Air Separation Facilities 
- Air heaters burner management systems
- Dehydration valve sequencing
- Air and oxygen compressor systems revamp
- Controls upgrade/control panels
MCSI has been providing quality instrumentation and electrical systems for the air separation industry for over 15 years. In 1987, MCSI supplied an air pre-heater burner management system for an upgrade to a unit. MCSI has provided I&E for packaged process skid units complete with junction boxes for interconnect to existing facilities control systems. We have been involved in numerous cost studies to retrofit new control systems for entire facilities. Over the years, we have relocated heaters, oxygen and air compressors per requirements. From medium voltage compressor driven to O2 clean process tubing, MCSI can provide the right control systems to meet your needs. View More
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Cryogenic Gas Processing Plants
- Gas super cooled process (GSP) cryogenic expander plant upgrades
- Sizes ranging from 10 MMSCFD to 465 MMSCFD capacity
- Block mounted and Modular (skid) packaged plants
- Turn-key control systems and construction for new facilities. Control upgrade and revamp for plant moves and relocations
Since its establishment in 1981, MCSI has been a pioneer in control philosophy applications specifying the correct PLC/DCS control system for processing plants. With more than 250 cryogenic gas plant projects completed, we offer vast experience in controls and automation. Whether it is boost, pre, post or refrigeration compression, 2, 3 or 5 tower dehydration, gas or product treating, turbo expander, ethane rejection, regeneration/hot oil/waste heat recovery unit, product loading/pipeline, sampling/chromatograph, lighting or fire and gas detection/suppression, we have the knowledge and experience to provide you with the right control system for each application. Most plant relocations start with a small MCSI crew making critical determinations on where to disconnect and cut loose controls and power feeders to complement and reutilize in the reinstallation construction phase. MCSI performs the complete I&E construction and provides competent technicians and on-site engineers to provide complete checkout and start-up/ commissioning of new control systems. Hands-on operator training is provided with involvement in instrument loop tuning to enable the owner to learn and have confidence with the plant control systems. View More
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Dew Point Control Plants
- Plants ranging from 40 MMSCFD to 500 MMSCFD in capacity
Over the years, MCSI has provided detailed design, control philosophy, modular skid I&E assembly and complete I&E field construction for three (3) dew point control plants located in North America.
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Early Production Facilities / Test Facilities
- Portable well test facilities
- 40 to 64,000 BPD early production facilities
Our largest project in this category was performed in 1991 for Elf, Gabon, a 40,000 BPD early well production facility of a modular design. The entire facility was assembled in a Houston yard, then disassembled and shipped to Gabon, Africa. MCSI provided I&E work including detailed design for a prefabricated control/MCC building, skid I&E and a 20’ container with all materials, tooling and test equipment. An eight man crew went to Gabon, Africa and performed the required field construction within ten weeks. Two men remained an additional two weeks for startup, commissioning and operator training. In 1989, MCSI provided a similar early production facility for Al Furat Petroleum Company located in Syria. View More
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Fired Process Heaters
- Regeneration heaters
- Heat medium heaters
- Asphalt heaters
- Hot oil heaters
- Ethylene furnaces
- CO2 heaters
- Line heaters
- Amine Reboiler heaters
- Coke furnaces
- Glycol regeneration heaters
- Muffle furnaces
- Slug heaters
- Dowtherm vaporizer heaters
- Pyrolysis furnaces
- Waste heat recovery units
- Duct burners
Early in 1985, MCSI began concentrating on burner management systems and fired heaters/ furnace controls and upgrades. To date, MCSI has completed well over 150 projects totaling an estimated 350 burner management systems in service world wide and in most applications. Well over 75% of our designed BMS are fully automated, utilizing purge cycles and complete ignition trial cycles provided by PLC based control panels. Field startup and commissioning of BMS is provided along with startup and one-year spare parts. One of our largest BMS projects was over $1 million in contract value for BP/AMOCO located in Canada. BMS’s have been supplied for projects located all over the USA, Canada, Mexico, Venezuela, Peru, Columbia, Algeria, Ivory Coast, Gabon, Yemen, China and Russia. View More
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Gas and CO2 Injection/Storage Facilities
- Motor driven gas injection facilities up to 5,800 BHP
- Engine driven gas injection facilities up to 19,200 BHP
- Integral engine drive gas injection facilities up to 11,000 BHP
