Automating Processes.
Optimizing the Future.
Your partner in the design, automation, and maintenance of complex industrial systems.
We increase your productivity through precise engineering and continuous support.
Your partner in the design, automation, and maintenance of complex industrial systems.
We increase your productivity through precise engineering and continuous support.
Your partner in the design, automation, and maintenance of complex industrial systems.
We increase your productivity through precise engineering and continuous support.
Transform Your LegacySystems Into Smart Operations.
Transform Your LegacySystems Into Smart Operations.
Client and location
Client and location
The project was carried out for A2A S.p.A. in Milan, one of the leading Italian energy companies focused on sustainable development and energy supply. The focus of the intervention was on a steam turbine within their production facility.
The project was carried out for A2A S.p.A. in Milan, one of the leading Italian energy companies focused on sustainable development and energy supply. The focus of the intervention was on a steam turbine within their production facility.
Challenge
Challenge
The main impetus for the project was the technical obsolescence of the existing overspeed protection system (EPRO MMS6350D) and the AC160 controller (model PM644). The critical shortage of spare parts on the market and the difficult maintenance jeopardized the operational safety of the turbine, which required an urgent upgrade to a modern technological platform while maintaining the existing process stability.
The main impetus for the project was the technical obsolescence of the existing overspeed protection system (EPRO MMS6350D) and the AC160 controller (model PM644). The critical shortage of spare parts on the market and the difficult maintenance jeopardized the operational safety of the turbine, which required an urgent upgrade to a modern technological platform while maintaining the existing process stability.
Solution
Solution
The backbone of the new system consists of three ABB TP800 cards that replaced the old EPRO system. This technology enabled the configuration of advanced 2oo3 (two-out-of-three) measurement logic, where two speed measurement probes are connected to each card. A special engineering challenge was the integration of the new measurement technology with the existing AC160 processors via Profibus communication. Due to the generational difference in hardware, the solution required complex synchronization of communication protocols and in-depth modification of the software in the CBA (Control Builder A) environment, along with the adjustment of visualization and alarms in the ABB 800xA system.
The backbone of the new system consists of three ABB TP800 cards that replaced the old EPRO system. This technology enabled the configuration of advanced 2oo3 (two-out-of-three) measurement logic, where two speed measurement probes are connected to each card. A special engineering challenge was the integration of the new measurement technology with the existing AC160 processors via Profibus communication. Due to the generational difference in hardware, the solution required complex synchronization of communication protocols and in-depth modification of the software in the CBA (Control Builder A) environment, along with the adjustment of visualization and alarms in the ABB 800xA system.
Execution
Execution
The project was carried out through strictly defined phases, starting with the laboratory establishment of communication in the office to ensure the compatibility of the equipment. After verifying the communication parameters, the control logic was changed and the parameters for overspeed protection were precisely adjusted. The entire system underwent rigorous testing in simulated conditions before the final implementation and testing in a real plant at the location in Milan.
The project was carried out through strictly defined phases, starting with the laboratory establishment of communication in the office to ensure the compatibility of the equipment. After verifying the communication parameters, the control logic was changed and the parameters for overspeed protection were precisely adjusted. The entire system underwent rigorous testing in simulated conditions before the final implementation and testing in a real plant at the location in Milan.
Result
Result
With the successful integration of the ABB TP800M system, the A2A plant has achieved maximum safety and redundancy. The modernization eliminated risks associated with outdated equipment, ensured more accurate measurement of turbine performance, and laid the foundation for long-term digital stability of the entire power unit.
With the successful integration of the ABB TP800M system, the A2A plant has achieved maximum safety and redundancy. The modernization eliminated risks associated with outdated equipment, ensured more accurate measurement of turbine performance, and laid the foundation for long-term digital stability of the entire power unit.
