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If you are in the middle of choosing between traditional stick build process systems and modular process skids, these two options are considerably different.
Modular design can be put together in different configurations and are designed offsite, whereas stick-built systems are manufactured on your site.
Modular process skids have plenty of incredible advantages over stick-built systems and advantages that can really benefit your process plant project. That’s why we will tell you the five incredible advantages of modular design and why you should choose this design for your project in this article.
Modularity and modular design: What do these terms mean?
Modular design involves using independent parts that can be easily upgraded. A designer puts together a modular design, and a technician creates things from the design – in this case, a modular skid is created using technology, components and elements, and the independent parts have standard interfaces. Such a standard interface permits the individual parts to join together. Modularity involves dividing the system into functional elements that are scalable and permit an upgrade to take place to meet your changing needs. Designs can be customized for your platform in different ways so the concept and ideas behind your project can develop.
Modular design examples
Some key examples of modular design include computer programming, modular furniture, and modular vehicles, but in process plant engineering, modular design is usually used to describe a skid that has been designed into different units or modules. The modules of the frameworks or skids make it easy to mount types of process equipment and valves, as well as components and instrumentation onto the frame and transport them to the required location. Now, there are several advantages of modular design in terms of a process plant. Let’s now take a look at some of the crucial advantages that you can gain with modular design and modular skids.Top 5 advantages to modular skid design
Now we have covered what modular design is, and a few examples of modular design, here are the five advantages to using it in your project.1. Reduction in project timelines
You’ll have no problem achieving a faster time to market when you choose a modular system design. There are a few key reasons for this. Let’s take a look at three advantages in terms of project timelines.Offsite fabrication means shorter timelines
The main reason for the shorter project timelines is that the fabrication process, development, and assembly all happens offsite. Fewer delays can be expected because of this, so project timelines are shorter.Indoor design and fabrication mean less delays
It’s also the case that because modular skids are developed in an indoor environment, there are significantly fewer, if not no weather delays with modular skid fabrication.Testing happens before shipping meaning shorter timelines
Reductions in project timelines can also be achieved with modular systems design because the entire system is fully assembled based on designs created by designers and even tested or assessed prior to being shipped. The start-up time is reduced, which means the overall timeline is kept to a minimum.
2. Enhanced safety advantages
There are many key reasons why modular skid designs help to enhance safety and ensure that you reap the safety advantages. Here are the main ones.OSHA conditions reduced for crew members
With modular skid designs being carried out offsite, personnel that would onsite will work in fewer OSHA conditions. Their crew sizes will also be reduced, meaning that there are enhanced safety advantages for crew members. The designs are carried out in safer conditions, which is why modular designs are ideal.Ideal construction conditions to keep crew members safe
What’s more, since fabrication facilities are enclosed, the conditions of construction are ideal for mitigating the risks related to safety, so fabricators can work in better conditions and remain safe during collaboration and execution of designs.Testing is done before shipping to ensure safety is upheld
Because testing is carried out before the shipment takes place, and any errors are identified and corrected, all safety issues related to the way the modular skid functions are kept to a minimum.3. Lower costs and greater savings
Saving on the costs of modular skids is possible with modular design. For example, you can save on approximately a quarter of the costs with modular design. Here are the key savings.Modular skid design means faster timelines and less completion costs
Choosing a modular skid design approach means that timelines for projects are shorter (as mentioned). The design of modular skids means that labor costs are reduced as less hours of work are required, and operational costs are also reduced.Costs for materials are greatly reduced
By factoring in the specific materials into the modular skid design, you can save on the cost of materials since they are used efficiently. Since designs for modular skids can be used to create duplicates from the first design, you gain the advantage of lower costs. It’s also possible to avoid expensive costs that are caused by plant shutdowns because the modules that are part of the modular design are constructed offsite. What’s also possible is getting incremental upgrades instead of getting different systems, or entire systems installed. This can save you more on manufacturing costs.
4. Less resources, waste and space required
There are several reasons why modular skid design and modular construction requires less resources and space, and leads to less resource waste.Conditions reduce waste
For modular designs and manufacturing, the conditions in which fabrication takes place is ideal for keeping material waste to a minimum.Component simplification leads to less waste of space and cost
The simplification of components ensures that the costs of construction are reduced and the difficulties of maintaining parts are also mitigated. This means you can avoid material waste and save on costs.Timelines and resources reduced due to offsite crews
Resources in terms of the size of the manhours, crew size, and labor efforts are minimized because they are not required to be present on the site. This is because assembly doesn’t take place on the site. You will also spend less time searching for a technician to complete assembly and fabrication because they will already have been sourced by the fabrication shop.Significantly fewer problems with space on the site
It’s also the case that you won’t need to make space on site because the systems are not fabricated there, so moving your resources around is not required to accommodate the system. This is possible since you could even stack a modular skid on top of another one, which is one reason why they are better than stick-built systems. If you have been wondering how the process system and modular skid will in your plant, consider this: since traditional, non modular design, such as stick-built systems, occupy more space compared with modular skids, and can even occupy the entire plant space, the best option for your plant engineering project is a modular skid.Portability is simple with skid designs
Will you need to move the skid designed unit around? Will you need resources to move it? If you’re looking for an answer to how you’ll move it, skid designs are portable. You can move them to completely different locations or facilities. Compare this to a stick-built system, which must be ditched when you move to a different site or facility, or you may have to move it unit by unit, which will cost you more resources.