- Motor drive CO2 injection facilities up to 38,000 BHP
- Engine driven CO2 injection facilities up to 4,000 BHP
- Turbine driven CO2 injection facilities up to 7,800 BHP
Our initial experience with gas injection was in 1984, providing I&E installation for three (3) turbine packages destined for offshore service in the Gulf of Suez. Our largest injection facility, located in west Texas, consisted of four (4) 5,500 BHP and two (2) 8,000 BHP motor driven CO2 injection compressors comprising a station total of 38,000 BHP. Power distribution was provided at 12.4 KV and 6.6 KV to drive the motors. Our scope included detailed electrical and instrumentation design, power distribution, area and compressor building lighting, hi-pot testing and stress cone termination for a turn-key installation. World wide projects have included five (5) injection facilities in Venezuela and one (1) in Brazil. View More
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Gas Specialty Processing Plants
- Butane isomerization plants 5,000 BPD capacity
- High and low pressure gas meter proving facility
- Depropanyzer plant 5,000 BPD expansion
- De-ethanizer process skid installed on 100 MSCFD cryogenic plant
- Fractionation plants from 3,000 BPD capacity to 12,000 BPD
- Used motor oil conversion to marine diesel fuel facility
- Crude topping units ranging from 1,000 to 10,000 BPD capacity
- Condensate stabilizer facilities ranging from 1,750 BPD to 12,000 BPD
- Pump station for NGL Products underground storage to barge loading facilities
- Land fill methane gas processing facilities ranging from 3 MMSCD to 10 MMSCFD capacity
Gas specialty processing plants are where we acquired our largest single contract to date of $4.2 million dollars. The butane isomerization project was performed in 1991/92 and consisted of two (2) 5,000 BPD units, one located in Bushton, Kansas and the other in Geismar, Louisiana. MCSI specified and purchased all instrumentation and process control valves. Both units utilized Honeywell TDC3000 DCS which we programmed, configured and commissioned. This project category has been instrumental in bringing broad project knowledge to us for servicing the oil and gas industry. View More
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Gas Transmission / Compression Facilities
- Motor driven gas compressor stations up to 20,000 BHP
- Engine driven gas compressor stations up to 9,750 BHP
- Integral engine driven gas compressor stations up to 15,000 BHP
- Turbine driven gas compressor stations up to 40,500 BHP
A large portion of our business evolves from gas transmission/compression facilities. Gas processing plants typically contain compression capabilities, whether it is pre, post, boost or refrigeration. A mainstream throughout our business history, these facilities have allowed us to gain vast experience and control knowledge ranging from grass roots I&E engineering, design and construction to control retrofits for turbine and reciprocating engines, gas detection/suppression, telemetry/communications and remote start/stop operations. We have provided turn key I&E construction for over 25 facilities to date. Project locations have ranged from the continental US to Venezuela, Azerbaijani and Argentina to name a few. View More
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Gas Treating Plants
- Amine treating plants with and without glycol dehydration units ranging from 10 GPM to 750 GPM
- Sulfur recovery units ranging from 10 LTD to 50 LTD
- 190 GPM sulfinol gas treating units
- Dow sulfenox gas treating unit
- 40 MMSCFD CO2 removal plant
- 30 MMSCFD N2 rejection plant
- Block mounted and Modular (skid) packaged plants
Over the years, MCSI has played an important role in providing our customers with some of the most advanced control systems for their gas treating plants. We have worked closely with our customers, starting with P&ID and plot plans development to set the parameters for the right control application. We assist our customers with P&ID and HAZOP studies to assure that a safe and economical control system is provided to obtain optimum process recovery.
Detailed control systems provided for these treating plants have ranged from relay logic, PLC/HMI based and DCS control systems. MCSI provides detailed programming and configuration along with hands-on F.A.T. with our clients prior to moving into the field for start-up and commissioning by our staff engineers and technicians. View More
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Incinerators and Flares
- Waste gas flares
- Tail gas flares
- Utility gas flares
- Trash/debris incinerators
- Medical waste incinerators
- Hazardous waste incinerators
MCSI has performed new turn-key I&E installations of incinerators and flares for the oil and gas industries in varied applications and services. We have provided controls upgrade/revamp for used and relocated incinerators and flares. Our experience with fired process heaters and furnaces over the years has allowed us in-depth knowledge in this category. Whether it is a local or international project, MCSI can and will provide the right control system for the application.