Used technology
Used technology
Control system: ABB AC160 (PM644)
Protection system: ABB TP800M (Overspeed Protection)
HMI / SCADA: ABB 800xA
Software environment: CBA (Control Builder A)
Communication protocol: Profibus DP
Configuration: 2oo3 (Two-out-of-three) redundant logic
Control system: ABB AC160 (PM644)
Protection system: ABB TP800M (Overspeed Protection)
HMI / SCADA: ABB 800xA
Software environment: CBA (Control Builder A)
Communication protocol: Profibus DP
Configuration: 2oo3 (Two-out-of-three) redundant logic
EKON Eti Maden: Siemens turbine upgrade and start-up automation
EKON Eti Maden: Siemens turbine upgrade and start-up automation
Client and location
Client and location
The project was implemented at the EKON Eti Maden power plant in Bandırma, Turkey. The project included the modernization of two Siemens turbines, models T5866 and T5867 (NG25/20/12.5-3DA series), with the aim of increasing the level of automation and safety of the plant.
The project was implemented at the EKON Eti Maden power plant in Bandırma, Turkey. The project included the modernization of two Siemens turbines, models T5866 and T5867 (NG25/20/12.5-3DA series), with the aim of increasing the level of automation and safety of the plant.
Challenge
Challenge
The primary challenge was the outdated system that allowed only manual local start of the turbines. This mode of operation limited operator flexibility and prevented centralized control from the control room. In addition, the vibration monitoring and rotating equipment protection system required replacement with a more modern solution that could be fully integrated into a modern DCS architecture.
The primary challenge was the outdated system that allowed only manual local start of the turbines. This mode of operation limited operator flexibility and prevented centralized control from the control room. In addition, the vibration monitoring and rotating equipment protection system required replacement with a more modern solution that could be fully integrated into a modern DCS architecture.
Solution
Solution
The existing system was transformed into a fully automated solution controlled by ABB 800xA DCS. Actuators were added to the mechanical start-up equipment, enabling remote process control. A new system for monitoring and protection of rotating equipment ABB MCM 800 (Symphony Plus) was implemented for precise monitoring of vibrations. The heart of the system consists of AC 800M controllers and TP800 modules, and the entire control logic was developed in the Control Builder M environment. The engineering team created complex automatic sequences for starting the turbines with integrated additional safety checks for each individual device.
The existing system was transformed into a fully automated solution controlled by ABB 800xA DCS. Actuators were added to the mechanical start-up equipment, enabling remote process control. A new system for monitoring and protection of rotating equipment ABB MCM 800 (Symphony Plus) was implemented for precise monitoring of vibrations. The heart of the system consists of AC 800M controllers and TP800 modules, and the entire control logic was developed in the Control Builder M environment. The engineering team created complex automatic sequences for starting the turbines with integrated additional safety checks for each individual device.
Execution
Execution
The project started with the detailed design of the system architecture and the creation of HW and network specifications. Software development included PLC programming and the design of an HMI graphic interface adapted to operators, including advanced displays of historical data (trends) and an alarm system. Before the actual implementation at the location, rigorous testing was carried out in simulated conditions (FAT - Factory Acceptance Test), followed by installation, final testing in real conditions (SAT - Site Acceptance Test) and expert training for power plant operators.
The project started with the detailed design of the system architecture and the creation of HW and network specifications. Software development included PLC programming and the design of an HMI graphic interface adapted to operators, including advanced displays of historical data (trends) and an alarm system. Before the actual implementation at the location, rigorous testing was carried out in simulated conditions (FAT - Factory Acceptance Test), followed by installation, final testing in real conditions (SAT - Site Acceptance Test) and expert training for power plant operators.
Result
Result
The modernization achieved complete digital control over the operation of the turbines, which eliminated the need for exclusively manual interventions. The new MCM800 system provided superior protection of rotating equipment, while integration into the ABB 800xA system allowed operators full visibility and control security from a remote location, significantly increasing the plant's operational efficiency.
The modernization achieved complete digital control over the operation of the turbines, which eliminated the need for exclusively manual interventions. The new MCM800 system provided superior protection of rotating equipment, while integration into the ABB 800xA system allowed operators full visibility and control security from a remote location, significantly increasing the plant's operational efficiency.
