Dynamic Simulations
Process Control
Process Engineering
HAZOP - LOPA studies

RENEWABLES – Engineering & Design Solutions for a Sustainable Future

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At PCA-PROCESS, we provide engineering and process design services tailored to the evolving needs of the renewable energy sector. Our expertise spans across hydrogen, e-fuels, and automation for clean energy systems:

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• Ammonia Cracker Design
  Conversion of Ammonia to high-purity Hydrogen using advanced thermal and catalytic systems.

• High-Pressure Hydrogen Systems
  Engineering and design of safe, efficient, and robust hydrogen storage, compression, and distribution systems.

• Green Methanol Production Facilities
  Complete process design for methanol synthesis from renewable Hydrogen and captured CO₂.

• e-Gasoline Processing Facilities (MtG)
  Integration and design of synthetic gasoline production routes from green methanol intermediates.

• Wind Farm Platform Automation
  Design and implementation of HVDC and HVAC control systems for offshore wind platforms, ensuring reliable energy transmission and system integration.

• Sustainable Aviation Fuel (SAF) Facilities
  End-to-end design of SAF production plants aligned with international sustainability standards and aviation fuel specifications.

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At PCA-PROCESS, we specialise in providing advanced and 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 the highest standards of technology, safety, and industry regulations.

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1. SCADA, HMI & Automation Systems

We offer end-to-end services for Supervisory Control and Data Acquisition (SCADA), Human-Machine Interface (HMI), and comprehensive automation systems, crucial for the efficient and safe operation of wind farms and substations.

• System Design & Architecture:

  • Development of robust and scalable SCADA architectures for centralized monitoring and control of wind turbines, meteorological masts, and substation equipment.

  • Design of intuitive and user-friendly HMI interfaces for operators, providing real-time data visualization, alarm management, and control capabilities.

  • Integration of various communication protocols (e.g., IEC 61850, Modbus, OPC UA) for seamless data exchange between diverse systems.

• Software Development & Configuration:

  • Programming and configuration of SCADA/HMI software platforms (e.g., Siemens, Honeywell, Yokogawa

  • Development of custom control logic and automation sequences for optimal wind turbine operation, grid synchronization, and fault management.

  • Implementation of advanced data logging, historical trending, and reporting functionalities for performance analysis and compliance.

• Cybersecurity Integration:

  • Assessment and implementation of cybersecurity measures for SCADA and automation systems, adhering to industry best practices and standards (e.g., IEC 62443).

  • Network segmentation, firewall configuration, and secure remote access solutions.

• Testing, Commissioning & Training:

  • Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) of SCADA, HMI, and automation systems.

  • On-site commissioning and optimization to ensure seamless integration and operation.

  • Comprehensive training programs for operators and maintenance personnel.

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2. Wind Farm & Substation HVAC- & HVDC-Technology & Automation

Our expertise encompasses both High Voltage Alternating Current (HVAC) and High Voltage Direct Current (HVDC) technologies, which are critical for efficient power transmission from wind farms to the grid.

• HVAC Systems for Wind Farms & Substations:

  • Design and engineering of HVAC collection systems within wind farms (medium voltage) and HVAC transmission systems from substations.

  • Selection and integration of switchgear, transformers, circuit breakers, and protection relays.

  • Implementation of reactive power compensation and voltage control systems for grid stability.

  • Automation of HVAC systems for load shedding, grid connection/disconnection, and fault isolation.

• HVDC Systems for Offshore Wind Farms & Long-Distance Transmission:

  • Feasibility studies and conceptual design for HVDC converter stations (onshore and offshore).

  • Detailed engineering of converter valves, cooling systems, AC filters, and DC switchgear.

  • Development and implementation of advanced control and protection schemes for HVDC systems, including grid code compliance.

  • Integration of HVDC automation with overall wind farm SCADA for centralized control and monitoring.

• Power Quality & Grid Integration:

  • Harmonic analysis and filter design for power quality improvement.

  • Grid code compliance studies and implementation of necessary control strategies to meet grid operator requirements.

  • Dynamic performance analysis of wind farms connected to HVAC/HVDC grids.

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3. Wind Farm & Substation HVDC - HAZOP / PHA / SIL / LOPA

Safety is paramount in high-voltage environments. We provide specialized safety studies for HVDC systems, ensuring compliance with international safety standards and minimizing operational risks.

• HAZOP (Hazard and Operability Study):

  • Systematic identification of potential hazards and operability problems in HVDC converter stations and associated infrastructure.

  • Facilitation of HAZOP workshops with multi-disciplinary teams to analyze design intentions against deviations.

• PHA (Process Hazard Analysis):

  • Comprehensive analysis of potential hazards associated with HVDC processes, including electrical, chemical, and operational risks.

  • Identification of potential failure modes and their consequences.

• SIL (Safety Integrity Level) Determination & Verification:

  • Determination of required Safety Integrity Levels (SIL) for Safety Instrumented Functions (SIFs) in HVDC systems, based on risk assessment.

