Novelty Steel Fabricates Process Skids and Modules for Oil and Gas ,
Chemicals, Food and Beverage Projects.
1. What is a Process Skid ?
A process skid is a modular, self-contained system that houses all the necessary components for a specific industrial process. These units are built on a steel frame (the “skid”) and include a combination of pumps, piping, valves, instrumentation, and control panels designed to perform a defined function—such as chemical dosing, heat exchange, or fluid handling.
2. Types of Process Skids
| Type of Process Skid | Function | Applications | Key Components |
|---|---|---|---|
| Filtration Skids | Remove impurities (solids, liquids, or gases) | Water treatment, gas purification, chemical processing | Filters (membrane, cartridge, bag), pumps, pressure gauges, control valves |
| Heat Exchange Skids | Transfer heat between two mediums to regulate process temperatures | Cooling/heating in chemical processes, HVAC systems, oil refineries | Heat exchangers (plate, shell-and-tube), pumps, temperature sensors, piping |
| Mixing and Blending Skids | Combine liquids, gases, or solids to achieve a uniform mixture | Food and beverage, chemical production, pharmaceuticals | Agitators, mixers, blending tanks, flow meters, automated controllers |
| Chemical Injection Skids | Controlled injection of chemicals into a process | Oil and gas (corrosion inhibitors), water treatment, refining | Dosing pumps, chemical tanks, metering systems, pressure relief valves |
| Separation Skids | Separate components through distillation, stripping, or absorption | Petrochemical refineries, biogas plants, chemical production | Columns, separators, compressors, heat exchangers |
| Gas Compression Skids | Compress gases for transport or further processing | Oil and gas (natural gas compression), industrial gas storage | Compressors, separators, cooling systems, pressure sensors |
| Dosing Skids | Precise injection of measured amounts of liquid, gas, or chemicals | Water treatment, pharmaceuticals, oil and gas, chemical processing | Dosing pumps, flow meters, storage tanks, valves, controllers, calibration systems |
| Batch Process Skids | Handle batch-based production processes | Pharmaceuticals, specialty chemicals, food production | Batch tanks, agitators, flow meters, automation systems |
3. Design of Process Skids
4. Advantages of Process Skids
6. Quality Control of Process Skids
| Stage | QC Measures | Purpose |
|---|---|---|
| Material Inspection |
|
Verifies the use of high-quality materials suited to specific process conditions. |
| Welding and Assembly |
|
Confirms weld integrity and ensures proper alignment and tolerances in assembly. |
| Instrumentation Testing |
|
Ensures accurate measurements and proper operation of automation systems. |
| Factory Acceptance Testing (FAT) |
|
Verifies the skid’s functionality and readiness before delivery. |
| Documentation and Traceability |
|
Provides complete traceability and certification for materials and processes. |
| Site Acceptance Testing (SAT) |
|
Ensures seamless operation and integration at the installation site. |
How can we help you ?
Piping fabrications are indispensable to industrial projects and their success depends on the careful selection of contractors
Novelty Structures stands out as a reliable partner in providing high-quality piping solutions tailored to demanding industrial needs.
FAQ
Yes, process skids are highly customizable. They can be designed to meet specific process requirements, space constraints, and industry standards. Engineers work closely with clients to ensure all performance, material, and safety needs are addressed.
Process skids are designed to meet industry-specific standards, such as:
- ASME (American Society of Mechanical Engineers) for pressure vessels.
- API (American Petroleum Institute) standards for oil and gas.
- ISO certifications for international projects.
Common materials include carbon steel, stainless steel, duplex stainless steel, and high-performance alloys. The choice of material depends on the process conditions, such as temperature, pressure, and the chemical properties of the fluids being handled.
Key tests include:
- Factory Acceptance Testing (FAT) to simulate real-world operating conditions.
- Leak testing using hydrostatic or pneumatic methods.
- Instrument calibration and automation system validation.
Visual and dimensional inspections to ensure adherence to design specifications.
Process skids are designed for ease of transportation. They can be shipped as a single unit or broken down into smaller modular components for easier handling. We also ensure that skids comply with shipping and road transport regulations.
Costs vary widely based on size, complexity, materials, and customization. While initial costs may seem high, process skids often save money in the long run by reducing installation and operational expenses.
Lead times depend on the complexity and scope of the project but typically range from 12 to 24 weeks. Early involvement of the client in the design phase helps streamline the process.
Novelty Structures accomodates scope changes, but these can affect timelines and costs. It’s important to establish clear project goals and communicate changes as early as possible.
