Main recommendations for the design and use of modular process equipment

Modular process equipment installed on skids, such as CIP systems, bioprocessors, blowers, dryers, compressors and pumps, is becoming increasingly common. That is why we have developed the following design recommendations to help you ensure that your control systems are flexible and easy to integrate, thereby simplifying your plant maintenance.

• 1. Create interface layer
  To apply ISA S88 in an environment with many different OEM equipment units, which have their own way of handling recipes, you must create an integration layer for central control, monitoring and management of recipes and batches. Do not force the OEM supplier to customise their product according to your wishes.This creates problems with vendor support, qualification and additional costs, among others. It uses the vendor standard, but implements an integration layer to perform the specific translation of the unit procedure into the OEM equipment language using the specific interface required (OPC, XML, etc). The integration layer acts as the only interface between ISA 95 level 2 and level 3.
• 2. Skid design tips for modular process equipmentAll pipe inlets and outlets shall be self-sealing and quick-connect on one side of the skid, with a 90 degree horizontal bend (or 45 degrees if more convenient). The inlet and outlet shall be marked with an arrow that is engraved or otherwise made permanent.Valves must be accessible for removal from one side of the skid. The skid must be fully protected with a controlled interlock if doors are provided, allowing natural ventilation or directed ventilation if necessary. Provide toughened safety glass windows in which indicators or mechanical actions should be observed for verification or debugging of casual processes.
• 3. Construction of skids for modular process equipmentEnsure that the materials used in the construction of skids for modular process equipment are acceptable for the intended plant environment. Some installations will not allow wooden skids, for example, and a substitute for this must be approved well in advance.
• 4. Modular design
  The best way to design modular process equipment is to do the design at the beginning and determine the area required. In the design phase, one can do one to determine the best location fit.Although skid designs vary according to the engineer involved, the best approach is to provide a modular design so that changes can be made in the future with the least amount of effort. Modular is the best design because it allows for changing requirements.
• 5. Component-based skid design
  Create standard skids based on the most important and standard components, such as the number of diaphragms for RO units or other diaphragm systems, or based on typical blower and tank capacity.Be sure to simulate the system to determine if it will allow selection of an operating range. Work on modules placed in parallel or in series to increase capacity.
• 6. Size for container frames
  If you want modular mobile process equipment, design and choose machines that can fit inside a container frame. Some plumbing systems can be pre-engineered into the frame; install and test them in a dedicated workshop to ensure that quality standards are met.Mounts starters and controls on the wall. Installs vacuum pump/blower configuration plugs only with power supplied, allowing plug-and-play replacement of spare units.
• 7. Try before you buy
  Thoroughly inspect a demo unit before specifying and ordering. Specify parts you already have access to in the network. Drive standardisation.

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