Compact Skid Mounted Vertical High Speed Process Pump Modular Plug and Play
Skid Mounted Process Pump
,Vertical High Speed Centrifugal
,Modular Plug Play Pump
Product Description
Our skid mounted pump program originated from a 2016 project where a Southeast Asian refinery requested a completely factory-integrated chemical injection pump package that could be installed and commissioned within a single 12-hour shift during a planned unit turnaround. The project's schedule constraint—installation during a 48-hour total turnaround window with only one 12-hour shift allocated for pump installation—necessitated a fundamental rethinking of our traditional pump delivery approach.
The resulting compact skid mounted vertical high speed process pump package, factory-assembled and string-tested before shipment, was positioned, connected, and commissioned in 7 hours, contributing to the refinery's successful achievement of their turnaround schedule. This practical demonstration of the skid-mounted concept's value led to the formal development of our modular plug-and-play pump product line, which has now been adopted for over 80 installations in chemical dosing, fuel gas conditioning, seal flush, and utility water services.
Every skid mounted pump package is assembled, aligned, and tested as a complete system in our factory integration bay before shipment. The factory acceptance test replicates site operating conditions as closely as possible within our test facility capabilities, including mechanical running tests, seal support system verification, functional testing of all instrumentation loops, and a 4-hour uninterrupted run with comprehensive data recording.
| Parameter | Specification | Factory Verification |
|---|---|---|
| Package Configuration | Single-Lift Skid-Mounted Assembly | Certified lift test with weight report |
| Pump Type | API 610 12th Ed., OH6 Vertical Integrally Geared | Performance test per API 610 |
| Maximum Flow Rate | 57 m³/h (250 GPM) | Magnetic flow meter, calibration cert |
| Maximum Differential Head | 442 m (1,450 ft) | Pressure transmitters, deadweight-tested |
| Motor Power Range | 15 to 56 kW (20 to 75 HP) | Motor solo-run test certificate |
| Skid Footprint (Typical) | 1.2 m * 2.4 m (4 ft * 8 ft) | As-built dimensional report |
| Seal System | Integral API 682 Cartridge, Plan per Service | Seal air test, system function check |
| Instrumentation | Pressure, Temperature, Vibration, Level | Loop check, calibration certs |
| Control Interface | Local Panel with Dry Contacts for DCS | I/O point-to-point continuity test |
| Surface Treatment | SA 2.5 Blast, Multi-Coat Paint System | DFT measurement, adhesion test |
| Documentation | Full FAT Report + As-Built Drawings | Issued within 2 weeks of FAT completion |
- Complete Factory Acceptance Testing: Based on our experience with commissioning support at client sites worldwide, we have developed a comprehensive FAT protocol that aims to identify and resolve every potential issue in our factory rather than at the client's site. The FAT program includes pre-test inspection, solo motor run, coupled mechanical run, hydraulic performance test, seal support system functional test, instrumentation loop check, and post-test inspection.
- Single-Point Responsibility Supply Chain: Our integrated skid approach addresses client frustration by taking single-point responsibility for the complete package: pump, motor, coupling, seal system, instrumentation, control panel, baseplate, piping, valves, and wiring. This eliminates traditional site coordination challenges and provides one point of contact for all warranty and aftermarket support.
- Standardized Maintenance Across Multiple Units: For clients installing multiple skid mounted pump packages, we apply a standardization philosophy that significantly reduces maintenance complexity. All pumps within a client's fleet share common seal cartridge types, bearing sizes, and identical lubrication oil specifications, simplifying operator training and reducing procedural errors.
- Rapid Deployment Engineering: Our skid mounted plug-and-play pump package reduces total site installation duration from the industry-typical 3-5 days to typically 4-8 hours. For each project, we provide detailed site installation procedures with estimated craft hours by discipline, enabling accurate scheduling within project timelines.
This has occurred on approximately 3% of our skid mounted pump FATs based on our quality records, and we have a defined corrective action process that we follow transparently. If the measured performance deviates from the guaranteed values by more than the test instrument uncertainty allowance, we stop the test and perform a structured troubleshooting investigation. The corrective action, re-test, and final results are documented in the FAT report. We do not ship a pump that has not demonstrated its guaranteed performance on our test stand.
Control system integration is addressed during the order engineering phase, not during site commissioning when schedule pressure is highest. We request the client's control system interface specification during the engineering review within 4 weeks of order acceptance. Our local control panel is configured to match these interface requirements, with all terminals labeled per the client's cable schedule. During FAT, we simulate DCS commands and verify all feedback signals using a test box that mimics the client's control system inputs.
Yes, and this is one of the operational advantages our clients have identified from the skid-mounted approach. The entire pump package remains a self-contained, single-lift assembly throughout its operational life. We have documented cases where clients have relocated skid mounted pump packages to different process units during plant reconfigurations, with the relocation completed during a normal maintenance window without requiring civil or structural modifications.
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