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Modular systems have become a staple part of chemical processing for plant engineers across the globe. But you might not be aware of what modular systems are and why they are so important. There are several reasons why modular systems are a practical approach to process engineering, which we have covered in this article. If you already know why modular systems are ideal for your project, we have also explained why our partner, DG-SKID, is the one of the best options for modular systems, how they can help your project, and why you should choose them for your next project.

Modular systems and product architecture defined

A simple way to explain modular systems is to compare them to building blocks that are used for moving process systems. Modular construction processes can ensure that the systems can be reconfigured to transport process systems.  Creating product architecture from modular process systems involves bringing together a collection of modular process systems used for transportation. A top example is the Ferrari product architecture and car platform services carried out by Pro Support Solutions’ exceptional partners.

Modularity design defined: What is modularity?

Modularity refers to a design concept whereby an entire system is divided into modules or smaller modular process skids. They can be created independently and switched around for different process systems, which is precisely why modularity is a practical approach to process engineering.

What is an example of modularity outside of process engineering?

Aside from being used for new building processes (also known as fabrication) and transportation for chemical process plants, one of the best examples of modularity and systems that use modular components are types of computer platforms or computer engineering platforms that feature USB ports to load software. 

Modular system design process

The years of experience that DG-SKID has in the field of modular systems makes them the leaders in design, manufacturing, and commissioning. They are the experts who will ensure that quality is assured and commissioning and functions assessment is carried out to an exceptional standard and make modular systems a practical approach to process engineering. Our partners work with clients and business stakeholders to establish and create a superior modular system design that works with your process system. Before any designs are formulated, DG-SKID has an in-depth talk with clients to gather data and establish solutions for the main challenges of the project. We factor in all angles of the modular process system and then optimize a final design.

Building new modular products and technology for customers: The key benefits

The essential benefit of having experts such as DG-SKID create new modular products and modules for your company is that they deliver a solution to help you reduce time to market.  Their efficient process means that the cost for product development is reduced and customers can reap the benefits of exceptional components. Each component and module are integrated into a modular system, which is manufactured to help companies achieve their projects.

How are modular systems practical for process engineering?

If a modular system is designed and executed in the right way, it can be incredibly practical for process engineering. Comprehensive designs and solutions involve a few critical steps that make modular systems a practical option. For example, these steps include the development of control and PLC systems, the development of technology, the analysis of business models, and designs of process packages.

Control and PLC system development

As well as establishing the settings of control and PLC systems, DG-SKID must also carry out integration of PLC systems. They are also on hand to carry out commissioning of the industrial PLC settings and the control systems.

Development of technology 

In addition to the simulation of processes, experts in modular design and development complete process conceptualization and selection of unit operations. DG-SKID will also carry out pilot testing to ensure that the modular system design process is practical and increases efficiency.

Analysis of business models

In terms of analysis of business models, taking into consideration the strategy for funding and carrying out commissioning and performance assessments is an essential part of modular system planning and design.

Designs of process packages

For the modular design of process packages, industry experts in modular process design will carry out in-depth engineering, thorough construction, and the complete integration of systems.

How are plant operations and modular process systems facilitated by computer use?

The operation of plants and process systems is made easier with a computer. Hardware and programmable logic controllers are also referred to as industrial computer devices that make services for the process industry and operations easier.

Why choose modular systems when compared with stick-built systems?

Process engineering and plant processing equipment is best transported with modular systems and not stick-built systems for a few key reasons.

Less on-site work means more safety

Onsite work is significantly reduced for employees, which ensures that safety is enhanced when the modular systems are fabricated.

Increases in project flexibility

It’s also the case that the construction schedule can be improved and made more flexible, as workers can complete the fabrication from several locations.

Less effort thanks to on-site fabrication

Since modular process systems are built on-site, construction and installation requires less effort when compared with off-site fabrication.

Less commissioning schedule requirements

As pre-commissioning takes place on the separate modules, the schedule for commissioning is reduced significantly in modular process system fabrication.

What factors lead to successful modular process system fabrication?

There are also several factors that lead to modular process system fabrication success and ensure that modular systems are a practical approach for process engineering, including modularization strategies, dimensional accuracy, module interfaces, piping design integration, and logistics and transportation.

Carry out a strategy for modularization

Manufacturers must carry out a strategy for modularization at the beginning of the project and avoiding partial modularization at the manufacturing stage. This comprises the choices made for modular product architecture and breaking down an entire facility into smaller modules.

Prioritize dimensional accuracy

Dimensional accuracy should be a priority when manufacturing modular process systems. This will ensure that the system is practical and can fit accurately on the site. Precise tolerances should be used to achieve this.

Consider interfaces between modules

Interfaces between modules should be an important focus and include piping, instrumentation, and structural factors in a project.

Prioritize the integration of piping design

For each module, piping design should be prioritized and acknowledged in a schedule for the breakdown of work. It’s critical that piping dimensions are measured and that a single reference is used to prevent the tolerance accrual.  As part of piping design prioritization, it’s important to ensure the right piping supports are designed to ensure that the piping system remains stable throughout the transportation process. What’s also crucial is controlling the weight of the piping dimensions, which can be achieved by using a 3D model to plot the dimensions accurately. This approach will ensure that the shipped systems do not carry excessive weight, or weight that exceeds the specified amount. It’s essential that manufacturers log details of the supports that are going through temporary transportation so that when they are dismantled, the shippers can go through a comprehensive checklist.

Logistics and transportation are critical

Logistics and transportation can lead to a successful modular system and ensure that the system is a practical approach to process engineering. Ensuring that site access and load sizes are accounted for is important, and the shipper must be aware of the weight or height restrictions that may apply to the module that is being shipped along the route of transportation.

Go to the Pro Support Solutions website for more on modular system installation 

Pro Support Solutions is the product innovator and supplier for industrial process plants in North America and Canada, with all the critical facts you need on modular system installation. If you are looking for more information on custom modular systems and have the idea of getting one developed, our partners have the tools and ability to assist you with your projects. Information on piping supports and components for modular systems can be found at Pro Support Solutions, and if you need to purchase a system that will cope with the scope of your next project concept, explore Pro Support Solutions and DG-SKID for more information. Our employees are here to assist you when it comes to completing your project with ease.