Anyone planning a process plant faces the same challenge again and again: compressors, pumps, filters, valves and instrumentation have to be brought together into a working overall system — usually under time pressure, often in a confined space and rarely under ideal site conditions. Modular industrial plants, known as SKID systems, move exactly this complexity from the site into the workshop.
As Armaturenfabrik we build SKID systems together with Industriefabrik Schneider GmbH as a complete system — from design and manufacture through to commissioning. This article explains what defines a SKID module, which types of plant we build and why modular construction pays off for many industries.
What a SKID system is
The term SKID comes from English and originally described the skid or frame structure on which a plant is transported. Today SKID stands for a fundamental manufacturing principle: valves, pumps, filters, instrumentation and control technology are combined on a compact, pre-assembled frame — designed, manufactured and tested before the plant leaves the works.
A typical SKID module comprises:
- a welded and surface-treated mounting frame
- piping, filters, pressure vessels, compressors, pumps and industrial valves
- safety valves, positioners, pressure transmitters and pressure switches
- insulation and complete wiring
The result is not a collection of individual components but a tested, functioning system that essentially only has to be connected at its destination.
Which types of plant are built as SKIDs
Modular construction suits a broad range of applications. The most common types of SKID plant include:
Compressor systems — for biogas plants, drinking water treatment or industrial compressed air supply, for example.
Pumping stations — from high-pressure pump systems for water management to redundant pumping stations for critical processes where failure is not an option.
Valve stands and valve stations — compact assemblies with several shut-off and control valves, frequently used in the oil and gas industry.
Steam packages — for the tyre and rubber industry and other processes with high steam demand.
Dosing systems — particularly in the chemical industry, where precise dosing is safety-relevant.
Each of these plants is designed individually to the customer’s requirements — standard components are the exception here, not the rule.
Why prefabrication in the works beats assembly on site
The central advantage of modular construction lies in where the value is added: in conventional plant assembly, piping, valves and instrumentation are brought together only on site, whereas with SKID systems the entire assembly is created in the workshop.
Shorter assembly time on site: the module is delivered fully prefabricated — most of the piping and wiring work is no longer needed on site.
Minimised downtime: every hour of lost production counts, especially when extending or modernising existing plants. A prefabricated SKID module can be integrated considerably faster than a plant that is first built on site.
Ideal for confined spaces: because the design is compact and optimised, SKID systems are particularly suitable for locations with little available space.
Greater process reliability through testing at the works: every component — from the weld seam to the control wiring — is tested before the plant leaves the works. Faults are found before they go into operation, not afterwards.
Complete documentation: welding and material certificates, function tests and connection diagrams are supplied with the plant — a basis that would be considerably more laborious to produce during on-site assembly.
Why the control technology decides the outcome
A SKID module is more than the sum of its mechanical parts. Automated valves, actuators and measuring points need a well thought-out pneumatic and control concept — pressure regulators, filter regulators, solenoid valves and wiring have to be matched precisely to one another so that the plant works reliably as a whole.
This matters all the more because a SKID module is delivered fully prefabricated: whatever is not right in the switchgear from the outset can hardly be corrected once the module has been installed on site. For that reason every control component is tested individually before the plant leaves the works.
More on the automation of valves and actuators, which are frequently part of SKID modules, in the article Valve automation: part-turn actuator, limit switch, function test.
Insulation as an integral part
Many SKID systems carry temperature-critical media — steam, hot water or chilled process fluids. Piping, vessels and valves inside the module are therefore often fitted with high-performance insulation before the plant leaves the works.
Because insulation jackets and pipe insulation are manufactured in our own workshop, they can be matched exactly to the individual geometry of each SKID module — an advantage over insulating later on site, where accessibility and precise fit are often limited. More on this at Isolierfabrik.com.
Industries for which SKID solutions are suitable
Modular industrial plants are used across industries:
- Chemicals and pharmaceuticals — dosing systems, CIP/SIP-capable components, high purity requirements
- Energy — compressor and steam plants, turbine peripherals
- Water and wastewater — high-pressure pumping stations, redundant pumping stations for security of supply
- Food industry — hygienic heat exchanger and filter modules
- Oil and gas — valve stands, valve stations, explosion-protected automation
From concept to a ready-to-run plant
A SKID project follows a clear pattern: recording the requirements and sizing, designing the frame and the pipe routing, manufacturing and assembling all components, wiring and control integration, a complete function test, documentation and finally transport and commissioning support on site.
Depending on size and destination, transport is by lorry, rail, ship or aircraft — Armaturenfabrik will also handle the shipping formalities on request.
Conclusion
SKID systems move the complexity of plant construction to where it can best be controlled: into the workshop. What is created there in pipe prefabrication, control technology and insulation reduces assembly time, downtime and the risk of error on site. Armaturenfabrik supplies SKID systems together with Industriefabrik Schneider GmbH as a complete system — including modification, automation and matching valves from a single source.
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