Process Skids

Mission Controls has a 2000 square foot welding and fabrication shop at our Santa Ana, California headquarters, providing full capabilities for the complete construction of process skids. But wait...

The manufacturing procedures used at Mission Controls are as important as appropriate shop space, state-of-the-art equipment, and trained personnel.

• Our Process Engineering department first develops a complete and exact understanding of the plant’s requirement. Close coordination with the people who must operate the skid in the plant is continuous throughout design and construction. Our engineers will ensure that all process requirements are fulfilled, correctly.
• Mission Controls process engineers then work directly with our AutoCAD department to prepare precise drawings. And, of course, the drawings are in 3D Virtual Process Design format.
• When the Mission Controls Project Manager arrives at the plant with the drawings, it’s "show time," and everyone in the plant will want to watch. The design of the skid will be first presented in moving virtual reality on a television monitor or projector screen showing each view of the skid in full detail as the observer appears to move around and over the skid. Pipes look exactly like pipes, with bends precisely where they must be, tanks are shiny and of correct shape and dimension, valves and instrumentation are all seen just as they will appear on the finished skid – all relationships among equipment may be seen and studied.
• 3D Virtual Process Design printouts will display on paper the various views of the skid to be fabricated, in perfect and precise detail, with all the supporting information easily visible. No one will have to interpret a line drawing: it’s all displayed as if photographs had been taken of the skid to be fabricated.
• Programming is all independently tested on a PLC that duplicates the exact controller in the plant. The skid control panel, fabricated in our integrated UL 508 panel shop, is loaded with the fully functional code.

The Mission Controls shop is not just a fabrication floor, but a test room as well, with full water, 480VAC power, and compressed air capabilities.

• If the system being built involves wall-hung process piping, frame walls are constructed in our shop to exactly duplicate the dimensions of the room where the skid system will be installed, so that integrated piping and associated hardware can be precisely fitted before being moved to the plant.
• When construction is finished, the skid is connected to utilities and all its functions are completely tested. The skid is run on water, right in our shop, so that all functioning can be proved. Plant personnel are invited to observe.

The skid is delivered only after every function is proved in our shop. When it arrives at the plant it only needs to be single-point connected to electricity, steam, condensate return, chemical and water lines as appropriate. When it is started, it works. Downtime is minimized, stress on everyone is reduced, production continues. We think this is how it should be done, so that’s how we do it: it’s not more expensive to do it right.

Because of our expertise and history of success, Mission Controls has a close professional relationship with the USFDA, and guarantees regulatory acceptance of the systems we install.