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Modular Process Capabilities


Process engineering consultants oversee modular fabrication of skids

Process Systems Engineering Capabilities

Do you need a drawing package developed? Help with equipment selection? From drawing development to construction site management, EPIC offers a variety of services for process systems engineering to our clients. As process skid manufacturers that also have in-house expertise in chemical process design, mechanical design and model development, we offer a wide range of process solutions in a one-stop-shop.

Our engineers and craftsmen have a wide range of capabilities, from scale-up to professional welding and pipe fitting. Through over twenty years of process skid manufacturing, we have developed expertise in the following areas:

Quotes & Estimating Capabilities

At EPIC, we handle process systems engineering quotations differently. Our unique front-end engineering approach shortens the design phase of projects and delivers more accurate quotations with clearly defined scope. Visit our FEE page to learn more about this step of our turnkey process, which includes the following capabilities:

  • ROM (Rough Order Magnitude) Quote development
    • +/- 50%
    • +/- 15%-5%
  • Refined quotations
  • Fixed bid quotations
  • Quote peer review
  • Technical peer reviews
  • Scope development
  • Boundary limits
  • Defined deliverables
  • Project timelines
  • Contingency planning
  • Equipment, instruments & valve lists

Process Systems Engineering Capabilities

By only hiring experienced, proven plant engineers we add value to your project by providing expertise that other process engineering companies cannot, in the following areas:

  • Concept development
  • Intermediate processing steps development
  • Process flow diagrams (PFD’s)
  • Material balances
  • Mass and energy balances
  • Material compatibility/corrosion engineering
  • Heat transfer
  • Liquids processing
  • Modeling/simulation
  • Aspen Plus and HYSYS process modeling
  • Applied mathematical models
  • Process simulation
  • Micro-susceptible process design
  • Sanitary system design

Engineering Studies Capabilities

Any combination of the following studies  may be conducted by EPIC’s experienced process design engineers:

  • Process safety & HAZOP studies
  • Area classification studies
  • OEE & uptime/downtime studies
  • Feasibility Studies
  • Ergonomic studies
  • Enzyme handling evaluations

Process Scale Up Capabilities

Making the leap from lab-scale to a production-style system requires expertise in:

  • Mechanical & process skid design
  • 3-D modeling for feasibility
  • Aspen Plus and HYSYS process modeling
  • Data collection & instrumentation
  • Process skid fabrication
  • Commissioning at production rates
  • Process safety
  • Challenges to scale-up
    • Non-linear scale-up
    • Modeling methods
    • Equipment selection and materials of selection

General Automation Capabilities

Practically meeting your manufacturing objectives is our goal when designing your process control system. We have almost 20 years of experience with the following industrial automation elements:

  • Automation design
  • Consulting for automation planning
  • Control panel fabrication
  • Control system development
  • Controls integration services
  • Electrical design
  • Drafting services
  • MES & SCADA solutions
  • Plant floor IT solutions
  • Robotic work cell integration
  • Safety engineering

Physical Design Capabilities

Your processing needs, production requirements and cost are all balanced by EPIC’s expert process systems engineers who use their knowledge of manufacturing to build your custom solution, including the following:

  • Complete mechanical and physical design for systems
  • Piping & instrumentation diagrams (P&ID’s)
  • Equipment layout
  • Piping design
  • Modular skid design
  • 2D & 3D modeling/simulation
  • Drawing development
  • FEA analysis
  • Lift & installation plans

Electrical Design Capabilities

EPIC delivers custom designed, effective electrical systems/panels that operate in NFPA hazardous-classified environments and include the following:

  • Custom parameters
  • Explosion proof enclosures
  • Fittings
  • Intrinsically safe devices
  • Isolation barriers
  • Proper grounding
  • Purged electrical cabinets

Process Programming Capabilities

We follow a practical approach to process automation and implement our unique techniques for faster production throughput, improved product quality, consistency, and reduced overall production costs.

