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Capabilities | Pilot Plant Design & Construction

capabilities for production scale systemsWe have a wide range of capabilities for pilot plants beyond simply design and fabrication. From process simulation to pressure vessel fabrication, we offer a wide range of services and value-add capabilities. Our proven methods take your technology to a full demonstration or production scale system.

Our engineers bring a unique mix of technical engineering knowledge and real-world manufacturing plant experience. Our craftsmen are highly skilled, full time employees who are experts at at production style fabrication of pilot modules. We take turnkey responsibility for every module we build, starting with design and seeing every project through fabrication until commissioning is completed. Specific capabilities include:

Estimating & Quotes

We provide several different types of quotes and estimates. Our preferred method of quotation is to complete a full front-end engineering effort where we fully explore project goals and return a set quote. We can provide the following for quoting and estimating:

  • Basic System Layout
  • Deliverables Scope
  • Equipment & Instrumentation Lists
  • Fixed Bids
  • ROM (Rough Order Magnitude) Quote development
    • +/- 50%
    • +/- 15%-5%
  • Project Timelines
  • Project Peer Reviews
  • Scope Development

Process Engineering

Our process engineers bring a unique mix of process plant experience and creative engineering. We offer the following services to get your process to pilot or production scale:

  • Applied Mathematical Models
  • Aspen Plus Simulation
  • CFD – Computational Fluid Dynamics
  • Development of Intermediate Processing Steps
  • Heat Exchanger Design & Integration
  • HYSYS Modeling
  • Liquids Processing
  • Mass & Energy Balances
  • Pipe Flow & Stress Modeling
  • Process Flow Diagrams (PFD’s)
  • Reactor Design
  • Sanitary Design

Engineering Studies

We conduct engineering studies to clarify unknowns, determine scope or establish thresholds. We commonly do the following types of studies, but can complete other types of studies upon request:

  • Area Classification
  • Ergonomic
  • Feasibility
  • OEE & Uptime
  • Process Safety

Pilot Plant Automation

We develop controls, automation and electrical panels in-house at EPIC as part of our turnkey services. Our automation capabilities include:

  • Automation Design
  • Control Panel Fabrication
  • Control System Development
  • Controls Integration
  • Electrical Design
  • Drafting Services
  • Safety Engineering


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

Physical Design

Physical system design starts in the quoting phase and continues after the conclusion of front-end engineering. Our physical design process includes:

  • 2D Drawings
  • 3D Modeling
  • Drawing Development
  • Equipment Layout
  • Equipment Selection and Planning
    • Ancillary Equipment
    • Instrumentation Selection
    • Valve Selection
  • FEA Analysis
  • Lift & Installation Plans
  • Mechanical Design
  • Piping & Instrumentation Diagrams (P&ID’s)
  • Piping Design
  • Modular Skid Design
  • Process Simulation

Electrical Design

Our electrical shop produces top-tier panels and eletrical systems for all our pilot and demonstration plants. Our electrical systems can be built to meet most area classifications in-house and NFPA hazardous-classified environments. Capabilities in this area include:

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


Pilot plant equipment integration happens both in our shop during assembly and in your plant upon installation. We ensure systems are fully integrated and running correctly on-site before we complete commissioning and training. EPIC’s integration capabilities are:

  • Adjustments to Power Distribution &Panels
  • Continuing Support
  • Control Processor Compatibility
  • Coordination of Site Installation
  • Custom Plant Conditions
  • Equipment Installation
  • Link Infeed and Outfeed Equipment Installation
  • Machinery Handshaking
  • Modifications to Motor Control Centers
  • Plant System Integration
  • Process Hookups
  • Punch List Resolution
  • Successful Comissioning and Support
  • System Training


Our pilot plant fabrication plant and our skilled craftsmen create production style, high quality skids that reduce project timelines, OSHA exposure hours and installation time. Our manufacturing capabilities include:

  • 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
  • Sanitary System Fabrication
  • Sheet Metal
  • Structural Fabrication
  • Tooling
  • Tube Fitting, Bending and Installation
  • Welding

System Documentation

All systems and pilot plants come with full documentation. That means the following are included at a minimum:

  • Component Specifications
  • Control panel schematics
  • Program Logic Documentatoin
  • Mechanical Drawings
  • Operation Manuals
  • Maintenance Manuals
  • Recommended Spare Parts List
  • Schematic Drawings
  • Troubleshooting Checklists
  • QA logs

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EPIC Pilot Plants
4134 Meramec Bottom Rd
St. Louis, MO 63129, US