Process skid builders pre-assembling pumps, instruments, and pipework for fast on-site installation.

    Find a Skid Fabrication Provider

    Matched providers: 7

    Top countries: United Kingdom, Indonesia

    Popular technologies: Acid Dosing Systems, Aerated Lagoons, MABR

    Water Treatment Skid Fabrication: Design Standards, Materials, and Factory Acceptance Testing

    Skid fabrication for water and process treatment integrates pumps, valves, instrumentation, pipework, and control panels onto a structural steel baseframe, delivering a pre-assembled, pre-tested unit that minimises site installation time and commissioning risk. Structural design: skid base frames are designed to BS EN 1993-1-1 (Eurocode 3, structural steel) or AISC 360 for North American projects; standard structural sections (RHS, SHS, I-beams) in S275 or S355 structural steel; skid frame stiffness is designed to limit deflection during lifting (typically 1/360 of span under full process weight); lifting lugs designed and certified by chartered structural engineer (CE marked, BS EN 13155 or BS EN ISO 10855 for offshore). Piping: process pipework on skids is engineered to BS EN 13480 (metallic industrial piping) or ASME B31.3 (process piping) for ASME-code projects; pipe material selection: 316L stainless steel for pharmaceutical, food, and high-purity applications (Ra roughness less than 0.8 um for hygienic pipework, BS EN 10357 tubes, orbital welded); duplex 2205 for seawater or high-chloride service; carbon steel ASTM A106 Grade B for non-corrosive process fluids; PVC/CPVC, PVDF, or GRP for aggressive chemical service. Skid weight: typical water treatment skid 1 to 50 tonnes; offshore process skids to 500 tonnes requiring heavy-lift crane planning; transport split for road transport restricted to 4.3 m width, 27.4 m length, 4.65 m height, and 44 tonnes gross vehicle weight (UK road haulage regulations).

    Instrumentation and control integration: process control panels mounted on skid (IP54 minimum, IP65 for washdown environments; BS EN 60529); PLC selection (Siemens S7-1200/1500, Allen-Bradley CompactLogix/ControlLogix, Schneider Modicon); SCADA interface via Profibus, Profinet, Modbus TCP/IP, or OPC-UA; HMI (7 to 21-inch touchscreen, Siemens KTP or Allen-Bradley PanelView); remote access via secure 4G/5G modem or site Ethernet; IEC 62443 cybersecurity requirements for industrial control systems on water infrastructure. Instrumentation: flow meters (electromagnetic, Coriolis, or ultrasonic, to BS EN ISO 4064 or OIML R49 for custody transfer); pressure transmitters (4 to 20 mA, SIL-rated where safety function required, BS EN 61508); analytical instruments (conductivity, pH, ORP, turbidity, dissolved oxygen, chlorine residual) with 4 to 20 mA output or digital HART/Profibus; temperature sensors (PT100 class A, BS EN 60751). Electrical design: BS 7671 (IET Wiring Regulations, 18th Edition) for UK; hazardous area classification per BS EN 60079 and IECEx if process involves flammable or explosive atmospheres; ATEX equipment selection where required; motor starters (DOL, star-delta, or variable frequency drive); power distribution within skid on DIN rail with MCB, MCCB, or fuse protection.

    Factory acceptance testing and quality assurance: FAT is conducted at the fabrication facility before dispatch, using the approved ITP (Inspection and Test Plan) witnessed by the client, third-party inspector (DNV, Bureau Veritas, Lloyds Register), or end-user representative. FAT scope: dimensional check against certified GA drawing; hydrostatic pressure test of pipework (1.5 times design pressure for ASME B31.3 Category D; 1.5 times MAWP for PED-classified pressure vessels, BS EN 13480); electrical continuity and insulation resistance test; control system function test (all I/O simulated; alarm and trip testing; SCADA communication verify); instrument calibration certificates verified; paintwork inspection (DFT measurement to specified coating system; BS EN ISO 12944 corrosivity category C2 to C5M). SAT (Site Acceptance Testing): repeat key functional tests after installation on site; production water quality verified against specification; motor rotation check; flow meter verification. Typical UK skid fabricators: WABAG, Veolia, Biwater, Arvia, Fluidity (John Crane Water), Nijhuis Saur Industries (formerly Biothane), and specialist fabrication shops (Hydro X, Keytas, Process Systems).

