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  • Writer's pictureCraig Drabyk

Benefits of Prefabricated Modular and Super Skids: Maximizing Efficiency and Quality in Process Construction

Modular skids are prefabricated units that integrate process equipment, piping, and instrumentation into a transportable assembly. Used in various industries, including pharmaceuticals, oil and gas, food and beverage manufacturing, water treatment, and chemical processing, modular skids provide numerous advantages over process systems constructed on-site and installed in place. These benefits make them particularly attractive to facility owners and construction managers.


Because modular skids are constructed under controlled conditions, they provide higher quality control standards. They help streamline schedules and reduce trade stacking, making them ideal for fast-track projects and delayed starts. Modular skids arrive at the site pre-tested and ready for utility connection and tie-in to the rest of the process facility, allowing greater predictability and improved cost control. Pre-testing also means that problems are minimized during commissioning and final testing.


Similar to modular skids are super skids, which are large, integrated skid systems that incorporate multiple processes within a single structure. They are often used in large-scale projects or facilities and can include components such as reactors, separators, heat exchangers, pumps, and other ancillary equipment. Because of their size, super skids can be more challenging to transport. Some are shipped in segments and assembled onsite, while oversized super skids may require specialized transportation arrangements.


After a modular skid arrives at the work site, it is precisely positioned into its pre-coordinated location. If a skid is shipped in segments, it is reassembled, and the connection to power, control wiring, and pneumatic tubing is established. Control panels, human-machine interfaces (HMIs), and other instruments shipped separately from the modular skid to prevent damage during transport will also require integration.


Once all controls and power wiring are complete, continuity check and loop check can commence. At this stage, the instrumentation contractor may work with the vendor to perform on-site instrument calibration and help verify the sequence of operation before the equipment goes online. Most skid-mounted equipment will also be tied into the building’s process network for monitoring, alarm, and control.  



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