Turnkey Process Systems From Top Process Engineering Consultants
EPIC’s process engineers collaborate with industrial and sanitary and manufacturers to solve unique process engineering and design challenges. As a turnkey process systems engineering company, EPIC has 25+ years of experience engineering, designing and fabricating modular process systems in their entirety. This includes process and mechanical engineering, industrial controls and automation, and physical design for process systems.
Unlike other process engineering consultants, EPIC can contribute as early as the concept development phase. We can walk you through front-end engineering (FEE), process flow diagrams (PFDs), and piping and instrumentation diagrams (P&IDs).
In tandem with their process engineering and design expertise, EPIC’s process engineers are experienced project managers. Once your project is approved, EPIC can facilitate equipment procurement and continue to manage your project through fabrication, factory acceptance testing (FAT), startup and commissioning.
Process Systems Project Examples
EPIC partnered with Gas Technology Institute (GTI) – a non-profit organization supported by the U.S. Department of Energy – to engineer and fabricate a pilot process system that tests the process of carbon dioxide removal from flue gas at coal-based power plants. If the technology is proven to be successful at the pilot level, it could be scaled up and implemented at every coal plant in the country. The end result would significantly reduce America’s carbon footprint.
- Key Features: Continuous Process, Gas-Liquid Membrane Absorption Unit, Carbon Dioxide Sequestration Unit, Liquid Ring Compressor
With a limited budget and limited floor space, the client needed to double the flavors mixed in their existing facility. A pre-engineered, field-proven in-liine blending skid from EPIC provided a fast, economic solution that allowed the client to drastically expand the product portfolio with minimal equipment additions.
- Key features: Outside pre-mix blending skid, JIT in-line blending system, coupled filling and blending system, back pressur control, control logic PLC, product-to-product washout.
This project posed the unique challenge of re-engineering a faulty control system while ensuring a pharmaceutical grade operating environment. EPIC handled the 8,000 pages worth of documentation, checkout process, and ad validation for the operating environment, and completely redesigned the control system. The result was a fully automated, highly efficient CIP system that increased productivity corrected all control errors, and complied with FDA regulations.
- Key features: 2 integrated clean-in-place systems, 3 Allen Bradley control panels, InBatch by WonderWare software, validation documentation
EPIC’s process engineering consultants deliver far more than theoretical feasibility. Every project EPIC manages, benefits from 30 years of practical process engineering and design experience in commercial plants like yours.
Concept Development – You bring the process technology and EPIC will do the rest. Whether it’s a sketch on a napkin or a full PFD, EPIC can help you flesh out your project specifics and determine the steps required to successfully design and build your system. Read more about our concept development capabilities.
Engineering Studies & Feasibility – Before you make any major purchases, EPIC’s process engineers can give you peace of mind. We will determine the viability of your proposed system and set the right production expectations. EPIC also conducts studies of HAZOP, safety, area classification, ergonomics and more.
Front End Loading (FEL) – Whether you’re looking for a fixed bid quote or a simple rough order of magnitude (ROM), EPIC provides thorough cost estimation resources that will allow you to make an informed decision about your investment. Learn more about EPIC’s FEL options.
Process & Mechanical
Process Flow Diagram (PFD) – EPIC’s EPIC’s process engineering consultants will create detailed PFDs to indicate the general flow of your process plant and outline major chemical and equipment requirements for your newly proposed process.
Piping & Instrumentation Diagram (P&ID) – EPIC’s process technicians will use their vast industry experience to specify valves, piping, instrumentation and all other mechanical equipment required to safely meet the precise scope of your process systems project.
Welding Procedure Specifications (WPS) – Beyond the standard PFDs and P&IDs, EPIC’s process and mechanical engineers collaborate with an in-house quality assurance team to specify exactly how your skid should be fabricated. A WPS outlines the pipe thickness, size, material construction, technology used and several other specifications to accommodate the unique structural and sanitary requirements of any given project.
The physical design and equipment layout of your system can be just as important to your success as the process chemistry. In addition to the obvious implications for floor-space in your plant, the physical characteristics of a system can affect the chemical reaction or ingredient mixing process.
2D & 3D Modeling/Simulation – EPIC’s modular designers create 2-D and 3-D CAD designs that allow you to visualize how your process skids will fit inside your plant prior to fabrication and installation. Process skids are designed modularly for ease of transport from shop to plant and pre-plan for safe installation.
Equipment Selection & Layout – EPIC objectively provides you with the most suitable equipment for your process and do not maintain formal relationships with vendors. To maximize accessibility, equipment is arranged to the outside edges of the skid, providing both outside access and an inner pathway down the center of the skid.
Lift & Installation Planning – Ensuring system safety during shipment and installation means developing comprehensive lift and installation plans. By working closely with shipping vendors and our in-house safety management team, EPIC’s project managers can ensure that your system will arrive intact and ready for operation.
EPIC’s industrial automation and control engineers work on your process skid’s electrical design in tandem with process and mechanical engineering. This in-house collaboration results in cohesive, cost-effective process engineering and design.
General Automation Capabilities – EPIC’s automation engineers take turnkey responsibility for designing process automation systems that include control panels, programmable logic controllers (PLCs), electrical design and power distribution, SCADA and special safety considerations, like intrinsically-safe I/O.
Process Programming – EPIC utilizes an expert team of in-house programmers for programming PLCs, DCS, HMIs, data collection systems and several other applications. EPIC’s process control systems can drastically improve your plant conditions for workers and reduce the cost of employee insurance by eliminating hazardous tasks.