Mastering Common Challenges in Pump Skid Design and Installation

31 October 2024

Designing and installing pump skids in industrial cooling systems is a complex task that requires precision and expertise. These systems are essential for efficient fluid transfer and pressure management, but they often come with significant challenges, from space constraints to seamless integration with existing infrastructure. We spoke with Jack Osborne, the Technical Design Graduate at Summit Process Cooling behind the design of Summit Process Cooling’s new innovative and customisable pump skids, who offers valuable insights into how Summit is leading the way in tackling common challenges with advanced engineering solutions tailored to customer needs. 

1. What are most common challenges you encounter when designing and installing pump skids?

One of the biggest challenges is space constraints. Many industrial facilities have limited space, which can prove initially difficult to fit pump skids into the available footprint. Inefficient designs and layouts can lead to higher installation costs and cause maintenance difficulties. Another challenge is integrating new skids with older systems, especially when dealing with non-standard configurations, different fitting types and existing pipework. Operational efficiency is also crucial, as pump skids need to be optimised for energy use, flow rates, and pressure requirements. Lastly, ensuring the design meets industry standards and allows easy maintenance/accessibility are all key factors we have to tackle. 

2. How does Summit Process Cooling address the issue of space constraints?

We focus on creating bespoke, customisable pump skids that fit into the specific footprints of each facility. Our engineering team collaborates closely with clients to design pump skids that maximise efficiency and utilisation without taking up unnecessary floor space. At Summit we focus on every detail as we know even small aspects can have a massive influence in improving system performance. By tailoring each skid to the unique requirements of the facility, we ensure that even with limited space, customers still get a high-performance solution without compromising operational flexibility. 

 

3. Integrating new pump skids with older systems can be tricky. How does Summit ensure a smooth process?

Integration is definitely one of the more complex aspects, especially when you're working with older equipment and existing pipework. We use advanced engineering tools and design software like SolidWorks to create detailed 3D models of the skid and how it will interface with the existing infrastructure. This precision allows us to make sure everything fits together seamlessly, minimising any potential downtime or unexpected issues during installation. It also helps us avoid costly adaptations or additional components. 

Our standard pump skid range covers a broad scope of pipe header sizes from 1-6”.  Within this standard range we offer a low or high pressure pump option, meaning our range of skids on offer can acclimate to a breadth of flow and pressure demands, making it an adaptable solution when integrating with new or old systems. This range can include single or dual pump skid configurations, inverter controlled, i.e. fixed-speed or variable-speed operations. As well as further optional extras or modifications, the design also ensures additional components can be added in the future, for example our optional inverter frame is attachable.  Whilst we offer our cost-effective standardised pump skid range, for customers that want a full bespoke solution this is not an issue. 

Jack Pump Skid Designer

4: How do you ensure that the pump skids operate as efficiently as possible for each facility? 

A: We focus on various aspects, but the key is design implementation. For instance, we ensure the pipework is designed to minimise pressure losses within the system, what type of fluid will be used, what type of componentry and position of these components will be most effective etc.  We offer a range of options that allow customers to specify exactly what they need from their pump skid.  By matching the pump skid’s capabilities to the actual requirements of the facility, we ensure optimal performance without overworking the system and consequent energy demands and moreover potential damage to the pumps.

Our selections are designed to produce the optimal flow rates so there is no risk of potential damage to the pumps, such as pump cavitation or any unnecessary wear and tear. We understand the importance of maintaining temperatures, consequently our skids are suitable for lagging.  It’s all about finding the right balance to keep operational costs down, efficiency high and maximising performance capability.  

5: Maintenance accessibility is always a concern. How do you ensure your pump skids are easy to maintain? 

A: We make maintenance accessibility a top priority in our designs. Our design team ensures all components such as binder points, drains, pressure transducers, temperature sensors, valves, pumps, strainers etc. are easy to access. This is vital for maintenance and/or commissioning purposes. As an example, our standard dual pump skids are designed to operate in a run standby configuration, which ensures the system running operation doesn't need to be stopped, this because one side can be easily isolated whilst a strainer needs emptying for example. Modular arrangements and removable features are incorporated so that maintenance is never an issue and all parts big or small can be accessed. This reduces downtime during maintenance and helps keep labour costs lower because repairs and adjustments can be done quickly and efficiently. Ultimately, it keeps the facility running smoothly. 

 

6: Adhering to industry standards is crucial in any design. How does Summit ensure compliance? 

A: We take compliance very seriously. Our engineering team stays up to date with the latest industry standards and regulations, which ensures that every pump skid we design meets the necessary safety, reliability, and performance criteria. Whether it’s ensuring compliance with standards or specific industry guidelines, we make sure all our systems are built to the highest standards. This attention to detail gives our customers peace of mind, knowing that their equipment is both safe and reliable. 

In summary, how does Summit Process Cooling lead the way in overcoming these challenges? 

We focus and can implement a wide range of solutions at Summit. Our standard range covers a great scope of flow and pressure requirements and provides a cost effective and easy to install solution to many industrial demands, within this range we offer optional extras from inverter control, flow switches, reorientation of suction and/or discharge headers to further improve adaptability. In addition to our new standard range, we offer full bespoke more customised solutions, whether this is pump skids with additional (>2) pumps, skid stacking etc. whatever you are looking for, at Summit you are not restricted. Moreover, our fabrication skillset is not limited to welded pump skids, we can also offer these in pressfit (≤2.5”).  

From addressing space constraints with bespoke designs to ensuring seamless integration with existing systems, we tailor our pump skids to meet the exact needs of each facility. Our use of advanced design tools allows us to optimise performance and ensure easy maintenance. Plus, we’re always on top of industry standards, so compliance is never an issue. At Summit, we aim to deliver pump skids that provide reliability, efficiency, and value, no matter the challenges we face. 

By leveraging advanced fabrication techniques, cutting-edge design tools, and a deep understanding of industry needs, Summit Process Cooling ensures that every pump skid delivers optimal performance, reliability, and value. Whether you are looking to upgrade your existing systems or install new ones, Summit Process Cooling has the expertise and solutions to meet your needs and exceed your expectations, get in touch today at hello@summitprocesscooling.co.uk to discuss your requirements and our solutions. 

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