Design and Engineering of Process Skids
This article discusses the importance of quality design and engineering for process skid fabrication. Specifically, this article respects the value of compliance with Good Manufacturing Practices guidelines and Underwriters Laboratories requirements for UL listed panel shops.
Quality begins with expert process skid engineering and design services.
The quality level of engineering and design servicesdrives the operational efficiency, performance, and reliability of every process skid. Additionally, it aids in achieving compliance with regulatory standards and guidelines. This is especially important in highly regulated industries such as pharmaceuticals, cosmetics, and personal care products.
What is the UL 508A Industrial Control Panel Shop Program?
The UL website introduces the program in the following manner; "The UL 508A Industrial Control Panel Shop Program is part of our General Coverage Program, which offers control panel manufacturers flexibility in applying UL Certification Marks to a wide range of industrial control panel designs.
Our Industrial Control Panel Program covers multiple requirements like proper component usage, enclosure environmental ratings, wiring and motor protection, safety markings, and conformance to the National Electric Code® (NEC) and Canadian Electrical Code (CEC)."1
Understanding Modular Process Skids
Structure, Components, and Suppliers
Modular process skids are custom-fabricated units. The skid manufacturer does the in-house fabrication of the steel structure. This includes the frame, racks, rails, stairs, mezzanine, and other structural items. The fabricator adds components such as tanks, pumps, valves, piping, control panels, wiring, and metering systems made by industry-best manufacturers. Arcadia Equipment selects top-rated components that meet or exceed the unique performance specifications for each skid.
Why Quality Design and Engineering Matters
Quality design and engineering are pivotal in ensuring that modular process skids not only meet operational needs but also adhere to stringent industry standards and guidelines. The following are key aspects of quality design and engineering.
1. Regulatory Compliance
GMP guidelines require that equipment be designed, constructed, and maintained in a manner that guarantees the quality of the product being manufactured. This compliance needs extensive attention to design specifications, materials used, and overall construction quality.
GMP Guidelines: Quality Management: GMP emphasizes a robust quality management system that includes design controls ensuring that every aspect of the process skid—from design to commissioning—is meticulously documented.
Validation: All processes associated with the usage of the modular skid must be validated. This includes design validation to demonstrate that the skid will perform as intended, which is crucial in regulated environments.
Risk Management: Quality design incorporates risk assessment strategies to identify potential failures in the modular skid operations, ensuring that contingencies are in place to mitigate any risks.
2. Material Selection and Construction Quality
The choice of material grades is an important part of process skid design. Utilizing durable, non-corrosive materials and easy-to-clean materials is essential in the pharmaceutical, cosmetics, and food processing industries. High-quality construction minimizes problems caused by equipment failure and costly downtime.
Example: Stainless Steel for Process Components: Stainless steel is frequently the material of choice for modular skids in GMP-regulated industries. Its inert properties prevent contamination and its resilience prolongs the skid’s operational lifespan. Moreover, the design of joints and connections must be seamless to avoid the accumulation of bacteria, aligning with GMP requirements for hygienic manufacturing.
3. Electrical and Control Systems
Electrical systems within modular skids must adhere to UL standards to ensure safety and reliability.
UL Requirements for Electrical Panels
Safety Standards: UL establishes rigorous safety standards for electrical panels, ensuring they can withstand environmental stresses such as heat, moisture, and electrical loads.
Fail-Safe Mechanisms: The design must incorporate fail-safe mechanisms to protect both the system and operators. This may include circuit breakers and emergency shutoff controls, critical for chemical processing environments.
Control Systems Integration: Quality design integrates advanced control systems to enhance automation, offering real-time monitoring and control capabilities essential to maintaining production efficiency. Compliance with UL standards ensures these systems will operate safely under expected load conditions.
4. Traceability and Documentation: A critical aspect of quality design is the creation of thorough documentation and traceability protocols. GMP guidelines stress the importance of maintaining accurate records relating to design, materials, and maintenance activities.
Importance of Documentation
Maintenance and Reliability: Comprehensive documentation of the design and engineering considerations allows for easier maintenance and identification of potential issues, enhancing reliability and uptime in production environments.
Regulatory Audits: Our compliance inspections position our design team to establish and maintain confidence among regulators regarding adherence to GMP and safety standards.
5. Testing and Validation Procedures
Before deployment, modular process skids should undergo rigorous testing to validate performance under various operational conditions. These tests must align with GMP requirements to ensure products manufactured meet safety and efficacy standards.
Types of Testing
Performance Validation: Testing skids to ensure they meet specified performance metrics before being deployed ensures they will deliver as promised.
Functional Testing: Electrical panels must be tested under load to verify they function correctly and safely. This testing ensures that safety systems operate effectively to prevent accidents.
Compliance Testing: Validating compliance with UL and GMP standards through appropriate testing methods establishes a solid foundation for operational reliability.
Continuous Improvement and Lifecycle Considerations
Designing a modular skid is not a one-time event; it involves ongoing evaluation and improvement. Quality design and engineering incorporate feedback loops to understand performance issues and apply lessons learned to future projects.
Pre-Shipping Evaluation
We conduct quality checks and evaluations before shipping every skid. This is one of the extra steps we take to confirm that our skids arrive problem-free and ready to put into use. Additionally, the acquired knowledge from our inspection process is reintroduced to our continual internal improvement process.
Lifecycle Management
Managing the lifecycle of the modular skid—from design through decommissioning—ensures that the unit remains safe, compliant, and efficient over time. This involves regularly scheduled maintenance, scheduled upgrades, and, when necessary, decommissioning with proper disposal of material to adhere to safety and environmental regulations.
Summary and Key Takeaways
Quality design and engineering must be at the forefront of the development of modular process skids, particularly for industries governed by GMP and electrical safety standards such as UL. Emphasizing regulatory compliance, material selection, electrical safety, comprehensive documentation, and rigorous testing not only enhances operational efficiency but also ensures consumer safety and organizational reputation.
By prioritizing quality of design and engineering, a process skid manufacturer can better ensure reliability, efficiency, and top-level performance. We strongly believe that our commitment to quality serves the best interests of our customers.
Arcadia Equipment is a full-service skid manufacturer with an exceptional design and engineering team. If you have a new project in mind, reach out to us and learn what we can do for you. Call us at 770-509-1470.
CREDITS and FOOTNOTES
- 1 Staff Writer, "Industrial Control Panels and the Panel Shop Program", May 3, 2023, Available from UL Solutions
- Photo is the intellectual property of Arcadia Equipment. Image is not approved for use by third parties without expressed written approval by Arcadia Equipment.
No responses yet