    Frequently Asked Questions

    What standards apply to water treatment skid fabrication?

    Key standards for water treatment skid fabrication: Structural: BS EN 1993-1-1 (Eurocode 3, structural steel design); AWS D1.1 (structural welding, USA/international); DNV-OS-C401 (fabrication and testing of offshore structures). Pressure vessels: BS EN 13445 (unfired pressure vessels, EU); ASME VIII Division 1 (pressure vessels, ASME code); PED 2014/68/EU (Pressure Equipment Directive, UK retained as PSSR 2000 Pressure Systems Safety Regulations). Pipework: BS EN 13480 (metallic industrial piping); ASME B31.3 (process piping); BS EN 10357 (stainless steel tubes for food, beverage, pharmaceutical). Welding: BS EN ISO 3834 (quality requirements for fusion welding of metallic materials); BS EN ISO 15614-1 (welding procedure qualification for steel); BS EN ISO 9606-1 (qualification of welders); WRAS approval for drinking water contact materials. Electrical: BS 7671 18th Edition (IET Wiring Regulations); BS EN 60079 series (ATEX, hazardous area); IEC 62443 (cybersecurity for industrial control systems). Functional safety: IEC 61511 (safety instrumented systems, SIS) for safety-critical applications; SIL assessment (SIL 1, 2, or 3) for shutdown valves and emergency stop systems on chemical dosing or high-pressure systems. Coatings: BS EN ISO 12944 for paint systems; NACE RP 0188 for holiday testing of coatings. WRAS (Water Regulations Advisory Scheme) approval required for all wetted materials and components in contact with drinking water.

    How is a water treatment skid sized and designed?

    Water treatment skid sizing and design process: (1) Process design basis: source water quality (flow rate in m3/h, quality parameters, variability); product water quality requirement; operating hours per day and year; chemical dose requirements; backwash or regeneration flows and volumes. (2) Mass balance and hydraulic calculations: flow balances (feed, product, reject, recycle streams); sizing of pumps (Q-H curve; NPSH available vs NPSH required; BS EN ISO 9906 hydraulic performance); sizing of vessels (contact time calculation for DAF - 10 to 20 minutes; filter bed depth and EBCT for carbon contactors; membrane system flux and recovery). (3) Piping and instrument diagram (P&ID): developed to ANSI/ISA 5.1 symbols; reviewed by process engineer, instrument engineer, and control system engineer; issued as IFR (Issued for Review) then IFC (Issued for Construction) after client approval. (4) 3D modelling: Autodesk Plant 3D, AVEVA E3D, or PDMS used for skid layout; minimum clearances: 600 mm on pump seal side; 1,000 mm on valve actuator operating side; 750 mm between parallel pipe runs; headroom for overhead maintenance. (5) Structural sizing: skid weight (operating, hydro-test, and empty weights calculated); skid stiffness check; lifting lug design (4-point lift standard; 2:1 safety factor minimum on each lug at worst-case lift angle 45 degrees). (6) Design review: HAZOP for safety-critical skids; HAZOP report with action register resolved before FAT.

    What materials are used in skid pipework for water treatment?

    Skid pipework material selection for water treatment: (1) 316L stainless steel: standard for drinking water contact (BS EN 10357, smooth bore, orbital welded to Ra less than 0.8 um hygienic standard); pharmaceutical purified water and WFI systems (passivated to ASTM A380, electropolished interior); food and beverage (EHEDG guidelines; 3-A Sanitary Standards). (2) 304 stainless steel: lower-cost alternative to 316L for non-aggressive water applications; not suitable for chloride-containing water above 200 mg/L Cl- (pitting corrosion risk) or seawater service. (3) Duplex 2205 (UNS S31803): higher corrosion resistance and strength than 316L; selected for seawater, high-chloride brackish water, or sodium hypochlorite service above 2 percent concentration; 20 to 40 percent premium over 316L but eliminates stress corrosion cracking risk. (4) Carbon steel ASTM A106 Grade B / BS EN 10216-2: for service water, cooling water, and raw water where corrosion is managed by chemical treatment or internal coating; hot-dip galvanised (BS EN ISO 1461) or epoxy-coated internally for potable water contact (DWI/WRAS approved coatings). (5) PVDF (polyvinylidene fluoride): chemical resistance to acids, alkalis, and halogens; used in ozone, chlorine, and chemical dosing pipework; rated to 140 degrees C; electrofusion or butt-welded joints. (6) CPVC: lower cost than PVDF; suitable to 93 degrees C; common for chemical dosing pipework up to 200 mm diameter. (7) GRP (glass reinforced plastic, filament wound to BS EN 1120 or AWWA C950): large diameter corrosion-resistant pipework for aggressive chemical service at lower cost than metallic alternatives.

