In today's world of rapidly advancing technology it is reassuring to know that there is one process automation specialist that still places customer service, quality and reliability above all else.

We at Process Control Systems (PCS) are recognised throughout the European Community for our specialist expertise in process design, implementation and automation, founded in 1988, with the vision of covering skills from several process industries, having an impressive track record of experience in such diverse industries as…

We are able to provide a comprehensive range of services to all industries, handling projects of any size, from feasibility study through to the conceptual design. From detailed engineering, procurement and installation, to commissioning and final hand-over, maintaining the flexibility to undertake individual sections of a project with the same level of professionalism as a complete turnkey project.

Our company and personnel are able to provide a full Consultancy, Project Management and Engineering Service, in the following fields:

SCOPE OF SERVICES

R Electrical

Within the electrical field we have completed several plant-wide distribution systems from the Local Electricity Authority supply, to plant switchgear and associated transformers, radiating to intermediate distribution/motor-control centres and final sub-circuits. PCS have specified, designed and commissioned complete A.C. and D.C. variable speed and supervisory control equipment, for both large and small systems.

We are currently responsible for installations both within the UK and Europe.

R Control & Instrumentation

We have experience of distributive and sequential systems by the following manufacturers:

R Mechanical

With experienced mechanical project engineers forming an integral part of PCS; turnkey projects can be handled with a seamless interface between mechanical and E&I project requirement. Process changes can be taken from flowsheet conception, to a fully commissioned installation.

PERSONNEL STRUCTURE

PROJECT MANAGER

R Develop project programme. In detail for initial project phase, assigning tasks and

timescales to be adhered to by engineering team.

R Establish contacts and organise meetings with:

· Equipment suppliers.

· Equipment refurbishers

· Shipping agents

· Civil contractors

· Engineering services.

R Involvement / Preparation of contracts between Client and suppliers.

R Site assessment and nominate:

· Civil contractors.

· Engineering services (where required).

· Access and revise initial project budgets

R Co-ordinate between project disciplines, contractors and liaise with project

co-ordinator during manufacture & construction phase.

· Monitor progress planning, milestones and take corrective action when required.

· Maintain cost expenditure records and cash flow plan.

· Ensure implementation and conformance with Health & Safety Regulations.

· Provide construction status reports to project co-ordinator.

ELECTRICAL ENGINEER

R Develop single line power distribution diagram for HV/LV networks.

R Develop equipment-tagging system in conjunction with other engineering disciplines.

R Produce AC/DC motor schedules for equipment. Establish maximum electrical demand for distribution network.

R Produce fault level analysis.

R Attend meetings with package equipment suppliers.

· Specify electrical standards to be adopted

· Agree on key electrical switchgear suppliers i.e. contactors, relays, switch fuses, etc

· Establish standards of documentation.

· Establish extent / limits of engineering design, and links (interlocks) with associated process machinery.

· Establish power supply requirements.

R Produce detailed specifications for:

· HV /LV switchgear.

· Transformers.

· Motor control centres

· Electrical installation practices.

CONTROLS ENGINEER

R Assist in the production of the process flow diagram.

R Develop equipment-tagging system for Input / Output devices.

R Establish a plant-wide control philosophy.

R Establish the type and nature of the operator interface i.e. push-button / switches,

local operators panels, Scada systems.

R Production of an input /output database.

R Establish standards for the supply of process sensors.

R Access principal control systems suppliers and nominate general standards for the project.

R Attend meetings with package equipment suppliers.

· Ensure control systems to be supplied will integrate into overall plant control systems.

· Ensure standards meet with relative standards and specifications for the supply of process sensors and control equipment i.e. relays, converters, enclosures etc.

· Established standards of documentation to be supplied.

· Establish power supply requirements.

R Produce detailed specifications for:

· Process sensors.

· Control cabinets.

· Installation practices.

PLANNING ENGINEER

R Be familiar with intended project, client and delivery dates.

· Working with designer, construction, commissioning Project Team Members as well as suppliers.

· Informing managers and contractors of site construction progress or delays.

· Competent with project management systems.

· Be aware of construction company procurement systems.

· Liaison with design staff with plant modification and contractual suppliers for materials.

R The planning engineer to develop and control PM system and methodologies.

· Use of Barchart Planning software to report site/construction progress.

· Define common standards to report progress.

· Presentation of overall and detailed reports.

· Analyse progress for the above for engineering and contract sub groups.

· Set milestones for submission of documentation, drawings, material and acceptance tests.

· Indicate to contractors where delays are incurred when resources are not met.

