The Complete Guide to Packaged Skid Water Heating Systems
Packaged skid water heating systems are complete thermal solutions mounted on a base (called a skid) for ease of transport and mobility within a manufacturing facility, or to tie in multiple processes that require a larger heat load. They typically consist of electric heaters, pumps, piping, valves, sensors (flow/temp. limits), and controls. Packaged skid systems are turnkey ready for final plumbing and electrical hook-up from source supply. They range greatly in size, configuration (vertical/horizontal), and complexity, from single water heater units to larger multi-water heater systems with redundancy assemblies.
Packaged Skids vs Traditional Approaches
Packaged skids designs are a more comprehensive solution than a piece-by-piece approach. They provide one-source supply, maximize process installation, and provide a single system and supplier for warranties and spare parts.
The key differentiator is that most of the heavy lifting is done at the factory. The process starts with the buyer stating their needs, and the manufacturer configures and builds the solution. Instead of a mechanical contractor doing much of the work on-site, the manufacturer builds, pipes, wires, and tests the system in a controlled environment. The finished skid arrives on the job site ready for plumbing and electrical hookups. It can be easily placed, fitted, and often rotated for different processes once in the plant.
Key System Components
While configurations will vary by application, most systems include the following components:
Electric/steam-fired water heaters - instantaneous, storage type, heat pump, and/or tankless
Circulating pumps - required to move heated water through the loop
Piping and headers - pre-fabricated and pressure-tested at the factory
Valves - isolation, check, and balancing valves for system control
Controls - required for temperature setpoints, flow, redundant safety limits, and remote monitoring. Many systems are configured with specific hardware or software to tie into existing process systems
Expansion tanks and air separators - manage system pressure and eliminate trapped air
Steel base - this is the "skid" itself, engineered for lifting and anchoring
Types and Configurations
Packaged skid industrial water heating systems are not a one-size-fits-all solution. Each one is customized to the user’s requirements. Configurations or key considerations are as follows:
Single-Water Heater – these are usually smaller and simpler setups that consist of one water heater, one set of pumps, and one control panel used for a single purpose, such as one building or a less demanding production line.
Multi-Water Heater – these are larger, more complex systems that contain at least two water heaters and multiple pumps. Control options will vary based on use. These systems often have built-in redundancy and may be broken into multiple skids.
Fuel Type – one key to a successful installation is to accommodate the current fuel supply. Hubbell packaged skid systems can accommodate electric and steam.
When To Choose Packaged Skid Water Heating Systems
Several benefits of this modular approach are fueling its popularity. These include:
Faster Installation – most or all the fabrication happens off-site, allowing for much quicker and more efficient installation.
Reduced On-Site Labor – while skilled labor is required for the final connections, less labor is needed overall to get a packaged skid system online. This means fewer third-party technicians are required. It also allows operators to maximize their in-house mechanical and other resources.
Quality Control - rather than leave the assembly and other tasks to multiple personnel or trades, heating system manufacturers will build and test heating systems under tightly controlled quality processes.
Compact Footprint – space is always at a premium, whether it’s manufacturing floor space, mechanical rooms, or limited space in boats. Packaged skid systems are compact and typically take less overall space than conventional systems.
Easier Commissioning – flipping the switch on initial startup is always a tense moment. Since these systems arrive pre-wired and pre-tested, there’s a significantly greater likelihood of a successful startup.
While packaged skid water heating solutions come with a long list of benefits, there are a few drawbacks worth mentioning. They are more expensive to build upfront, and most designs are custom to each process, so working with engineering can extend initial installation lead times. While not impossible, changes after design/fabrication can be more challenging. However, for most needs, these drawbacks are outweighed by the many benefits, especially with careful consideration and planning before building and shipping.
Typical Applications
Operators can use packaged skid systems in an extensive range of applications and industries. Their combination of speed, reliability, and quality makes them ideal for any use that requires dependable heating without the complexities of a field-built solution. Below are several common ones, but this is by no means a complete list:
- Marine/Maritime: naval fleets, ships/barges, FLNG (transfer systems), tankers
- Aquatic/Rec Facilities: neutral buoyancy labs, wet trainer (welding, Military), water parks
- Manufacturing: industrial processing and testing facilities, ex. calendar rolls, thermal fluid transfer
- Oil/Gas: offshore rigs, fracking, liquid terminals, transfer stations, drill testing, freeze protection, viscosity reduction
- Healthcare: hospitals, laboratories, medical device sanitation/cleaning, healthcare campuses
- Commercial, Government and Municipal Buildings: hot water demand, boiler feed, steam generation/processing, food service
Conclusion
Demand for packaged skid water heating systems continues to grow, and for good reason. Shifting the bulk of the labor away from the field and onto the complete-source manufacturing company brings increased efficiency and reliability. No two applications are exactly alike. Packaged skid systems offer greater flexibility and are designed and built with that in mind.
For organizations planning on a new or replacement commercial/industrial water heating solution, this approach is well worth consideration. We’ll leave you with one key tip. Be sure to bring an experienced manufacturer into the process at the early stages. This is the best way to ensure you are building the most efficient system that can deliver the many benefits that packaged skid water heating systems provide.
Considering a skid-mounted water heating system? Hubbell specializes in designing and building custom skids to meet any need, no matter how simple or complex. Please reach out to us with your detailed requirements to begin the conversation, or click here to learn more.