Modular Skids


GPE modularizes complex process plants by dividing them into skid assemblies using latest process simulation and 3D modelling software. These individual skids are pre-assembled according to project requirements and completely tested by a comprehensive Factory Acceptance Test and then transported to the project site. ‘Plug and Play’ nature of these skids allows our customers to quickly install and commission them.

GPE modularizes complex process plants by dividing them into skid assemblies using latest process simulation and 3D modelling software. These individual skids are pre-assembled according to project requirements and completely tested by a comprehensive Factory Acceptance Test and then transported to the project site. ‘Plug and Play’ nature of these skids allows our customers to quickly install and commission them.

Deployment of robust project management and progress tracking system enables GPE to custom deliver these plants in record time. Tie-up with process experts from Europe and USA gives GPE a clear competitive edge.

Process equipment fabrication is GPE’s core competency and our shop is certified by ASME. Our procurement team can help source bought out components complying to vendor lists of almost all leading engineering consultants, process licensors and endusers. Deployment of ERP modules on SAP B1 platform enables GPE to offer complete material traceability, on time project delivery, control on engineering changes and online QAC documentation.

Strict compliance with our integrated management system covering ISO 9001, 14001 and 45001 helps us ensure consistency and superior product quality.

We offer a complete range of customized options for design and supply of modularized process plants. Customers can choose from our product and service offerings based on their scope of work, technical specifications, delivery timelines, outsourcing policies and enduser guidelines.



Process engineering

Process simulation, heat & mass balances, process flow diagrams, piping & Instrumentation diagrams, static and rotary equipment process datasheets, flare analysis, HAZOP and SIL studies, control logic and CFD reports.

Detail engineering

3D modelling, mechanical design & code calculations, thermal design, fabrication drawings, piping isometrics and stress analysis, structural analysis, cable schedules, JB allocation, instrument datasheets, valve lists, control panel wiring diagrams.

Procurement

Sourcing of raw material such as pipes, plates, flanges, fittings, structural steel and bought outs such as desiccants, process internals, valves, instruments, motors, heaters, blowers, analysers and control panels from project approved OEMs.

Fabrication

ASME U stamped pressure vessels and heat exchangers, skid piping in carbon, stainless and alloy steels with API. NACE, HIC, hydrogen service compliance. GTAW, SMAW, SAW and FCAW welding processes.

Assembly

Mock assembly of skid base frames, equipment, piping and valves, surface preparation & painting, final assembly, insulation, instrument installation, cable tray work, cable laying, termination and ferruling, tubing, clamping and tagging.

Testing

TPI stage inspection of equipment, piping and skids. Inspection of bought outs as per project ITP. Comprehensive Factory Acceptance Test covering leakage test, functional test of PLC system, actuated valves, transmitters, heater and VFD panels.

Packing and transportation

Domestic packing, export packing with phytosanitary certification, nitrogen filling, ODC consignment loading, inland transportation, containerized & break-bulk freight handling, customs clearance, insurance and destination services.

Training and commissioning

Erection supervision, integrated cold trials, pre-commissioning and commissioning services, performance trial runs, final dossier, MDR, IO&M manuals, system training for operators and maintenance personnel.

Process engineering

Process simulation, heat & mass balances, process flow diagrams, piping & Instrumentation diagrams, static and rotary equipment process datasheets, flare analysis, HAZOP and SIL studies, control logic and CFD reports.

Detail engineering

3D modelling, mechanical design & code calculations, thermal design, fabrication drawings, piping isometrics and stress analysis, structural analysis, cable schedules, JB allocation, instrument datasheets, valve lists, control panel wiring diagrams.

Procurement

Sourcing of raw material such as pipes, plates, flanges, fittings, structural steel and bought outs such as desiccants, process internals, valves, instruments, motors, heaters, blowers, analysers and control panels from project approved OEMs.

Fabrication

ASME U stamped pressure vessels and heat exchangers, skid piping in carbon, stainless and alloy steels with API. NACE, HIC, hydrogen service compliance. GTAW, SMAW, SAW and FCAW welding processes.

Assembly

Mock assembly of skid base frames, equipment, piping and valves, surface preparation & painting, final assembly, insulation, instrument installation, cable tray work, cable laying, termination and ferruling, tubing, clamping and tagging.

Testing

TPI stage inspection of equipment, piping and skids. Inspection of bought outs as per project ITP. Comprehensive Factory Acceptance Test covering leakage test, functional test of PLC system, actuated valves, transmitters, heater and VFD panels.

Packing and transportation

Domestic packing, export packing with phytosanitary certification, nitrogen filling, ODC consignment loading, inland transportation, containerized & break-bulk freight handling, customs clearance, insurance and destination services.

Training and commissioning

Erection supervision, integrated cold trials, pre-commissioning and commissioning services, performance trial runs, final dossier, MDR, IO&M manuals, system training for operators and maintenance personnel.



Modularization offers several benefits over conventional site execution such as reduction in project costs and timelines, enhanced project management, streamlined erection and commissioning activities, better stage-wise inspection and comprehensive factory acceptance testing of skid packages.

API pump skid

  • - API 610 hydrocarbon pumps
  • - 4.5 m (L) X 2.5 m (W) X 3.0 m (H), 6 Ton (Wt)

    • Clay treater skid

  • - Skid mounted jet fuel treator
  • - 6.8 m (L) X 2.5 m (W) X 5.0 m (H), 15 Ton (Wt)

    • Diaphragm compressor skid

  • - 2 Stage H2 compressor for refinery application
  • - 8.0 m (L) X 2.2 m (w) 3.3 m (H), 15 Ton (Wt)

    • Ethylene filter skid

  • - Duplex particulate filters with actuated valves
  • - 3.0 m (L) X 2.5 m (W) X 2.0 m (H), 2 Ton (Wt)

    • Heat exchanger skid

  • - TEMA R, BKU kerosene reboiler for distillation plant
  • - 5.3 m (L) X 3.3 m (W) X 3.2 m (H), 12 Ton (Wt)

    • Hot oil skid

  • - 2.2 MW electric heater for heating Dowtherm A
  • - 8.0 m (L) X 3.6 m (W) X 5.4 m (H), 30 Ton (Wt)

    • Hydrogen PSA skid

  • - Changeover skid with 29 actuated valves
  • - 6.0 m (L) X 2.2 m (W) X 2.0 m (H), 3.5 Ton (Wt)

    • Separator skid

  • - KO Drum with valves & instruments for H2 at 60 bar
  • - 2.5 m (L) X 2.2 m (w) X 3.2 m (H), 4 Ton (Wt)