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Offshore Platforms
- Modular Compressor skids
- Process equipment packaging
- Modular control/MCC buildings
- Fire and gas detection/suppression systems
- Paging systems
- Control systems
- Fired process heaters burner management systems
In 1983, MCSI’s first offshore module project was for ARCO’s High Island production platform which consisted of “Hi/Low test separators” and “produced water filtration” control racks and process skids' instrumentation. In 1985, MCSI provided the complete instrument and electrical system for Seagull’s single lift platform located offshore from Galveston, Texas. Since 1997, we have provided 12 modular control/MCC buildings for PEMEX’s Bay of Campeche production platforms totaling over $2 million in contract price. Customers include ARCO, PEMEX, Exxon-Mobil, Maraven, Pennzoil Caspean Corp., Aminoil Corp., AMOCO/ Gupco, Conoco, FMC, Marathon Oil, Petrobras, McMoran, POGO Producing Co., Chevron, Texaco, Placid Oil and Shell. View More
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Petrochemical / Refineries & Terminal Facilities
- Fired process heaters and furnaces
- Motor driven hydrogen compressors
- Fire and gas detection/fire deluge systems
- Tail gas incinerators
- Control panel swap-out and upgrade
- Compressor control systems revamp/upgrade
- Crude and NGL terminals
MCSI has completed over 100 projects to date under this category, with its first contract for a H2O and CO2 analyzer package for E.I. DuPont in 1984. Over the years, we have designed and fabricated over 50 burner management systems for fired process heaters/furnaces for petrochemical facilities and refineries worldwide. We have over 25 compressor projects ranging from hydrogen and vapor recovery compressors to compressor packaging and controls revamp/retro fit. Most of these supplied systems conformed to each customer’s rigid specifications to allow interface of packaged control systems with the refineries’ central DCS. These were worldwide projects and a brief listing of customers includes: AMOCO, CITCO, Syncrude, Exxon, Mobil, Texaco, Chevron, BASF, Dow Chemical, Marathon, Samsung, Maraven, Petrobras, Nisseki, NALCO, Fauji Oil, Coastal, DuPont, Pennwalt, Phillips and Shell.
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Power Generation Facilities
- CEMS – Continuous Emission Monitoring Systems
- Gas measurement and metering system
- Instrument air installation
- Fiber optics communications
- Barge mounted generation units
In 1986, MCSI performed its first power plant project consisting of I&E construction for Central Power and Lighting gas measurement and metering facility for the Lon C. Hill Power Station near Corpus Christi, Texas. Since that project, MCSI has performed numerous projects over the years for the power generation industry. From installation of instrument air compressor systems to CEMS on coal and gas fired generation plants to integration of control systems via fiber optics interconnect. MCSI has been there and has the experience.
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Refrigeration Gas Processing Plants
- Sizes ranging from 5 MMSCFD to 120 MMSCFD in capacity
- Modular/skid packaged plants.
- Turn-key control systems and construction for new facilities. Control upgrade and revamp for plant moves and relocations
For over 22 years, MCSI has provided detailed I&E engineering and construction for refrigeration plants world wide. In 1996, MCSI provided single source, turn-key detail design, drawing package, main control panel, processing skid I&E fabrication in a Houston area shop, and sent a 10 man crew to install all field interconnect wiring, power, controls, grounding, lighting and start-up/commissioning of a 120 MMSCFD refrigeration plant in Equatorial Guinea, West Africa. All aspects of packaged refrigeration plants can be analyzed for proper control philosophy application that is a right fit for each application. View More
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Water Injection Facilities
- Waste water injection facilities
- Motor driven water injection facilities up to 64 BPD
- Engine driven water injection facilities
Our first project for water injection facilities was in 1986, south of Midland, Texas. Much of the process piping was fiberglass for corrosion resistance. We provided winterization for exposed process piping to prevent rupture during freezing conditions utilizing electrical heat tracing. Projects contained engine driven injection pumps and medium voltage motor driven injection pumps. We have provided turn-key I&E for total facilities installations. View More
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