Used technology
Used technology
DCS system: ABB 800xA
Hardware: AC 800M Controller, ABB TP800, Symphony Plus MCM
Software: Control Builder M, MCM Configuration Tool
Turbines: Siemens T5866 & T5867 (NG25/20/12,5-3DA)
DCS system: ABB 800xA
Hardware: AC 800M Controller, ABB TP800, Symphony Plus MCM
Software: Control Builder M, MCM Configuration Tool
Turbines: Siemens T5866 & T5867 (NG25/20/12,5-3DA)
EKON Eti Maden: Siemens turbine upgrade and start-up automation
Client and location
The project was implemented at the EKON Eti Maden power plant in Bandırma, Turkey. The project included the modernization of two Siemens turbines, models T5866 and T5867 (NG25/20/12.5-3DA series), with the aim of increasing the level of automation and safety of the plant.
Challenge
The primary challenge was the outdated system that allowed only manual local start of the turbines. This mode of operation limited operator flexibility and prevented centralized control from the control room. In addition, the vibration monitoring and rotating equipment protection system required replacement with a more modern solution that could be fully integrated into a modern DCS architecture.
Solution
The existing system was transformed into a fully automated solution controlled by ABB 800xA DCS. Actuators were added to the mechanical start-up equipment, enabling remote process control. A new system for monitoring and protection of rotating equipment ABB MCM 800 (Symphony Plus) was implemented for precise monitoring of vibrations. The heart of the system consists of AC 800M controllers and TP800 modules, and the entire control logic was developed in the Control Builder M environment. The engineering team created complex automatic sequences for starting the turbines with integrated additional safety checks for each individual device.
Execution
The project started with the detailed design of the system architecture and the creation of HW and network specifications. Software development included PLC programming and the design of an HMI graphic interface adapted to operators, including advanced displays of historical data (trends) and an alarm system. Before the actual implementation at the location, rigorous testing was carried out in simulated conditions (FAT - Factory Acceptance Test), followed by installation, final testing in real conditions (SAT - Site Acceptance Test) and expert training for power plant operators.
Result
The modernization achieved complete digital control over the operation of the turbines, which eliminated the need for exclusively manual interventions. The new MCM800 system provided superior protection of rotating equipment, while integration into the ABB 800xA system allowed operators full visibility and control security from a remote location, significantly increasing the plant's operational efficiency.
Used technology
DCS system: ABB 800xA
Hardware: AC 800M Controller, ABB TP800, Symphony Plus MCM
Software: Control Builder M, MCM Configuration Tool
Turbines: Siemens T5866 & T5867 (NG25/20/12,5-3DA)
GUBERSAIL Tires China:
Development of software for a tire calendering line
GUBERSAIL Tires China:
Development of software for a tire calendering line
Client and location
Client and location
The project was implemented for the GUBERSAIL Tires factory in Jiangsu Province, People's Republic of China. The focus of the project was the development of a complete control software for a new tire calendering line, a key process in tire production that requires extreme precision in material application.
The project was implemented for the GUBERSAIL Tires factory in Jiangsu Province, People's Republic of China. The focus of the project was the development of a complete control software for a new tire calendering line, a key process in tire production that requires extreme precision in material application.
Challenge
Challenge
The construction and assembly of a completely new production line required the development of a software architecture "from scratch". The main challenge was to integrate complex project documentation into a functional and reliable system that must synchronize numerous drives and ensure maximum safety of workers and equipment in a high-speed production environment.
The construction and assembly of a completely new production line required the development of a software architecture "from scratch". The main challenge was to integrate complex project documentation into a functional and reliable system that must synchronize numerous drives and ensure maximum safety of workers and equipment in a high-speed production environment.
Solution
Solution
Advanced PLC software and an intuitive operator interface were developed within the Siemens TIA Portal V18 environment. System management is entrusted to a Siemens S7-1500 (CPU 1516F-3 PN/DP) controller with integrated Simatic Safety functions. A wide range of Siemens frequency converters from the G120, G120C and S120 series were used for precise control of motors and line speed. Process visualization and monitoring is enabled via a Siemens TP-1200 Comfort panel and Simatic PC Station terminal, giving operators full control over calendering parameters in real time.