    What is a factory acceptance test for a water treatment skid?

    A factory acceptance test (FAT) is a formal, witnessed test of a water treatment skid at the fabrication facility before dispatch to site, verifying that the unit meets contract specifications, design documents, and applicable codes. FAT participants: client's project engineer and instrument/control engineer; third-party inspection body (DNV GL, Bureau Veritas, SGS, TUV) if specified in contract; equipment vendors for specialist items (membrane manufacturer, analyser supplier). FAT procedure document: issued by fabricator 4 to 6 weeks before FAT date; client review and approval; specifies each test, acceptance criterion, and hold point (HP - fabricator must wait for client sign-off before proceeding) vs witness point (WP - client should attend but fabricator may proceed if client gives written waiver). Typical FAT checks: dimensional verification (skid footprint, nozzle positions vs certified GA drawing; tolerance plus or minus 5 mm for pipework nozzles); pipe hydrostatic test (1.5 times design pressure, 30 minutes, no visible leaks; BS EN 13480 or ASME B31.3); instrument loop checks (all I/O signals verified from field instrument to PLC/SCADA; simulated signals for 4 to 20 mA transmitters; valve travel and position feedback verified); alarm and trip testing (every high/high and low/low trip function activated and PLC response verified); control logic function test (automatic sequences run through in simulation mode). FAT punch list: deficiencies categorised as A (must fix before dispatch), B (fix before SAT), or C (cosmetic, acceptable on delivery); A-items closed and re-inspected before skid shipped.

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    Skid Fabrication Companies

    Process skid builders pre-assembling pumps, instruments, and pipework for fast on-site installation.

    7 providers

    This page is a good fit if you need:

    • Acid Dosing Systems or Aerated Lagoons, MABR capabilities
    • Suppliers with accreditations sector experience
    • Providers operating in United Kingdom or Indonesia
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    How to choose a skid fabrication provider

    • Start with providers that clearly operate in your target geography and project footprint.

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    Find a Skid Fabrication Provider

    Showing 1-7 of 7

    7 results from 7 matched providers

    Ecosystems International logo

    Ecosystems International

    Verified
    Indonesia51-200 employees
    Flat Sheet Microfiltration Units · Hollow Fiber MF Systems · Ceramic Microfiltration Modules +80 more
    apac · china · europe +3 more

    PT Ecosystems International (PT ESI) was established at Jakarta on 21st November 2006. We are an industrial effluent treatment systems integrator specializing in electrocoagulation (EC), a unique waste water treatment profile. PT ESI has capabilities in designing complete waste water treatment solutions by combining various effluent treatment systems such as the electro-coagulation, biological, chemical processes and membrane filtration, offering its customers a wide and comprehensive range of solutions, tailored to suit their various needs – ranging from basic effluent treatment for discharge to effluent recycling for water reuse. The Company is experienced in handling the design, engineering, procurement, construction and operation of new Effluent Treatment Plants (“ETP”) and possesses expertise in retrofitting existing ETP to increase the flow rate and treatment capability without any major infrastructure increase PT ESI is also a premier waste water treatment service company specializing in handling waste water generated from Exploration (Drilling) and Produced Water. Customers in Indonesia include major Oil & Gas companies such as Pertamina, Exxon, Chevron, Petro-China and Medco. Operations in Indonesia are provided by both mobile and fixed units. At drill sites where waste-water recycling is required, PT ESI supplement these treatment units with skid mounted mobile Reverse Osmosis systems. The technologies and solutions employed by PT ESI are developed in-house and examples of these are its proprietary Trident™ Electro Contaminant Removal (“ECR”) system, the Stage Contaminant Removal (“SCR”) process and Mobile On-Site Waste-Water Treatment (“OWT”) units