· Produce work schedules and state of design - construction targets or milestones.

· Indicate payment, milestones for delivery - construction - acceptance testing - finish.

· Recognise differences of contractor groups set up standard progress reporting.

· Set up management reporting for materials and equipment supply.

MECHANICAL ENGINEER

R Develop flowsheet in conjunction with client’s engineers.

R Develop equipment-tagging system.

R Produce detailed parts lists for equipment to be located.

R Access nature and extent of equipment supplier's scope.

R Attend meetings with proposed equipment suppliers, co-ordinate supply of detailed information.

R Specifications of work to be undertaken and timescale for completion.

R Develop preliminary layouts and elevations

R Collate static and dynamic floor loadings and foundation details for relocated equipment. This will form the basis of a detailed civil specification for the project.

CIVIL ENGINEER

R Conversant with proposed factory layout, equipment, operability, material movement and storage to give insight into design requirement and consideration to be incorporated within Civil’s package.

R Establish contracts with and meet Project Managers.

· Proposed Civil Contractors.

· Review and prepare additional appendix to employer’s requirements to meet local conditions, topography of site and local/state regulations.

· Assess construction programmes supplied with tenders to ensure compatibility with general construction plan.

· Develop a strategic material and construction plan with Planning Engineer.

· Assist in implementation of site safety plans, rules and procedures.

· Monitoring and advising contractors in areas of Health and Safety.

· Ensuring correct implementation of construction design, material quantities to meet Client requirements and equipment supplier requirements.

· Maintain register and records of all civil contractors, sub contractors, health and safety and declaration forms in line with safety plan.

R Provide to Project Manager construction status reports.

· Notice of slippage on problem areas.

· Provide work list and milestones to contractors.

· Evaluated contractor variations and monitor approved variations to ensure timely and cost effective works are produced.

· Prepare with Client and Contractor representative, a 'punch list' of items to be completed with priority and time scale before each area is approved for taking over as per form.

· Provide documentary evidence and report to Clients, Contract Co-ordinator and Project Manager to support or disclaim extras claims from Contractors.

ELECTRICAL CONTROL & FIELD ENGINEER

R Liase with Contractors to guide and assist with documentation, standards and methods to ensure installation conforms to construction standards.

R Act as point of contact for Contractors to mediate where interface problems occur.

R Implementation of erection plan whilst liasing with Mechanical Field Engineer and Project Managers.

R Monitor risk assessment documents submitted, prior to submittal to Project Manager.

R Monitor, advise and train Contractors on matters of Health and Safety.

R Produce weekly progress report to Planner and Project Manager to verify Contractor supplier information.

MECHANICAL FIELD ENGINEER

R The role within the project team is one requiring multi task skills, to complete the assignments.

· Provide machinery and equipment specifications for the fitting out of the maintenance workshop.

· Co-ordinate installation of machinery into workshop building which will support the project construction.

·

· Assess skills of maintenance and temporary mechanical work force supplied to the contract, providing training and guidance where required.

· Visiting with the Project Manager, local fabrication and engineering companies to evaluate the compliance of standards, procedures and skills required to carry out local project works.

· Inspection and Quality Assurance of contractors

· Expediting of awarded contracts to ensure plan milestone dates are met.

· Provide point of contact in the field, between all mechanical contractors, to mediate and assist with interface and installation problems that may occur.

· Ensure implementation of erection plan, whilst liasing with Electrical Field Engineer.

· Monitor and advise on risk assessment documents submitted, prior to submittal to Project Manager.

· Monitor, advise and train contractors on matters of health and safety and ensure conformance with Health and Safety Plan and Regulations.

· Produce weekly progress report to Planner and Project Manager to verify contractor supplied information.

CONSTRUCTION SUPERINTENDENT

R Work closely with Project Manager to co-ordinate construction activities to maintain scheduled milestones.

R Control and expedite shipping and transport programme to ensure deliveries meet construction schedule.

· Monitor, assist and advise on all aspects of field works to resolve any problems arising.

· Ensure directives, appointed contractors and field engineers carry out programmes of work without delay.

· Monitor and implement overall compliance of safety plan.

DRIVES ENGINEER

R Undertake feasibility and consultancy studies of digital and analogues systems.

R Capability to perform calculations, design and procure both electrical and mechanical hardware.

R Production of specifications, bills of materials, circuit diagrams and cable schedules.

R Witness, testing and site acceptance trials of sub-contractor equipment.

R On-site supervision of installation and commissioning.

R Training courses given in operation, maintenance and general state-of-the-art equipment.