Advanced PLC software and an intuitive operator interface were developed within the Siemens TIA Portal V18 environment. System management is entrusted to a Siemens S7-1500 (CPU 1516F-3 PN/DP) controller with integrated Simatic Safety functions. A wide range of Siemens frequency converters from the G120, G120C and S120 series were used for precise control of motors and line speed. Process visualization and monitoring is enabled via a Siemens TP-1200 Comfort panel and Simatic PC Station terminal, giving operators full control over calendering parameters in real time.
Execution
Execution
The project began with a detailed study of the documentation and specific requirements of the rubber manufacturing process. Throughout the development cycle, the engineering team created PLC algorithms for line synchronization, designed a user interface (HMI) focused on visibility, and configured a comprehensive alarm system for rapid diagnostics. Prior to delivery, the entire software and operator interface underwent rigorous testing in a controlled test environment to ensure flawless implementation at the customer's site.
The project began with a detailed study of the documentation and specific requirements of the rubber manufacturing process. Throughout the development cycle, the engineering team created PLC algorithms for line synchronization, designed a user interface (HMI) focused on visibility, and configured a comprehensive alarm system for rapid diagnostics. Prior to delivery, the entire software and operator interface underwent rigorous testing in a controlled test environment to ensure flawless implementation at the customer's site.
Result
Result
By delivering a modern and safety-optimized software solution, the GUBERSAIL Tires factory received a fully functional, high-performance line. The implementation of Simatic Safety standards and precisely synchronized Siemens drives ensured consistency in product quality with minimal downtime, thus achieving maximum efficiency of the new investment.
By delivering a modern and safety-optimized software solution, the GUBERSAIL Tires factory received a fully functional, high-performance line. The implementation of Simatic Safety standards and precisely synchronized Siemens drives ensured consistency in product quality with minimal downtime, thus achieving maximum efficiency of the new investment.
Used technology
Used technology
Control system: Siemens TIA Portal V18
Hardware: S7-1500 (CPU 1516F-3 PN/DP)
Panels: Siemens TP-1200 Comfort, Simatic PC Station
Drives: Siemens G120, G120C, S120
Safety system: Simatic Safety
Control system: Siemens TIA Portal V18
Hardware: S7-1500 (CPU 1516F-3 PN/DP)
Panels: Siemens TP-1200 Comfort, Simatic PC Station
Drives: Siemens G120, G120C, S120
Safety system: Simatic Safety
GE Power SKT TERGA Algeria: Upgrade of ABB 800xA DCS system
GE Power SKT TERGA Algeria: Upgrade of ABB 800xA DCS system
Client and location
Client and location
The project was carried out for GE Power at the SKT TERGA power plant, located in the city of Terga (Ain T'émouchent), Algeria. The plant consists of three energy blocks with combined gas (EGATROL) and steam (TURBOTROL) turbines, making it one of the key energy hubs in the region.
The project was carried out for GE Power at the SKT TERGA power plant, located in the city of Terga (Ain T'émouchent), Algeria. The plant consists of three energy blocks with combined gas (EGATROL) and steam (TURBOTROL) turbines, making it one of the key energy hubs in the region.
Challenge
Challenge
The main challenge was the technical obsolescence of the entire control system. The lack of spare parts on the domestic and international market, coupled with the difficult maintenance of hardware and software, jeopardized the reliability of the energy supply. It was necessary to carry out a complete modernization of the architecture without disrupting the long-term operational stability of the power plant.
The main challenge was the technical obsolescence of the entire control system. The lack of spare parts on the domestic and international market, coupled with the difficult maintenance of hardware and software, jeopardized the reliability of the energy supply. It was necessary to carry out a complete modernization of the architecture without disrupting the long-term operational stability of the power plant.