    Reverse Osmosis (RO) Systems
    Ultrafiltration (UF) Systems
    Multi-media Filtration (MMF) Systems
    +63 more
    agriculture
    manufacturing
    FLI Precast Solutions logo

    FLI Precast Solutions

    United Kingdom

    FLI Precast Solutions (formerly FLI Carlow) provide design, engineering and manufacturing services for the off-site manufacture of specialist concrete infrastructure and attenuation systems. Our markets include Water, Wastewater, Energy and Storm Attenuation in the UK & Ireland and bespoke projects globally. SERVICES INCLUDE Design, engineering and manufacturing services for the off-site manufacture of specialist concrete infrastructure and attenuation systems. Design to national and international water industry standards and our semi-precast modular designs make us the industry leader in off-site concrete engineering and manufacture. By early involvement and integrating with our clients’ design teams we can accelerate and improve design optimisation and reduce cost. The value is in the solution, and off-site manufacturing and fabrication leads to higher efficiencies and lower risks and costs. Framework agreements enable us to add more value through collaboration, innovation, economies of scale, supply chain partnering and cost management. Our products and designs are engineered to provide solutions to many challenges facing our clients: water retention, water storage, water conveyancing, water management, water treatment, fire-resistance criteria, chemical resistance parameters, infrastructural products, retaining walls, coastal erosion, decorative walls, to name a few. We are a solutions provider using innovative off-site concrete engineering and our industry leading semi-precast modular designs. The company is part of the FLI Group which is a diversified group of companies providing environmental solutions, services and technologies to private and public sector customers in the UK, France, Ireland and throughout the world. PRODUCTS INCLUDE Service reservoirs Process settlement tanks (PST / HST / FST / etc) Storm & attenuation tanks (network or site based) Process structures (ASP / TSR / GAC / RGF / etc) MCC service foundations Bund wall system Chambers Channel & lids Comms chambers Multi-purpose chambers Bespoke culverts Holding tanks Barriers Demountable fence supports (international airport approved) Ballast blocks Dry flow channelling Foundation bases Blast fence supports

    Precast Concrete
    Concrete Works
    Industrial Pipework Services logo

    Industrial Pipework Services

    United Kingdom

    At Industrial Pipework Services, we provide bespoke engineering services. With over 25 years’ experience IPS can offer complete mechanical engineering solutions including design, manufacture & installation services. Our experienced workforce are trained to the highest standards. IPS is situated within easy access to the M4 corridor approximately 30 minutes North of Cardiff. The company embraces innovative thinking while utilising the latest technology. IPS operating base comprises of 30,000 square foot of workshops, offices and assembly areas.  The Workshops are fully segregated for the manufacture of both carbon steel and stainless-steel products and are serviced by dedicated overhead gantry cranes. With over two decades of engineering experience the company strives to combine first class engineering and design to deliver the high quality that is required.  The Company maintains a proactive approach, working closely with our Clients to achieve our collective aims for each scheme. This ambition is underpinned by an uncompromising commitment to attain the highest standards of health, safety and environmental care. IPS provides continued excellence in design, manufacturing and installation gained from many years experience within the industry. Our In-House design capability allows the company to provide a full engineering design service using the latest Auto CAD software packages. IPS offers a design service for both pipework and steelwork systems from proposal drawings to the production of as built drawings. IPS Design Office provides all relevant AutoCAD drawings for steelwork and pipework, Isometric drawings for fabrication, general layout drawings for plant and equipment and As Built drawings. Structural steelwork calculations and flow characteristics are also provided as required. IPS offer a full 3D surveying services and production of cloud point data for project modelling. IPS operates primarily within the Water Industry and provides services for both clean water and sewage. IPS is a Tier One Mechanical Engineering Specialists Provider to Dŵr Cymru Welsh Water and the Strategic Alliance. IPS operate nationally and have delivered projects throughout the UK for many Water Utility companies including Anglian Water, Thames Water and Bristol Water. Continual improvement into our infrastructure and the development of new IT systems has brought us to a level consistent with the requirements of our clients. IPS offers a complete project management service, including operation of Principal Contractor role as well as delivering turnkey projects. Experience gained in the water industry has enabled us to manage the competing demands of cost, quality and safety for all our projects.