ELECTRICAL SUPERVISOR

R Site based Engineer to overview and maintain standards and discipline of contractors.

R Procurement of materials on behalf of client.

R Issuing of site instructions to maintain programme.

INSTRUMENT ENGINEER

R Specification of equipment.

R Production of data as follows:

· P & Id's, Loop Diagrams

· Data specification sheets

· Plant Control Systems

· PLC configuration

· Pneumatic control.

R General site supervision and co-ordination of suppliers and contractors.

APPLICATION ENGINEER (GRAPHICS & COMMUNICATION)

R Production of client’s graphics in the form of an overview, i.e. P & I or flowsheet type format.

R Engineering of general communication and interface units.

APPLICATION ENGINEER

R Specification of equipment.

R Issuing of system description.

R Co-ordination of information to form detailed ladder or statement type diagrams.

R Checking and approving of suppliers documentation for compatibility.

CAD DRAUGHTSMAN ELECTRICAL / INSTRUMENTATON

R From basic information produce detailed drawings as follows:

· P & I diagrams.

· MCC and Control panel layouts.

R Wiring diagrams.

R Motor/starter and cable schedules.

R Instrument hook-up diagrams and data sheets.

R Configuration and I/O lists.

R Location and general layout drawings.

MECHANICAL SUPERVISOR

R Site based Engineer to overview and maintain standards and discipline of contractors.

R Procurement of materials on behalf of client.

R Issuing of site instructions to maintain programme.

CAD DRAUGHTSMAN MECHANICAL

R From basic information produce detailed drawings as follows:

· Piping and Equipment layouts.

· Detail Piping Isometrics and B.O.M.

· Detail drawings of Tanks, Vessels and Structures.

· Equipment.

· Valve and Pump schedules.

The aforementioned disciplines are clearly defined, however, the flexibility of our company lends itself to an amount of overlap between disciplines, to cover the electrical and control content of projects. This gives a broad base if desired.

SUMMARY OF COMPLETED PROJECTS

Client : M- Real UK Paper –New Thames Mill

Main Supplier : METSO(formerly VALMET)

Approx Value : £2.5M

Project :

Major rebuild of the 2^nd Dyer and press sections of a 5m wide, 1100 meters per minute paper machine producing 200,000 TPA of Printing & Writing paper from furnishes ranging from 100% Deink – 100% Virgin or a mixture of both.

Duties:

Nominated by client for all project management services. Supply of permanent site based project manager, extensive liaison and supervision of METSO engineers involved in the rebuild.

Supply of new machine benchboards incorporating a networked based Allen Bradley PLC system and MMI interface. PLC programming to functional design specification supplied by METSO.

Contacts: Mr D. Mobbs M-Real

Mr J. Makinen METSO

Client : SCA Hygiene Products – Unifibres Mill, Prudhoe

Main Suppliers: Voith, Maule, FMW, Sulzer, KWI

Approx Value : £3M (£2M Turnkey Projects to PCS)

Project :

Quality upgrade of 180 ADMTD de-inking plant. Installation of new process equipment, design and build of new DAF building.

¨ Sulzer MC pumping system installation.

¨ Maule screw press installation

¨ KWI dissolved air flotation system installation.

Complete replacement of motor control and electrical distribution. Installation of intelligent MCC’s (Siemens Simocode).

Total plant control afforded by the installation of a new Scada/PLC based control system to manage approx. 150 motors, 100 PID control loops, 400 discrete I/O points.

Installation of distributed I/O network using Profibus-DP. Complete new electrical and control system cabling, extensive modifications to existing pipework.

All PLC and Scada system software written by PCS engineers according to a functional system description developed by PCS process engineers and SCA.

Replacement of plant lighting system to basement and operating floor levels.

Contacts : Mr A Richards SCA Production Manager

Mr M. Farrey SCA Project Manager

Mr J. Smith SCA Process Engineer

Mr P. Dinning SCA Control & Instrument Engineer

Client : Sonae (UK) Ltd

Principal Contractor : Alfred McAlpine Ltd

Approx Value : £75M

Project :

Construction of ‘cutting edge technology’ Particle Board Mill, from inception to handover to client. This key manufacturing facility has bucked the recent trend of upgrading older Mills, in favor of this major investment milestone for the Knowsley area in Merseyside. The plant is capable of processing virgin logs along with imported chip and recycled waste in varying measures. The design uses the vast knowledge base that has been built up in house, within what is now acknowledged as the leading particle board manufacturer in the world.

