Process Control Systems is a provider of specialised engineering services to the industrial gas production and related industries. We provide engineering solutions aimed at stable operation of plant that in turn improves energy efficiency, increases profitability and focuses on enabling safe operability to a wide range of process plants.
Knowledge of the process you are controlling is fundamental in being able to properly configure a system to control it.
About PCS
PCS was founded in 2007 by owner and managing director Jason Garrett. Jason is a hands-on, experienced control systems engineer with over 25 years’ experience in process control, instrumentation, electrical, commissioning, operations and safety – both as a tradesman and an engineer. With a mixture of both office and site experience in several process industries – Industrial Gases, Petrochemical, Pharmaceutical and Mining, Jason has completed a number of overseas process control commissioning and plant start up assignments. He has extensive process and machinery knowledge and a track record of successful problem solving.
In 2017, Jason was joined by Alastair Hewson, bringing immense knowledge and experience from over 35 years in the industrial gases industry. During this time, Alastair has worked in London, South East Asia and Australia where he has been responsible for the commissioning, troubleshooting and support of air separation, LNG, liquid helium, carbon dioxide and other industrial gas plants.
With over 70 years of combined experience in this specialised industry we have a track record of success in the design and customisation of control systems to provide the best possible plant operability outcomes.
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Capabilities
PCS specialises in the process control and automation of industrial plants - specifically in the production and downstream handling of liquids and gases. We provide process control resource expertise for our customers’ projects and process operations. We aim to increase our customers’ profitability by providing cost effective solutions that encourage safe and energy efficient operability.
We deliver value through technological excellence and exceptional customer service. Process Control Solutions builds relationships that encourage innovation, excellence and trust. These relationships significantly reduce risk on project quality and timing for our clients.
We also provide a range of associated services, including:
- Plant re-lifes – that is the replacement and re-commissioning of process plant with an upgraded modern control system
- Provision of remote specialist support systems to allow off-site support of plants
- Plant Autostart, Assisted start and Autostop functions
- Supervisory (Advanced) Control Systems – Linear Models
- Efficiency reviews and Plant Performance Testing
- Tuning and optimising plants for stable operation
- Identifying savings and inefficiencies
- Training of site personnel in safe and optimal plant operation
- Writing (retrospective) operations and maintenance documents
We do this from the standpoint of a technical advisory on Air Separation as well as other processes. Simply we know this process thoroughly – we know how to configure and optimise control systems to provide world class operability.
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Tuning individual PID loops is secondary to tuning the plant that the PID loops belong to.
Industries
Process control and automation of industrial plants - specifically in the production and downstream handling of gases in the following plants:
- Air Separation Plant-Cryogenic
- Air Separation Plant-Non-Cryogenic Pressure Swing Adsorption
- Air Separation Plant-Non-Cryogenic Vacuum Swing Adsorption
- Nitrogen Liquefaction Plant
- Gas Pipelines and Pipeline Back-up Systems
- Carbon Dioxide Production Plant
- Nitrous Oxide Production Plant
- Hydrogen Production plant - Steam Methane Reformers
- Hydrogen Vehicle Filling System
- Helium Liquefaction Plant
- Liquid Natural Gas Production Plant
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Energy Efficiency
Energy consumption is one of the greatest expenses faced by our industry - and one of the areas offering the greatest opportunities for fiscal savings.
PCS are experts in performing Plant Efficiency Reviews, which are a key method of identifying potential energy savings of a given process. All of the industries we support are highly energy reliant and even minor efficiency savings can become significant fiscal bottom line savings on an annualised basis. Focusing on plant stability at turndown can save significant amount of energy.
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Competencies
Within PCS we have the ability to provide either turnkey projects or be a part of wider projects and be the equal of any other company offering our type of specialist engineering service. We consider our process knowledge of a wide range of plants and technologies un-paralleled in our industry. Our core competencies can be detailed as below.
Control system upgrades to legacy plant using any of the following systems:
- Siemens suite products - S7/PCS7/WinCC
- Legacy systems - TI545/555, Intouch, Allen Bradley - fully conversant in reverse engineering any of these
- Remote operation and Auto or Assisted start systems are a speciality
Modifications and improvement projects to existing control systems:
- No project is too big or too small
- Fully conversant with Manangement of change procedures (IMS)
- Able to modify a wide range of Control systems both PLC/HMI and DCS systems
PCS can provide plant performance tests, plant mass balance reviews, control system audits, plant efficiency reviews, de-bottlenecking studies on any of the types of plants below:
- Air Separation Plants - Cryogenic
- Air Separation Plants - Non-Cryogenic Pressure Swing Adsorption
- Air Separation Plant - Non-Cryogenic Vacuum Swing Adsorption
- Nitrogen Liquefaction Plant
- Gas Pipelines and Pipeline Back-up Systems
- Carbon Dioxide Production Plants
- Nitrous Oxide Production Plants
- Steam Methane Reformer Hydrogen Production Plants
- Helium Liquefaction Plants
- Liquid Natural Gas Production Plants
PCS can provide specialist commissioning services including:
- Plant start-up support
- Plant thaws/De-riming
- P&ID reviews and auditing
- Alarm management and best practice
- Training of operators
- Writing and reviewing plant operation documents
We have strategic alliances with 2 companies that allow us to also offer:
- Full E&I design, procure, build, install and commission - full hazardous area compliance - ASU and LNG plant experience
- Systems design and automation of cylinder filling and handling systems.
Our personnel can offer:
- Over 70 years of gas industry specific experience with a wide range of plant and control systems
- iChemE accreditation
- Chartered Engineers
- Experience in over 30 countries worldwide - a large number of different cultures and jurisdictions
- Our PCS7 lead engineer has 10 years of experience, mostly with Siemens but more recently within the related oil/gas industry.
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Contact us
Process Control Systems (NZ) Limited
Registered Office: 54 Shore Road, Remuera, 1050, New Zealand
Postal Address: P.O.Box 26086, Epsom, Auckland 1344, New Zealand
Email info@pcsnz.kiwi.nz
Jason Garrett
Managing Director
NZ Ph +64 (0) 279 170 936
Aus Ph +61 (0) 450 558 477
Email jason.garrett@pcsnz.kiwi.nz
Alastair Hewson
B.Sc(Hons), C.Eng, M.I.Chem.E, RPEQ
Phone +61 (0) 401 719 401
Email alastair.hewson@pcsnz.kiwi.nz