Solution
Solution
A complete replacement of the control architecture was implemented, including new servers, operator stations and network components. The centerpiece of the solution is the new ABB 800xA system integrated with the ALSPA system. For advanced data acquisition and analysis, ABB Symphony Plus S+ Historian was installed. The system integrates different generations of controllers, including AC 800M, AC 800PEC and Advant Controller 160, using OPC DA and OPC UA protocols for seamless communication with external systems.
A complete replacement of the control architecture was implemented, including new servers, operator stations and network components. The centerpiece of the solution is the new ABB 800xA system integrated with the ALSPA system. For advanced data acquisition and analysis, ABB Symphony Plus S+ Historian was installed. The system integrates different generations of controllers, including AC 800M, AC 800PEC and Advant Controller 160, using OPC DA and OPC UA protocols for seamless communication with external systems.
Execution
Execution
The project included comprehensive engineering, from designing the architecture of the server cabinets and the control room to the precise HW specifications of the control system. The software part included the modification of the existing code in the Control Builder M and Control Builder A environments and the development of a modern HMI graphic interface. A special focus is placed on the visualization of historical data and the adjustment of the alarm system. After the phase of installation and adjustment of the S+ Historian system, rigorous FAT and SAT tests and professional training for local operators were carried out.
The project included comprehensive engineering, from designing the architecture of the server cabinets and the control room to the precise HW specifications of the control system. The software part included the modification of the existing code in the Control Builder M and Control Builder A environments and the development of a modern HMI graphic interface. A special focus is placed on the visualization of historical data and the adjustment of the alarm system. After the phase of installation and adjustment of the S+ Historian system, rigorous FAT and SAT tests and professional training for local operators were carried out.
Result
Result
By completely modernizing the DCS system, the TERGA power plant eliminated the risks associated with outdated equipment and lack of support. The new, robust infrastructure enabled more precise monitoring, faster diagnostics and significantly easier maintenance, ensuring stable and safe operation of the combined cycle power plant in accordance with the latest technological standards.
By completely modernizing the DCS system, the TERGA power plant eliminated the risks associated with outdated equipment and lack of support. The new, robust infrastructure enabled more precise monitoring, faster diagnostics and significantly easier maintenance, ensuring stable and safe operation of the combined cycle power plant in accordance with the latest technological standards.
Used technology
Used technology
DCS system: ABB 800xA & ALSPA system
Data archiving: ABB Symphony Plus S+ Historian
Controllers (Hardware): AC 800M, AC 800PEC, Advant Controller 160
Software tools: Control Builder M, Control Builder A
Communication protocols: OPC DA & OPC UA
Turbine equipment: EGATROL (gas) / TURBOTROL (steam) turbines
DCS system: ABB 800xA & ALSPA system
Data archiving: ABB Symphony Plus S+ Historian
Controllers (Hardware): AC 800M, AC 800PEC, Advant Controller 160
Software tools: Control Builder M, Control Builder A
Communication protocols: OPC DA & OPC UA
Turbine equipment: EGATROL (gas) / TURBOTROL (steam) turbines
Transform Your Legacy
Systems Into Smart Operations.
Do not let outdated technology limit your production capacity. We provide the technical expertise and innovative framework needed to scale your facility into a fully connected, high-performance digital ecosystem.
Precision-engineered solutions for complex industrial challenges, ensuring maximum reliability and growth for plants worldwide.
© 2026 Erga d.o.o. All rights reserved.
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Schedule
a discovery call.
Talk to our project manager and find out how we can turn your vision into reality.
Transform Your Legacy Systems Into Smart Operations.
Transform Your Legacy Systems Into Smart Operations.
Transform Your Legacy
Systems Into Smart Operations.
Don't let outdated technology limit your production capacity. We provide the technical expertise and innovative framework needed to scale your facility into a fully connected, high-performance digital ecosystem.
Precision-engineered solutions for complex industrial challenges, ensuring maximum reliability and growth for facilities worldwide.
Precision-engineered solutions for complex industrial challenges, ensuring maximum reliability and growth for facilities worldwide.
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