Pilot Plant: Where Ideas Take Shape & Scale
We bring our over three and a half decades of technical expertise, operational efficiency, and process integration knowledge to the pilot plant business. By leveraging our core competencies in piping design, fabrication, and systems integration, Dee Piping can deliver highly customized, cost-effective, and scalable pilot plant solutions, meeting the evolving needs of industries focused on innovation and sustainability. We are focused to align with the industry trends like Advanced Manufacturing, Green Chemistry, Renewable Energy which are driving demand for pilot plants. We are already equipped to handle complex systems & well positioned to capitalize on these emerging opportunities.
Pilot Plant/s plays a critical role in the chemical industry because they serve as an intermediate stage between laboratory-scale research and full-scale industrial production. Pilot Plant ensures Process Validation and Optimization, Risk Mitigation, Cost and Resource Efficiency, Regulatory and Safety Testing, Product Quality Assurance, Technology Demonstration, Training and Skill Development, Flexibility for Innovation. Hence the Pilot Plant/s are "The Gateway from R&D to ROI".
The industry is changing in several ways & expected a sustainable growth. Order to meet these fast-changing industry & their sectors, Skid & Modular pilot plant/s based businesses can gain a competitive edge through speed, flexibility, and cost efficiency, making them a forward-thinking choice in many industrial scenarios.
The main reason for this development includes system integrity flow characteristics, efficient power utilization and reduce turbulence, maintenance, and “Lifetime” costs.
Advantages of Skids & Modular Pilot Plants
1. Mobility and Compactness:
- Skid-mounted plants are built on a steel frame or "skid," which makes them portable. They can be easily transported to different locations for testing or operations.
- Modular plants are designed as smaller, self-contained units, which can be shipped and assembled quickly at the site.
- This makes them ideal for companies with multiple facilities or for remote locations where on-site construction is difficult.
2. Faster Deployment:
- Modular and skid-mounted plants are usually pre-fabricated and pre-assembled in a controlled environment, reducing on-site installation time and costs significantly.
- This approach often leads to faster project timelines compared to traditional pilot plants, which typically require custom-built structures and extensive site preparation.
3. Cost Efficiency:
- Pre-fabrication reduces labour costs and minimizes on-site construction expenses.
- Standardized designs can lower engineering costs, especially if modular units are reused or adapted for similar applications.
4. Flexibility and Scalability:
- Modular designs allow for easier upgrades or modifications. Additional modules can be added to increase capacity or functionality without major overhauls.
- Skid & Modular designs are particularly beneficial for R&D and pilot studies, where design flexibility is critical to accommodate experimental setups.
5. Ease of Maintenance and Safety:
- Components are often more accessible in a modular setup, simplifying maintenance tasks.
- Pre-engineered systems can be built with enhanced safety features, often adhering to strict industry standards.
6. Quality Control:
- Construction in a controlled factory environment ensures higher quality and reliability compared to on-site construction, which may be affected by weather, workforce variability, or other factors.
If requirements align with these strengths, skid-mounted or modular pilot plants are excellent options. However traditional pilot plants may still be preferable for highly specialized or large-scale operations where customization outweighs modularity benefits. Dee Piping is capable of handling all kinds of projects Skid-mounted, Modular or highly specialised projects.
Comprehensive Pilot Plant Services for Efficient and Scalable Solutions
Our specialized pilot plant services are designed to deliver end-to-end solutions, combining cutting-edge technology, precision engineering, and seamless integration. We ensure our pilot plant project is optimized for performance, scalability, and cost-effectiveness. Here’s how we support this journey:
1. Basic Design and Engineering Package (BDEP)
The foundation of any successful pilot plant project is a robust conceptual design. Our BDEP service provides:
- Process Flow Diagrams (PFDs): Defining the process layout, flow paths, and key operating conditions.
- Material and Energy Balances: Accurate calculations to optimize energy use and resource efficiency.
- Preliminary Equipment Sizing: Initial specifications for equipment based on process requirements.
- Feasibility Analysis: Ensuring the proposed design aligns with your technical and economic objectives.
2. 3D Modelling and Simulation
3D modelling and simulation services bring the pilot plant to life before construction begins. This ensures:
- Visualization: Realistic, high-resolution 3D models to visualize plant layout and space utilization.
- Process Simulation: Simulating operational scenarios to identify potential bottlenecks and optimize performance.
- Interference Checks: Detecting and resolving clashes between components and piping for seamless installation.
- Virtual Testing: Allowing for virtual commissioning to verify processes under various conditions.
3. Detailed Engineering
Once the conceptual design is approved, we move into the detailed engineering phase to create comprehensive designs for fabrication and assembly. Our services include:
- Piping and Instrumentation Diagrams (P&IDs): Detailed diagrams for all process control and instrumentation systems.
- Equipment Specifications: Precise technical specifications for all equipment, materials, and components.
- Structural Engineering: Detailed layouts for skids, platforms, and structural supports.
- Electrical and Instrumentation Design: Comprehensive wiring diagrams and control system schematics.
4. Fabrication and Installation
We ensure seamless transition from design to implementation with high-quality fabrication and precise installation services:
- Skid-Mounted Systems: Modular fabrication of compact, transportable pilot plants.
- On-Site Installation: Expert engineers & technicians ensure efficient assembly and integration of the pilot plant at the facility.
- Quality Assurance: All fabrication and installation are rigorously tested to meet industry standards.
- Startup Support: Assistance with commissioning and startup to ensure smooth operation.
5. Control Systems
Modern pilot plants rely on advanced control systems for accuracy and reliability. We include:
- Instrumentation Integration: Installation and calibration of sensors, transmitters, and control valves.
- Advanced Control Systems: Configuring systems for real-time monitoring and control of critical parameters.
- Safety Systems: Design and integration of emergency shutdown systems (ESD) for safe operations.
6. PLC/SCADA for Full Integration
To achieve fully automated and integrated pilot plant operations, we provide:
- Programmable Logic Controllers (PLC): Tailored PLC programming for precise control of equipment and processes.
- Supervisory Control and Data Acquisition (SCADA): Real-time visualization, data logging, and remote monitoring for comprehensive process oversight.
- System Integration: Seamless integration of PLC/SCADA with existing IT infrastructure.
- Customised Integrated systems: Intuitive interfaces for operators to monitor and control plant performance efficiently.
