PCA
PROCESS
PCA PROCESS BV
Renewables, Chemicals and Oil & Gas Engineers
PCA PROCESS
Process Engineers and Process Control Engineers with extensive expertise across the full lifecycle of industrial operations — from project development and facility design to operations support and automation.
Disciplines:
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Projects: FEED, EPC, Commissioning & Startup
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Process Safety: HAZOP, LOPA & IEC-61511 - Study Falitators
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Process Engineering
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Process Control & Automation
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Dynamic Simulation
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Process Technology
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Operational Excellence & Troubleshooting
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Remote Control Room
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Proven track record across industries, including:
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Oil & Gas
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Refining & Petrochemicals
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LNG & Gas Processing
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Steam & Power Generation
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Renewables
Renewables, Oil & Gas, Refinery, Petrochemicals LNG, Steam & Power generation
Comprehensive Process Engineering & Operations Solutions
PCA-PROCESS offers a full spectrum of professional services designed to optimize your process operations, enhance safety, and drive project success from conception to commissioning and beyond. Our expertise spans critical areas of process engineering, advanced control, project management, and operational excellence.
Process Engineering & Design
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We provide in-depth process engineering services to ensure efficient and safe plant designs. Our capabilities include:
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Pre-Feasibility Studies (PFS): Initial assessments to determine project viability.
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Piping & Instrumentation Diagrams (P&ID): Detailed schematics for process control and instrumentation.
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HAZOP Studies: Comprehensive hazard and operability analyses.
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Equipment Sizing: Accurate determination of equipment specifications.
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Safety Studies: In-depth analyses to enhance operational safety.
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Heat & Material Balances: Fundamental calculations for process design and optimization.
Dynamic Simulations
PCA-PROCESS service specialises in creating, deploying, and analysing dynamic process simulation models. These models are sophisticated digital representations of real-world oil & gas facilities, enabling the study of time-dependent phenomena, process upsets, control strategy effectiveness, and operational envelopes. Our expertise encompasses a wide range of applications, including gas processing, petroleum refining, and the dynamic analysis of critical equipment and systems.
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Key Capabilities & Applications
Our service provides critical insights and solutions across various facets of operations:
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We develop high-fidelity dynamic models for a variety of oil & gas processes, including but not limited to:
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Gas Processing: Detailed simulation of gas sweetening, dehydration, NGL recovery, fractionation, and cryogenic processes to understand transient behaviours, optimise start-up/shutdown procedures, and evaluate control system performance.
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Petroleum Refining: Dynamic modelling of crude distillation units, catalytic crackers, reformers, hydrotreaters, and other refinery units to analyse operational stability, identify bottlenecks during load changes, and test emergency shutdown sequences.
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Pipelines & Networks: Simulation of transient flow in pipelines, surge analysis, and network optimization under varying demand and supply conditions.
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Separation & Reaction Systems: Dynamic studies of complex separation trains (e.g., distillation columns, absorbers) and reactor systems to ensure stable operation and optimal product quality during dynamic events.
Process Control services
At PCA-PROCESS, we offer specialised, consultancy solutions in Process Control and Process Engineering, exclusively tailored by Chemical Engineers. Our deep expertise ensures optimized operations, enhanced safety, and improved profitability across a vast spectrum of industrial sectors.
Our Core Specialisation
We are a team of dedicated Chemical Engineers, fully specialised in the intricate domains of Process Control and Process Engineering.
Our mission is to deliver cutting-edge Process Control consultancy solutions that address the unique challenges of modern industrial processes. Industry Verticals We Serve, Our extensive experience spans a wide range of industries, enabling us to provide relevant and effective solutions globally:
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Oil & Gas: Upstream, Downstream, Refinery, Gas Processing, GTL (Gas-to-Liquids), NGL (Natural Gas Liquids), Pipelines
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Petrochemicals: Various petrochemical production facilities
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Speciality Chemicals: Fine chemicals, Polymers
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Energy & Utilities: LNG (Liquefied Natural Gas), Steam- & Power Generation, Utilities
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Environmental: Wastewater treatment
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Marine: FPSO (Floating Production, Storage, and Offloading) vessels
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Manufacturing: Tanning, Food & Beverage, Pharmaceutical
Process Engineering Services
During the Process Design & Development stage, deliverables include Piping and Instrumentation Diagrams (P&IDs), Control Philosophies, Cause & Effect Diagrams, Equipment Datasheets, and Operating Manuals, as well as detailed Heat & Material Balances for various scenarios.
