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Automation Applications

Flammable Reaction Skid Requires Intrinsically Safe PLC Control

plc control A custom engineered pilot plant was fabricated to convert material derived from a plant-based energy source (plant-based), to a replacement for a fossil fuel derivative. EPIC implemented intrinsically safe instrumentation and PLC control.

CLIENT: Fortune 500 Company

INDUSTRY: Oil and Gas, Alternative Energy


  • Future technologies proof-of-concept pilot plant
  • Class I, Group D, Division 1 and Division II hazardous areas present on the skid for highly flammable chemicals
  • FlexEx Intrinsically Safe I/O with intrinsically safe instruments and valves, to reduce installation costs
  • Rockwell ControLogix PLC control, utilizing intrinsically safe ControlNet communications to the I/O
  • Main control panel and drives for skid located separately in a general purpose classified area
  • Wonderware InTouch HMI with custom screens designed specifically for the process
  • Complete power distribution equipment was engineered and provided for the project


  • Proprietary technology scale-up
  • Skid design – all process equipment contained within two skids, to allow transport to the destination site and comply with highway restrictions
  • Layout – Ensuring all equipment and critical processes are accessible within skid
  • Hazardous chemical handling and area classification zones located within each skid
  • A temperature controlled raw material storage cabinet was supplied due to one of the raw materials being highly temperature sensitive
  • Multiple heat trace circuits on each skid due to multiple product stream temperature requirements

Get Started

Are you ready to get started with your automation project? Contact an engineer today 314-254-9768 to discuss your application. At EPIC you will be put in direct contact with a project engineer who will help you get started...

EPIC Industrial Automation
4134 Meramec Bottom Rd
St. Louis, MO 63129, US