Process Control Systems

ITS offers Black Start Systems that are integrated with main plant control systems, designed to reduce the loss of power in case of a grid connection failure or loss of primary on-site generation system services. The systems are managed by disconnecting loads from switchboards, allowing the black start systems to be brought online, and providing local power and grid synchronisation to enable reconnection to the grid and restart of the on-site primary generation system.

ITS offers a range of batch control systems, designed and implemented using the S88 standard to produce product batches repeatedly and consistently with minimum costs. The systems provide automated batch management including recipe development, batch management and execution, production scheduling, equipment performance monitoring, production history and material tracking. With a long history and knowledge of S88 batch requirements, our batch systems are designed to improve batch consistency and the automatic collection of real-time, reliable and accurate batch event data.

Through the use of advanced technologies such as data analytics, machine learning and AI, ITS can monitor and analyse equipment performance data in real time, detect early warning signs of potential equipment failures and predict maintenance requirements. This enables customers to take proactive maintenance actions, reduce unplanned downtime, extend equipment life and improve overall operational efficiency.

Distributed Control Systems are used where plant operations are spread over wide areas, they can be used to limit field wiring requirements, normally using only a central data highway such as ProfiNet or TCP/IP networks to join the distributed I/O or processor capability back to a central data hub.  DCS will cater for operations that must run to completion by separating specific control aspects that may be maintained on power failure by a local UPS whilst other elements that can stop and start without concern are distributed to another node. DCS systems can perform as PLC controls, and visa versa, but there are good reasons for selecting the right horse for each course.

ITS has an enviable record with Zero (0) Riddor or Lost Time accidents on all of the site work we have undertaken, that is because Safety is paramount, we are an engineering company that has seen the cost of failure in others to take a Safety First approach, we won’t. We recognise the need for reliable and robust Emergency Shutdown Systems (ESD) that comply with international safety standards, ensuring the safety of personnel and assets in hazardous situations. Our ESD systems are designed to respond to various detectors and can take multiple actions to mitigate hazardous events. ITS’ ESD systems are built to SIL 3 standards in accordance with IEC 61508, IEC 61511, and IEC 61513.

Whether you are looking into replacing an existing control system or investing in a system design for a new build facility, ITS’ team is on hand to assist with this ‘reverse engineering’ function and to guide you through the process of Front End Engineering Design (FEED). Our FEED activities can be performed to determine the feasibility of a project, screen alternative methodologies, convey the design intent, develop initial costing estimates, determine RoI and perform Value Engineering, they can also help to produce preliminary process and instrumentation diagrams.

ITS provides Load Shedding Systems to ensure power supply continuity during times of peak demand or loss of connection from the grid. The system is designed to detect a loss of the main grid supply, and standby generators will start and activate a load-shedding sequence, disconnecting lower-priority loads to ensure that the standby generation capacity exceeds the load demand from the site.

The team at ITS has experience in delivering Fire and Gas (F&G) Safety Systems for plant protection against hazardous conditions. These systems use detectors to monitor areas for potential fire or flammable situations and can initiate actions to alert personnel and minimise the consequences of a critical event. ITS' F&G Systems can interface with Emergency Shutdown Systems (ESD) to perform automatic plant shutdown if a hazardous event occurs.

Our SCADA, PLC & DCS control solutions provide real-time and accurate data acquisition and monitoring, enabling reliable control in manufacturing and processing industries. Our APM-accredited Project Managers and specialist Lead and Senior Engineers deliver high-quality solutions on time and within budget. We have experience in everything from single PLCs to networked systems running SCADA or product tracking solutions. Our team can design, write, test, and train operators on code in various languages, ensuring project objectives are met.

ITS provides simulation services to help clients simulate the operations of their process control systems in a safe, offline environment. Unlike some competitors, ITS has its own equipment so it is able to start and maintain your own plant systems. Our experience of using simulation tools like PICS Pro and Siemens SIMIT to accurately test and debug plant control systems, SCADA, and DCS systems before they get anywhere near your plant, or for changes performed on software controlling existing plants for over 30 years means you are in the best hands. By configuring simulation systems to replace the field I/O, ITS can test the system's positive and negative path, allowing the development and testing of changes and they can even be used for improved training of operators.

We appreciate that many companies do not have all the engineering resources they need to provide 24-7-365 cover, so we provide support and maintenance contracts through Service Level Agreements (SLAs), including the facility for 24-7-365 call-out cover and the provision of routine activities. Our SLA services are designed to be flexible, to meet your specific requirements in order to improve your company’s performance, by increasing process reliability and uptime.