Duties :

PCS’s involvement can only be described as truly multi disciplined. As a follow up to previously completed successful Projects in Portugal and South Africa PCS were invited by the client to undertake all the pre engineering, and source a suitable site for manufacture. During the construction phase PCS acted for and on behalf of Sonae (UK) as the client agent.

Upon completion PCS has provided the resource to establish a successful Project Department integrating seamlessly with the Mills production requirements.

During a recent construction Project worth £5m approx PCS acted as Project Manager, Health and Safety Coordinator, Principal Contractor and Planning Supervisor. All statutory body approvals were sought and obtained including negotiations with Planning, Building Control, HSE, Environment Agency, Environmental Health and Fire Authorities. PCS are currently obtaining Planning permission for further major Projects.

All disciplines were undertaken and have reinforced PCS’s standing as a leading turnkey Management and Installation Contractor within the Particle Board, Pulp, Paper and Board sectors.

Contacts : Mr R. Mitchell Sonae Project Manager

Mr H. Earl Sonae Technical Director

Mr A. Esteves Sonae European Director

Client : Abitibi Consolidated – Ellesmere Port

Main Supplier: Various Local engineering Companies

Approx Value : £1.2M

Project :

Machine guarding for PM1, PM2 & PM4 in accordance with Making Paper Safely (MPS) issued by PABIAC.

Duties :

Based on in house discussions with papermakers and maintenance engineers, produce detailed engineering packages for machine NIP guards, fencing, access doors and tail feed systems. All works compliance with relative BS and EN standards.

Contacts : Mr M. Bookbinder Project Manager

Mr L Jackson Papermaker

Client : Holmen Paper – Iggesund Paperboard

Main Supplier : ANDRITZ/SIEMENS

Approx Value : £56M

Project :

Quality and capacity upgrade of No 2 Pulpmill to 800 ADMTD. Installation, commissioning and start-up of the following equipment.

· Chip handling, washing and screening systems

· New 17mW refiner

· Modifications to Reject Refiners

· Screw presses (3), MC pumps and HC bleaching system (30%)

· New Refined Mechanical Pulp(RMP) 3300M3 storage Silo

· New associated chemical plant

· Major rebuild of treated stock and water systems e.g. pumps, piping, controls.

· Installation of 3 new Sunds JC02 Conflo refiners for BM2

Duties:

Nominated by client to act as lead engineers during construction, commissioning and start-up phases of the project. This role included extensive involvement with the main suppliers (Andritz) engineers.

Design responsibilities for areas outside Andritz scope of supply. Total design of Electrical, Control & Instrumentation systems for the chemical plant. Design of ‘Simocode’ based motor control centres from UK based suppliers. Installation of new 11kV Vacuum switchgear, 11/433V 1.6 mVA Transformer.

Turnkey supply of control system and motor control centre for JC02 refiners. Installation of dual redundant fibre optic profibus network, S7-400 PLC and ET200 I/O system. Modification of existing hardwired MCC’s to intelligent Simocode starters. Installation of 3 – off 500kW 3.3kV DOL motor starters.

Nominated by client as main contact with site based Siemens engineering team.

Contacts: Mr T. Jefferson Mill Electrical Engineer Holmen Paper

Mr S. Fleming Project Manager Siemens Automation & Drives

Mr J. Grobalber Andritz project manager

Mr M. Scherz Andritz project manager

Mr H. Unger Andritz Site Manager

Client : Abitibi Consolidated –Ellesmere Port

Main Supplier : Beloit Walmsley / Harland Simon

Approx Value : £27M

Project :

Wet end rebuild of No.2 Newsprint Machine. Comprising of a new stock approach system, vacuum system upgrade, consistency dilution headbox, and belbond former press section.

Duties:

Provide multi-disciplined site based engineering team to support mill personnel to complete the wet end rebuild of No.1 machine and associated equipment additions and modification of existing plant.

Provision of detailed engineering packages, electrical, mechanical, process, & civil content to complete location of new equipment within machine house, upgrade of paper machine drive system complete with associated 4 MVA distribution system. Produce associated documentation and complete as build engineering manuals.

Contacts: Mr D. Barker Engineering Manager

Mr M. Coughlin Project Manager

Mr M. Kelly C&I Engineer

Mr J. Harling Electrical Engineer

Mr N. Herd Project Engineer

Mr R. Heap Beloit Walmsley

Mr T. Irwin Harland Simon

Client : Charles Turner – Bolton, Lancs

Main Supplier : TOSCHI/SEEI

Approx Value : £5M

Project :

Greenfield installation of new Cresent Former Tissue machine, rewinder, stock preparation and deink plant.