  • Process Programming
    • Logic programming
    • PLC Programming
    • PC-base programming
    • DCS programming
    • Operator Interface & HMI Programming
  • Process data collection
  • Process simulation
  • Process instrumentation

Equipment & Instrumentation Selection Capabilities

Selection is completed by our project managers and is calculated to ensure your project will be completed on time. We maintain vendor neutrality to remove bias and deliver the best equipment and price to you.

  • Major equipment
  • Ancillary equipment
  • Instrumentation selection

Documentation Capabilities

We provide full documentation, including all of the following, plus any extra documents requested by the client:

  • Operation and maintenance manuals
  • Troubleshooting checklists
  • Component part numbers and specification
  • Recommended spare parts list
  • Mechanical drawings
  • Schematic drawings
  • Control panel layout drawings
  • Fully-documented logic programs

Fabrication Capabilities

Our skilled craftsmen build your system in our State-of-the-art fabrication and assembly plant. Our team can excel in all of the following and more:

  • Carbon-steel
  • Electrical development, wiring and testing
  • FAT testing
  • Frame fabrication
  • Green tags
  • Instrumentation installation
  • Insulation
  • Mechanical assembly
  • Non-carbon steel
  • Painting
  • Pipe fitting, bending and installation
  • Pressure vessel fabrication
    • R-stamp & U-stamp certified
  • Sanitary fabrication
  • Sheet metal
  • Structural fabrication
  • Tooling
  • Tubing fitting, bending and installation
  • Welding

Quality Assurance Capabilities

EPIC has a dedicated Quality Assurance Specialist who oversees our rigorous quality assurance (QA) program, covering:

  • Material control
  • Welding
  • Testing
  • Quality checks
  • Structural fabrication
  • Structural assembly
  • Equipment setting
  • Piping fabrication
  • Piping, valves, mechanical specialties and instrumentation assembly
  • Surface finishing
  • Electrical panel assembly
  • Electrical installation
  • Packaging/shipping

Construction/Site Management Capabilities

From simple site prep to subcontractor management, EPIC offers a full range of site management, including:

  • Site upgrades
    • Bid package development and sub-contractor selection.
    • Civil and utilities installations
    • Modifications to plant facilities or infrastructure
  • Power distribution construction including conduit and wiring installation to provide power to the new production line
  • Oversight by an experienced construction management team
  • Surface area grounds work including grading, compaction and drainage
  • Piping preparation and underground utilities installation
  • Structural modifications

Integration Capabilities

We provide full integration services, including:

  • Plant system integration including communication set-up between all equipment and corresponding equipment
  • Coordination of site installation
  • Installation of pre-fabricated, mechanical equipment, machines and hardware.
  • Link in-feed and out-feed equipment installation
  • Handshaking with other machinery
  • Control processor compatibility
  • Adjustments in power distribution
  • Modifications to motor control centers
  • Changes to power distribution panels
  • Custom plant conditions
  • Successful startup and support
  • Punch List Resolution
  • System training
  • Continuing support

Unit Operations Capabilities

Uniting major processing steps into complete, production-ready process systems requires a manufacturing integrator with experience in equipment sizing, material flow, reaction control and variety of other disciplines. EPIC is capable of designing, building and integrating the following unit operations into fully-functioning, production-level process systems:

  • Mixing & Blending
  • Reaction
  • Separation
  • Drying
  • Sizing
  • Heat Transfer
  • Transportation & Storage

Why Modular Process Systems & Custom Pilot Plants From EPIC?

We take your process technology and scale it up, without sacrificing quality. We are experienced at fully extracting your technical, operational and commercial specifications. We combine those with our knowledge of process systems engineering, scale-up, and modular design/build to help you “Do It Better.” Our process for building complete modular process plants includes:

  • Utilizing Front-End Engineering to ensure the proper steps are taken during project scope development
  • Modular design/fabrication that reduces traditional downtime through parallel construction and results in cost-savings, increased safety and faster project delivery. Learn more about the benefits of modular…
  • Maintaining an open door client policy to promote innovation and communicate. We invite clients to visit EPIC throughout projects
  • Imparting a transfer of knowledge, not just basic training, for the systems and equipment we provide

For a better solution, contact EPIC today.

EPIC Modular Process Systems
4134 Meramec Bottom Rd
St. Louis, MO 63129, US