Modular Process Skids & Skid-Mounted Equipment Solutions
Many industrial projects face tight schedules, difficult field installation, and high construction risk.
Gelan modular process skids combine equipment, piping, and instrumentation into factory-assembled modules that reduce site work and improve installation reliability.
What Is Skid Mounted Equipment in Industrial Plants?
A skid mounted process unit is a modular system where process equipment, piping, valves, and instrumentation are integrated onto a structural skid frame.
Instead of installing each component separately inside the plant, the entire system is assembled and aligned in the workshop before delivery.
Factory Assembly
Faster Installation
Less Field Work
Commissioning
Why Are Skid-Mounted Systems Used in Modern Industrial Plants?
In traditional projects, equipment and piping are often installed directly inside the plant. Modular skid-mounted systems take a different approach by integrating the process unit in the workshop before delivery.
Traditional Construction
- Equipment installed piece by piece
- Extensive field welding
- Multiple contractors
- Longer installation time
- Higher construction risk
Advantages
- Fully integrated modules
- Factory fabricated piping
- Single integrated package
- Faster installation
- Controlled fabrication
Where Are Modular Process Skids Used?
Factory integration reduces complex piping work inside operating facilities.
Petrochemical & Refining
Modular equipment packages make plant expansion and process upgrades easier.
Chemical Processing
Common for waste heat boilers and heat recovery systems in power and energy facilities.
Pre-assembled equipment helps projects meet tight construction schedules.
Energy & Power
Integrated equipment packages simplify complex process system installation.
Hydrogen Production
Modular systems allow environmental units to be installed in limited plant space.
Environmental Systems
How Modular Process Skids Are Designed and Delivered
Design
Engineers define process requirements, equipment sizing, and skid layout.
The module is designed for safe transport and efficient site installation.
Integration
Fabrication
Factory assembly improves fabrication accuracy and simplifies inspection.
Delivery
The completed skid-mounted unit is transported to the project site.
The module is lifted into position and connected to plant utilities, reducing installation time and field work.
Why Choose Gelan for Modular Process Skid Design and Fabrication?
Proven Engineering Capability
Gelan engineers modular process skids for demanding industrial process systems.
- Process systems designed for up to 900 °C service
- Engineering of large modular equipment packages
- Integration of vessels, heat exchangers, heaters, and piping
This ensures each skid module is engineered for safe transport and efficient installation.
Certified Fabrication & Quality Assurance
Gelan manufactures modular skid systems in ASME U & S certified fabrication facilities.
- ASME U & S stamped pressure equipment fabrication
- In-house NDT inspection including UT, RT, PT, and MT
- Workshop assembly of piping systems and skid structures
Factory inspection and documentation ensure equipment quality before shipment.
Integrated Modular System Design
Gelan integrates multiple process components into complete modular skid systems.
- Integration of vessels, heat exchangers, and fired heaters
- Modular assembly of piping, valves, and instrumentation systems
- Skid structures designed for large industrial equipment modules
Engineering experience from 20+ integrated equipment packages supports reliable module delivery.
Project Execution & Delivery
Gelan manages modular skid projects through structured engineering and fabrication coordination.
- 99% on-time delivery rate for equipment and modular systems
- 6-hour technical response for engineering and project coordination
- Engineering documentation prepared for EPC project integration
This approach helps ensure modules are delivered ready for installation.
Where Are Modular Process Skids Used?
Shell & Tube Heat Exchanger Skid
Challenge
A petrochemical plant required a high-temperature heat exchanger for a process unit expansion.
Installation space was limited and the EPC schedule was tight.
Solution
Gelan delivered a skid-mounted shell & tube heat exchanger system (TEMA design), rated for 420 °C and 3.5 MPa. The unit was fully assembled with piping and instrumentation in the workshop before shipment.
Result
The modular skid reduced on-site installation time by ~40%, minimized field welding, and allowed faster commissioning of the process unit.
Temperature
Modular Skid
Pressure Vessel Modular Skid
Challenge
A chemical processing unit required a high-pressure reactor vessel operating at 5.0 MPa and 350 °C, with multiple piping connections and strict safety requirements.
Solution
Gelan delivered a skid-mounted pressure vessel module, fabricated with ASME U stamp certification.
The vessel, piping, valves, and instrumentation were fully integrated into a 60-ton modular skid and assembled in the workshop before shipment.
Result
Factory modular assembly reduced field piping work and simplified installation of the pressure vessel system in the process unit.
MPa Design Pressure
Design Temperature
Ton Skid Module
Vessel
FAQs About Modular Process Skids
How large can a modular skid system be?
The size of a modular process skid is usually limited by transportation conditions. Most skid mounted units are designed to fit within road or sea transport limits, while larger systems can be divided into multiple modules for shipment and assembled on site.
What work is still required on site after delivery?
Although skid mounted equipment is fully assembled in the workshop, some site work is still required, including lifting, positioning, and connecting the skid to plant utilities and process pipelines.
Can modular process skids be customized for different projects?
Yes. Each modular process skid is typically engineered according to the process requirements, operating conditions, and layout constraints of the plant. Equipment configuration, piping integration, and skid structure are customized for each project.
Are modular skid systems easy to maintain?
Yes. Skid mounted systems are usually designed with accessible equipment layouts, allowing easier inspection, maintenance, and equipment replacement compared to tightly built on-site installations.
Can modular skids be expanded in the future?
Modular systems allow plants to expand capacity by adding additional skid mounted units. This approach is often used when plants increase production or add new process units.
Request a Modular Skid Consultation
Whether you are planning a new process unit or upgrading an existing facility, our team can support you with engineering consultation, modular skid design, and fabrication of skid mounted equipment.