Opal Australian Paper has partnered with ABB to upgrade the ABB Ability™ System 800xA DCS at its Maryvale paper mill in Victoria, Australia. Completed in eight weeks, the project deployed the latest market version to support Opal’s long-term automation strategy and future technology initiatives.
A Strategic Upgrade for a Historic Paper Mill
Since 1937, the Maryvale mill has played a major role in the Australian paper industry. The site has been using ABB automation systems for several decades.
As part of its automation lifecycle management strategy, Opal Australian Paper initiated the upgrade of its ABB Ability™ System 800xA Distributed Control System (DCS) to the latest version available on the market. As the Maryvale mill is a critical link in Opal’s industrial network, the project required detailed planning and close coordination to adhere to a strictly defined shutdown schedule and minimize production disruptions.
Site-Wide DCS Upgrade
Building on their long-standing relationship with Opal and deep knowledge of the mill’s automation systems, the ABB Australia teams completed the full upgrade of the ABB Ability™ System 800xA platform from version 5.1 FP4/E to the latest market version. The project was executed in eight weeks and finalized during a five-day scheduled shutdown.
The scope included:
-
A full system version upgrade of the ABB Ability™ System 800xA
-
Modernization of the operating systems across the site’s automation infrastructure, including servers, client workstations, storage systems, and networking equipment
-
Firmware updates for controllers and communication equipment to ensure compatibility, stability, and performance across the upgraded architecture
The Automation Software Maintenance (ASM) agreement between Opal and ABB was a key enabler for the project. This subscription program provided access to the latest software release alongside ongoing software lifecycle support, simplifying the upgrade process and supporting Opal’s long-term automation roadmap.
A Modern Foundation for Future Technological Developments
By adopting the latest version of ABB Ability™ System 800xA DCS technology, pulp and paper manufacturer Opal now has a modern automation environment featuring enhanced communication capabilities, continuous software support access, and compatibility with future digital applications within the ABB ecosystem. This upgrade also establishes a solid foundation for future technological developments and operational improvement initiatives at the site.
“The success of this project illustrates what can be achieved through close collaboration, local expertise, and a shared commitment to continuous improvement,” said Brad Burton, Pulp and Paper Industry Lead at ABB Australia. “We are very proud to support Opal Australian Paper on their automation journey and to have successfully delivered a complex, mill-wide upgrade within a strictly managed timeline. Together, we have deployed a platform that meets the site’s current operational needs while laying the groundwork for its future technology initiatives.”
Photo/ABB
RELATED NEWS
