Process Skid Fabrication and Utility Modules
Skids and Modules, Across the Full Size Range
State Service Company fabricates process skids and utility modules at a 70-acre waterfront yard in Ingleside, Texas, from single-function skids through multi-level pre-assembled units. Piping, structural steel, electrical and instrumentation are installed and tested in the yard, and completed units load out by barge.
Process Skids
Single-system packages with piping, controls and instrumentation complete.
Process Modules
Several systems integrated into one shippable, multi-level unit.
Utility Modules and PAUs
Utility, compression and treating scope off your critical path.
What We Fabricate
Process skids
A single system on one structural frame: a pump package, a compressor package, a metering run, a chemical injection unit or a treating package. Piping, controls and instrumentation are installed and functionally tested before shipment.
Process modules
Several systems integrated into one shippable unit, frequently across multiple levels, with piping, structural steel, electrical and instrumentation combined into a single lift.
Utility modules and PAUs
Pre-assembled units carrying utility, compression, treating, water or fuel gas scope. PAUs move that scope off the project critical path and out of congested site conditions.
Compression and treating packages
Skid-mounted or multi-level, with coatings and insulation complete before the unit leaves the yard.
What Ships With a Skid
- Structural frame engineered for lift, transport and field tie-in
- Piping fabricated to ASME B31.3 and B31.8, with NDT and hydrotest
- Rotating and static equipment set, aligned and grouted
- Electrical distribution, cable tray, conduit and terminations
- Instrumentation, tubing and control panel integration
- Heat tracing where lines cannot freeze or condense
- Coatings and insulation complete
- Pre-commissioning and functional testing
- Material test report and traceability documentation
Skids arrive with tie-in points defined and tested, so field work is limited to setting the unit and making the connections at its boundary.
Where a Skid Saves the Most
Scope that would otherwise be built inside an operating facility is the best candidate for a skid. Congested plots, live plants and remote locations all raise the cost of field labor and lower its productivity.
A facility of comparable scope built conventionally carries six to eight thousand people on site. State Service performs the fabrication scope with roughly 1,300 people working in the Ingleside yard, and the yard does it more efficiently than the same work performed in the field.
Size is also less constrained than it is for a truck-shipped skid. Units load out across 2,000 linear feet of bulkhead directly onto a barge, so a skid does not have to be sized around road permits, overpasses or intersections. See the yard.
Specifications
| Specification | Value |
|---|---|
| Piping codes | ASME B31.3, B31.8 |
| Structural standard | AISC |
| Testing | Hydrotest, NDT, functional and pre-commissioning testing |
| Steel bulkhead | 2,000 linear feet, load-bearing |
| Barge envelope | 125 ft x 400 ft x 22 ft |
| Minimum access water depth | 16 ft |
| Route to Gulf of Mexico | 12 miles, no vertical restrictions |
| Oversize units | Units exceeding Intracoastal limits transit offshore |
| Traceability | 100% material traceability, heat number tracked |
| Piping fabrication shop | 10,000 sq ft, 6 stations, GMAW, GTAW and FCAW |
Frequently Asked Questions
What is the difference between a process skid and a process module?
A process skid carries one system on a single structural frame. A process module carries several systems, often across multiple levels, integrated into one shippable unit. Skid describes the smaller, single-function end of the same continuum, and many buyers use skid for anything frame-mounted regardless of size.
What is a PAU?
PAU stands for pre-assembled unit. It is utility or process scope built off site as a complete module so it can be set and tied in rather than constructed in the field.
Is the skid tested before it ships?
Yes. Piping is hydrotested and inspected, and the assembled unit receives functional and pre-commissioning testing in the yard before load-out.
How large a skid can State Service build?
Larger than road transport allows, because units ship by barge. The barge envelope is 125 ft by 400 ft by 22 ft, and units exceeding Intracoastal limits transit offshore.
Can State Service work from owner-furnished equipment?
Yes. Equipment can be owner-furnished or procured by State Service as part of an EPC scope.
Let's build your next project together.