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Experience

John A. Shaw, president and founder of Process Control Solutions, is an independent consultant specializing in control systems for the process industries.
Summary Control Systems engineer with thirty (32) years experience in chemical, petro-chemical, refining, mining, textile, pharmaceutical, pulp and paper, and power generation projects.

Experience includes nearly twenty (20) years with the Taylor Instrument Company (now a part of ABB, Inc) working in project engineering, applications engineering, training, and project management.

Diverse background in process control systems engineering including development of scope and functional requirements documentation, estimates and schedule development, review and selection of vendors, P & ID development, design of control and logic systems, design of operator interface, programming and implementation of control systems, validation, commissioning, and startup.

Work has been international in scope, including extensive travel world wide.

Past Employment Duke Power Company, Charlotte, NC (1970 - 1975)
At Duke I started as an instrument and controls engineer in a new coal-fired super critical power plant. My work in the plant involved maintenance and modifications of instrumentation and controls, performance testing and analysis of thermodynamic performance tests.

Asea Brown Boveri (ABB), formally Combustion Engineering and Taylor Instrument Company, Rochester, NY (1975 - 1994)
At Taylor Instruments (now part of ABB) I worked in project and applications engineering, training, product planning, and project management, with most of my work involved with projects (control systems built for specific customers), including the pre-sales scope and proposal development, involvement in the contract negotiations, detailed hardware and software design and programming, commissioning and startup, operator training and initial operation. I worked with field instrumentation, single loop controllers, computer control, and distributed control systems.

Process Control Solutions (1994 - Present)
I left ABB in mid-1994 when the projects organization moved from Rochester to other locations. (I have had contract assignments with ABB since that time.) As principal of Process Control Solutions I provide consulting and contract engineering. Work ranges from consulting (single day conferences, etc.) to longer (up to 1.5 year) projects.

Selected Projects Following are selected major projects:

Pulp Mill - West Coast

Modified software for control system upgrade and improvements. Modified control software for power boiler.

Paper Mill - Northern NY

After previously shutdown mill was sold, I modified the control system to accommodate changes in the stock blending process and participated in the startup of the modified mill.

Power Plant Control System Engineer, Engineering Company

Reviewed and modified the DCS (Foxboro I/A) control logic for two combined cycle power plant and participated in the Factory Acceptance Test of the Foxboro I/A DCSs for the plants.

Pollution Abatement, Manufacturing Plant

Designed the control system, wrote functional specifications, implemented software, tested, and started up the process control system for a process to remove hazardous chemicals from the exhaust of a manufacturing plant.

Paper Mill, Northern NY

For an existing paper mill I wrote functional specifications, designed, implemented, and started up DCS controls for a batch stock blending system. This included working with the customer's engineering department, outside engineering consultants, vendors, and mill operations personnel.

I participated in the design, wrote functional specifications, implemented software, and started up the broke pulper and broke refining system for the addition of wet strength paper to the mill. After the initial startup I was involved in the test runs, analysis, and modifications to the system to achieve desired results.

I maintained an ongoing relationship with the mill that has involved numerous smaller projects, typically involving implementation of control loops or other software in the stock prep, chemical, and machine wet end areas. The mill was shut down in April, 2001.

Paper Mill - West Coast

Designed and implemented the graphic displays and controls for the conversion of the stock prep and wet end controls from existing panel board analog controls to DCS controls. The project included documentation and operator training.

Pharmaceutical Plant

Wrote detailed design specifications and implemented batch control software on a DCS for a pharmaceutical production facility. This work included interpretation of P&IDs and operational documentation to develop the specifications.

Pharmaceutical Plant

Developed the functional specifications of pharmaceutical process upgrade. This included the operation of an ultrafilter, CIP system, and other processes. As part of the work I help develop the validation documentation and validate the process. In a separate project for the same plant I designed the control system, programmed the DCS, developed documentation, and led the checkout, startup, and initial operation for a solvent recovery distillation system. The startup work included chromatography skids, ultrafiltration skids, and CIP system.

Carpet Finishing Mill

For the rebuild of a carpet finishing mill destroyed by fire, I participated in the design, wrote the functional specifications, implemented, and started up the utilities (steam, hot water, cooling water, chilled water) section of the mill. During the initial period, before the controls could be made fully automatic, I acted as a DCS operator for the hot and chilled water systems. I also consulted with other control engineers in other areas of the mill to assist in control loop tuning and control strategy design.

On this fast track project I was the lead DCS engineer for utilities and a member of the utilities team comprising personnel from the engineering firm, the textile company engineering department, the mill staff, and major vendors. The work included participation of all phases of the design and engineering effort, including P&ID review, equipment specification review, procurement, equipment checkout, and startup.

Pharmaceutical Plant

Designed and implemented batch control system on a DCS for a drug development facility. This included contact with the drug development personnel, engineering department, and equipment vendors to determine the needs and convert these needs into the actual specifications and control software.

I also developed and implemented the controls for the high purity water system (including distillation, storage, and distribution) for the facility.

Startup work included reactors, ultrafiltration, WFI production and distribution, CIP, and SIP controls.