  • Verification of achieved SILs for safety instrumented systems (SIS) components (sensors, logic solvers, final elements) according to IEC 61508/61511.

• LOPA (Layer of Protection Analysis):

  • Quantitative risk assessment technique to evaluate the adequacy of independent protection layers (IPLs) for identified hazardous scenarios in HVDC systems.

  • Assessment of risk reduction provided by each protection layer to ensure target risk levels are met.

• Safety Requirements Specification (SRS):

  • Development of detailed Safety Requirements Specifications for all identified SIFs, outlining functional and integrity requirements.

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4. Wind Farm & Substation Regulations DNV-GL / IEC / NORSOK

Compliance with international and industry-specific regulations is crucial for project success and operational integrity. We provide expert guidance and support to ensure adherence to relevant standards.

• DNV-GL Standards:

  • Guidance and compliance verification against DNV-GL standards for offshore wind farm design, construction, and operation.

  • Support for certification processes and technical due diligence.

• IEC (International Electrotechnical Commission) Standards:

  • Compliance assessment and implementation support for relevant IEC standards, including:

    • IEC 61850: Communication networks and systems for power utility automation.

    • IEC 61400 series: Wind turbine generator systems (design, testing, safety).

    • IEC 60076 series: Power transformers.

    • IEC 62271 series: High-voltage switchgear and controlgear.

    • IEC 61508/61511: Functional safety of electrical/electronic/programmable electronic safety-related systems.

• NORSOK Standards (for Offshore Applications):

  • Application and compliance with NORSOK standards, particularly relevant for offshore installations in the Norwegian continental shelf, covering aspects like safety, environment, and material selection.

• Grid Code Compliance:

  • Analysis and implementation of national and regional grid codes to ensure seamless integration of wind farms into the electricity network.

  • Support for grid connection agreements and technical compliance documentation.

• Environmental & Permitting Regulations:

  • Assistance with environmental impact assessments and compliance with local and international environmental regulations.

  • Support for obtaining necessary permits and licenses for wind farm and substation projects.

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5. Electrification Process Industry

Beyond wind farms, PCA-PROCESS offers specialised services for the broader electrification of industrial processes, driving energy efficiency and sustainability.

• Energy Efficiency & Optimization:

  • Audits and analysis of industrial processes to identify opportunities for electrification and reducing energy consumption.

  • Design and implementation of electric heating solutions, motor control systems, and variable speed drives.

• Integration of Renewable Energy Sources:

  • Feasibility studies and integration of renewable energy sources (e.g., solar, wind) directly into industrial facilities.

  • Microgrid design and implementation for enhanced energy independence and resilience.

• Power System Modernization:

  • Upgrade and modernization of existing industrial power distribution systems for increased capacity, reliability, and safety.

  • Implementation of advanced power management systems and smart grid technologies.

• Decarbonization Strategies:

  • Consulting on strategies for decarbonizing industrial operations through electrification and renewable energy adoption.

  • Support for carbon footprint reduction initiatives.

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6. Power-to-Gas Technology

As a key enabler for grid flexibility and long-term energy storage, Power-to-Gas (P2G) technology is an area where PCA-PROCESS provides specialized expertise.

• Feasibility Studies & Conceptual Design:

  • Assessment of technical and economic feasibility for Power-to-Gas projects (e.g., electrolysis for hydrogen production, methanation).

  • Conceptual design of P2G plants, including electrolyzers, gas processing units, and storage solutions.

• Integration with Renewable Energy Sources:

  • Design of optimal integration strategies for P2G plants with wind farms and other renewable energy sources to utilize surplus electricity.

  • Management of variable power input from renewables for stable P2G operation.

• Process Automation & Control:

  • Development and implementation of advanced automation and control systems for P2G processes, ensuring efficient operation, safety, and product quality.

  • Integration with grid management systems for demand-side response and grid balancing services.

• Safety & Regulatory Compliance:

  • Conducting safety studies (HAZOP, PHA) specific to hydrogen and methane production, handling, and storage.

  • Ensuring compliance with relevant safety standards and regulations for P2G facilities.

• Grid Services & Market Integration:

  • Analysis of potential grid services (e.g., frequency regulation, reactive power support) that P2G plants can provide.

  • Support for market integration strategies and business model development for P2G assets.

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Why Choose PCA-PROCESS?

• Specialised Expertise: Deep knowledge in renewable energy, high-voltage systems, automation, and safety.

• Holistic Approach: Comprehensive services covering the entire project lifecycle, from concept to operation.

• Safety & Compliance Focus: Unwavering commitment to the highest safety standards and regulatory adherence.

• Innovative Solutions: Leveraging cutting-edge technology and best practices to deliver optimal outcomes.

• Experienced Team: A dedicated team of engineers and consultants with a proven track record in complex industrial and energy projects.

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We look forward to partnering with you to achieve your renewable energy and industrial electrification goals. Please contact us to discuss your specific project requirements.