When expanding or modifying an existing plant, one cost that is often overlooked is the plant turnaround needed for installing new equipment. Investing in a new plant or expanding/modifying an existing one is a complex task that requires thorough technical and economic analyses. All the benefits from new equipment, like increased capacity or performance, must be weighed against the costs of purchasing, installing, and maintaining that equipment. During installation and testing, the plant (or part of it) must be stopped, and production halted to allow for equipment installation and integration with the existing setup. The longer the downtime, the higher the associated cost.
This cost is not a direct expense but results from reduced sales volumes. Even for a new plant, installation and commissioning time impacts the overall cost as it represents a non-productive phase. The longer this phase lasts, the lower the production volumes and, consequently, the revenue for the business.
How to Reduce Installation Time and Costs with Skid Plants
An effective way to minimize installation, testing, and commissioning time is to use Granzotto’s pre-tested industrial modules, G-SKID. Skid plants are pre-assembled, pre-tested modular units that are easy to transport and quick to install at the production site.
The term “skid” refers to the sliding movement used to position the modular plant for installation. Skid plants “slide” into position, ready to function. The key difference between a skid plant and a traditional plant is the support base or structure on which the plant is mounted before installation. This allows the manufacturer to assemble and test the skid plant beforehand, significantly reducing site work time.
Skid plant design differs from traditional plant design. Each modular unit must be designed for easy and quick interconnection with the main plant, typically by grouping connections at a single point. The support base must ensure the structural integrity of the plant during transport, installation, and operation. A suitable hardware architecture for the management system is also crucial to integrate the skid unit into the complete plant and allow full testing before installation.
Why Pre-Tested Industrial Modules are Important for Quality and Safety
The reliability of the skid plant during operation is a primary concern for Granzotto. This includes stability and safety aspects, such as maintaining structural integrity despite vibrations and external stresses, as well as meeting industry quality and safety standards, like ATEX compliance in explosion-risk environments.
Additionally, sectors with strict hygiene and cleanliness requirements, like food and pharmaceuticals, need structures that prevent dirt and product residue accumulation. This can be achieved by eliminating crevices, polishing surfaces, and rigorously welding structural components.
Granzotto’s Customized G-SKID Industrial Modules: Effective Solution to Plant Turnaround
Granzotto designs and manufactures skid plants (G-SKID) for various fluid management applications, such as product recovery using PIG, CIP systems for cleaning and sanitizing equipment, heat exchange systems, and dosing and mixing systems. Granzotto’s strength lies in customizing skid units based on client needs and industry specifics, selecting the most suitable materials and structural configurations.
In summary, using skid plants simplifies site management and significantly reduces the time and costs associated with installation, testing, and commissioning.
Planning a plant expansion and want to manage downtime effectively?
A Granzotto consultant is available to help.