Duties :

Acting on behalf of Charles Turner, responsible for the Project Management and associated Engineering services to enable the complete installation, commissioning and start-up of all equipment.

Installation of a Siemens S7-400 PLC based system with field located profibus I/O. Profibus interfacing to machine drive system.

Installation of new main transformer and supply of motor control centres and associated switchgear.

Contacts : Mr N. Samuel Managing Director

Mr T. Kelly Mill Engineer

Mr P. Collins Mill Production manager

Mr S. Zangolini Toschi Project manager

Mr M. Marco SEEI

Client : Kimberley Clark (Formerly Scott Ltd) – Barrow Mill

Main Supplier : Krofta, Emerson (Fisher-Rosemount)

Approx Value : £6M

Project :

Upgrade of existing deink plant process equipment and control system. Installation of new HC pulper and bale feed conveyor. Installation of new deink cells and screening systems. Installation of Krofta DAF Clarifiers. Installation of new DCS control system for the complete deink plant i.e. existing and new equipment.

Duties:

Turnkey project management and design service. Production of all Electrical Control & Instrumentation documentation.

Installation of new 2 MVA main transformer. Modification of existing MCC’s to accept DCS I/O signals. Configuration of DCS system and graphics for group sequence start/stop of the deink plant including washout sequences.

Contacts: Mr I. Parris KC Project manager

Mr G.Pilling KC Engineer

Mr J. Lacy KC Engineer

Mr S.Jack KC Instrument Engineer

Client : Kimberley Clark (Olayan – Kimberly- Bahrain)

Main Supplier : YUHAN/KIMBERLY

Approx Value : £25M

Project :

Construction of Greenfield tissue mill

Duties :

Nominated by client for project management responsibilities relating to the

construction, commissioning and start-up. Team Leader ( Mr D. Rigby PCS),

responsible for the construction, testing, commissioning and start-up of the new

Primary, Secondary & Biological Effluent Treatment plant for the new production

facility.

Contacts: Mr M. Ficus Production Manager

Mr J. Carrol Project Manager

Mr P. White Electrical Engineer

Client : Renova Tissue Mill - Portugal

Main Supplier : VOITH, SEW, ANDRITZ

Approx Value : £15M

Project :

Construction of Greenfield 90 BMDT/D integrated woodfree Deinking Plant for tissue and fine paper manufacture.

Duties :

Turnkey project responsible for the process design, specification, management, procurement, construction, commissioning and startup.

Installation and configuration of a plantwide Measurex Open DCS system with serial interface to siemens PLC systems.

Specification and procurement of ABB Motor Control Centres

Installation of new 33kV switchgear and transformer

Contacts: Mr A. Jose Simao

Mr P. Tavares

Mr J. Tavares

Client : Holmen Paper – Iggesund Paperboard

Main Supplier : Pilz UK, Castell

Approx Value : £150K

Project :

To design, supply and install category 3 electrical safety systems for the press sections of board machines BM1 and BM2 following improvement notices issued by the HSE.

Duties:

Following HSE improvement notices regarding safe working practices on the press sections of both board machines a mechanical guarding system had been designed by others.

Contacts: Mr T. Jefferson Mill Electrical Engineer Holmen Paper

Mr S. Fleming Project Manager Siemens Automation & Drives

Client : Bridgewater Paper Company Ltd

Managing Contractor : Fluor Daniel Ltd

Approx Value : £32M

Project :

Construction of De-Inking Plant NO.3. This new facility for Bridgewater Paper was designed to supplement existing facilities such that Recycled Waste would account for 98% of total production. The process conveyed loose waste from the existing facility across a new link structure where Kroftas are located and returned finished stock to any of the three Paper Machines that production required.

A new two storey Production building utilising reinforced concrete at the lower levels and steel frame at the upper was constructed on a very tight footprint, Tie-ins to existing services can only be described as extensive and complex.

Duties :

PCS provided the resource for all Contract Engineering and Project Management of various civil, structural and architectural packages. Contracts that were let, engineered and administered included site prep, civil phases 1 & 2, structural, mechanical, tankage, overhead cranes, Electrical, Control & Instrumentation insulation and architectural.

The Project was deemed a total success with stock brightness and quality exceeding anything seen before at the Mill. Completion was both on programme and within Budget.

Contacts : Mr D. Barker BPCL Engineering Manager

Mr M. Coughlin BPCL Project Manager

Mr N. Herd Project Engineer

PROJECT HISTORY