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Scope includes Equipment Sizing and Specification for key process components, including pumps, compressors, heat exchangers, separators, vessels, and control valves.
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Dynamic and Steady-State Simulations using tools like UniSim, HYSYS, and Aspen support design verification, Heat & Material Balance validation, and operational decision-making.
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Support for Process Safety Studies covers HAZOP, LOPA, and Cause & Effect Diagram development, ensuring safe and compliant design during engineering and operational phases.
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Services extend into the EPC execution phase, providing technical assurance, vendor package integration, and support during pre-commissioning, cold & hot commissioning, and plant startup. Additional expertise includes plant troubleshooting, root cause analysis (RCA), and lifecycle performance optimisation.
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Debottlenecking and Process optimisation identify constraints, reduce energy use, and enhance efficiency across process systems.
Comprehensive Process Engineering support across all project phases — from concept development through FEED, EPC, and commissioning & startup — for both greenfield and brownfield projects. Services include preparation of the Basis of Design (BoD), Process Flow Diagrams (PFDs), and Heat & Material Balances.
Renewable Industry services
At PCA-PROCESS, we specialise in providing comprehensive engineering and consulting services tailored for the renewable energy sector, with a particular focus on wind farms and their associated substations. Our expertise spans the entire lifecycle of your assets, from initial design and automation to operational optimization, safety, and regulatory compliance. We are committed to delivering innovative, reliable, and efficient solutions that enhance the performance, safety, and longevity of your renewable energy infrastructure.
This service offers details of our capabilities across critical areas, ensuring your projects meet standards of technology, safety, and industry regulations.
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PCA-PROCESS provides expert engineering and design services for renewable energy systems, focusing on sustainable fuel technologies and hydrogen-based solutions:
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Ammonia Cracker Design : Development of systems to convert ammonia into high-purity hydrogen for energy and industrial applications.
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High-Pressure Hydrogen Systems : Design of safe, efficient, and compliant high-pressure hydrogen production, storage, and distribution systems.
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Green Methanol Facilities: Engineering of process plants to produce green methanol from hydrogen and captured COâ‚‚, supporting carbon-neutral fuel strategies.
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e-Gasoline Production Units (MtG): Design of advanced e-Gasoline synthesis facilities converting methanol into synthetic gasoline for cleaner mobility.
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Sustainable Aviation Fuel (SAF) Plants: Design and development of SAF production facilities to meet growing demand for low-emission aviation fuels.
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Carbon Capture and Storage (CCS) design and review
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SCADA, HMI & Automation Systems
Functional design services for Supervisory Control and Data Acquisition (SCADA), Human-Machine Interface (HMI), and comprehensive automation systems are crucial for the efficient and safe operation of wind farms and substations.
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System Design & Architecture:
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Development of SCADA architectures for centralised monitoring and control of wind turbines, meteorological masts, and substation equipment.
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Design of intuitive and user-friendly HMI interfaces for operators, providing real-time data visualisation, alarm management, and control capabilities.
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Integration of various communication protocols (e.g., IEC 61850, Modbus, Profitnet, OPC UA) for data exchange between diverse systems.
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Software Development & Configuration:
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Functional design of SCADA/HMI software platforms (e.g., Siemens, Honeywell, Yokogawa
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Development of custom control logic and automation sequences for optimal wind turbine operation, grid synchronisation, and fault management.
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Implementation of advanced data logging, historical trending, and reporting functionalities for performance analysis and compliance.
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Cybersecurity Integration:
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Assessment and implementation of cybersecurity measures for SCADA and automation systems, adhering to industry best practices and standards (e.g., IEC 62443).
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Network segmentation, firewall configuration, and secure remote access solutions.
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Testing, Commissioning & Training:
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Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) of SCADA, HMI, and automation systems. SIT with 3rd party vendor PLCs
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On-site commissioning and optimisation to ensure seamless integration and operation.
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Comprehensive training programs for operators and maintenance personnel.
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