    Networks - Water Supply
    Contractors
    ABC Stainless Ltd logo

    ABC Stainless Ltd

    United Kingdom

    ABC Stainless Ltd (formed in 1981) are a specialist stainless steel company, offering a full range of services including design, manufacture, supply, installation and commissioning to main contractors and Water Authorities, in the Water Industry. We supply a diverse range of stainless steel products to both WTW and WwTW, including our unique ‘Weldless Collar Pipe System’. This system minimises site fabrication and attendance, supplying prefabricated pipe spools for installation. We welcome enquiries relating to both sheet, plate & tube in all grades of stainless steel including exotic and aluminum, manufacturing stainless steel pipework systems (metric, schedule, dairy etc.), biogas systems, hygienic tanks, pressure & vacuum vessels, platforms, launders, pen stocks, screens, skid process units, weirs etc. DWI Approval We have ISO 9001:2008 accreditation and Drinking Water Inspectorate (DWI 56.4.516) manufacturing approval for our ‘Weldless Collar Pipe System’, and ABC Storage, Process Tanks & Vessels, this is under regulation 31(4)(a) of the Water Supply (Water Quality) regulations 2000 No.3184 & the Water Supply (Water Quality) regulations 2001(Wales) No.3911. In all cases, products are manufactured specifically for each project after full discussion with our clients and our own design office. We offer a full design & draughting service using the latest 3D modelling software. Material certification, quality plans, procedures, employee certification and testing are available upon request, with third party Insurer witness testing where required. We offer a range of material finishes including bead blast, bright (mirror) polished, satine (brushed) polished and 2B.

    Renewables & Energy Management
    Accreditations
    Amazon Filters Ltd logo

    Amazon Filters Ltd

    United Kingdom

    Founded in 1985, UK-based Amazon Filters Ltd is one of Europe’s leading manufacturers and suppliers of bespoke filtration technology such as filter cartridges and housings. Our comprehensive range of products support critical liquid and gas applications in many industries. With over 40 years of continuous support to municipal water companies, we are ideally placed to solve water quality problems with our bespoke cartridge filtration technology. From small boundary boxes installations to large volume fully containerised system and rentable mobile skids, we can manufacture and supply it all. We offer solutions for: Turbidity Control Metals Removal (iron / manganese) Cryptosporidium removal Chlorine reduction Let us support your AMP 8 commitments: Securing Long Term Resilience Securing Cost Efficiency Securing Confidence and Assurance We operate a range of ISO-accredited Quality Management Systems to ensure excellence in customer service. We provide high quality, reliable products and services that exceed client expectations. We help you worry less about the filtration process so you can focus on what you do best.

    Accreditations
    JK Fabrications Ltd logo

    JK Fabrications Ltd

    United Kingdom

    With over 30 years of experience delivering expertise in the industry, JK Fabrications Ltd has become one of the front runners and will keep challenging ourselves and others to improve our Environment as we believe that; Our Environment, is our Future. At JK Fabrications, we are an engineering company that takes pride in our family roots, with an aim to continue to successfully grow our business. Our company values are incorporated into everything we carry out and we seek to work with like-minded companies. Established in 1998, JK Fabrications specialises in efficent, effective, and environmentally sensitive solutions to the Water Treatment, Waste Water, Waste to Energy, and Pharmaceuticals Industry. With over 30 years of experience delivering expertise in the industry, JK Fabrications has become one of the front runners and will keep challenging ourselves and others to improve our Environment as we believe that ‘Our Environment, is our Future’. With the ease of access to Northern Ireland’s principal motorway network and equal distance between both Belfast Airports and Dublin Airport, JK Fabrications’ 50,000 Sq/ft premises in Newry are the perfect location to produce and deliver your project. Design We have a fully equipped in-house design team with over 65 years of combined technical, manufacturing, and sector-specific experience, that are highly skilled and trained using the very latest design software. Manufacture We have built our reputation by producing specialised products for the waste-to-energy, wastewater, water treatment, and pharmaceutical industries. Our experienced welders and fabricators along with our state-of-the-art machinery make sure that each project is carried out to a high standard. Install We have an experienced installation team with a dedicated core team of engineers, mechanical fitters, and coded welders who have over 30 years of experience in the supply and installation of our fabricated products for a wide range of projects throughout the UK and Ireland. Commission Our experienced commissioning engineers will attend the site to oversee the installation of systems, plants, and equipment. They will commission, test, and optimise the equipment as well as provide the operators with operation and maintenance manuals. Products include: Stainless Steel Pipework | Stainless Steel Vessels (inc Pressure Vessels) | Mild Steel Pipework | Lamellas | Picket Fence Thickeners | Rectangular Bridge Scrapers | Half Bridge Scrapers | Conical Settlement Tanks

    Pipeline & Pipework Products
    Accreditations
    AJ Engineering & Construction Services Ltd logo

    AJ Engineering & Construction Services Ltd

    United Kingdom

    AJ Engineering & Construction Services Ltd provide a wide spectrum of engineering services ranging from steel fabrication and CNC machining to cladding and civil engineering, with our highly experienced team we provide on-time, on-budget quality solutions. From our bases in Forres and Fort William, and a team accustomed to travel we can meet our client’s needs wherever required. Having worked on various water and wastewater treatment projects for the past 25 years we have developed a great working relationship with water companies across the UK. Our in-house capabilities allow us to offer a turnkey service to our clients from reactive maintenance and manufacturing to planned infrastructure and non-infrastructure projects. Many of the projects we undertake in the water sector are within water treatment and wastewater treatment plants where cleanliness is paramount, all our water sector site teams hold certification and Water Hygiene cards. Our range of services collated into one means that we can take on multiple discipline contracts and deliver them as one which provides our clients with a number of advantages. It removes the need to have multiple contractors on site at once. Benefits in cost savings passed down on procuring large amounts of steel for a side wide project. Little risk of dimensional discrepancies between contractors We work alongside framework delivery partners throughout the UK providing the services below; Steel portal frame buildings (design, fabrication, erection & cladding) Design, manufacture and installation of pipe bridges Design, manufacture and installation of site wide access metalwork (walkways, access stairs, ladders etc) Design, manufacture and installation of modular water buildings transportable by road. Design of various process tanks, pipework and pumps. Fabrication of tanks and pipework (stainless and carbon) Mechanical Installation Modular Treatment Buildings and Mechanical Fit-out SR2 rated steel enclosures (quicker than GRP Kiosks) We appreciate how important quality and cleanliness is in the water sector and we are proud that we have completely segregated facilities for stainless steel and carbon steel. In addition to this we are also approved under the regulations 31(4)(A) of the water supply regulations 2016 to supply stainless steel and pipework fabrications to the drinking water sector.

    Networks - Sewerage
    Asset Maintenance & Rehabilitation

    Water Treatment Skid Fabrication: Design Standards, Materials, and Factory Acceptance Testing

    Skid fabrication for water and process treatment integrates pumps, valves, instrumentation, pipework, and control panels onto a structural steel baseframe, delivering a pre-assembled, pre-tested unit that minimises site installation time and commissioning risk. Structural design: skid base frames are designed to BS EN 1993-1-1 (Eurocode 3, structural steel) or AISC 360 for North American projects; standard structural sections (RHS, SHS, I-beams) in S275 or S355 structural steel; skid frame stiffness is designed to limit deflection during lifting (typically 1/360 of span under full process weight); lifting lugs designed and certified by chartered structural engineer (CE marked, BS EN 13155 or BS EN ISO 10855 for offshore). Piping: process pipework on skids is engineered to BS EN 13480 (metallic industrial piping) or ASME B31.3 (process piping) for ASME-code projects; pipe material selection: 316L stainless steel for pharmaceutical, food, and high-purity applications (Ra roughness less than 0.8 um for hygienic pipework, BS EN 10357 tubes, orbital welded); duplex 2205 for seawater or high-chloride service; carbon steel ASTM A106 Grade B for non-corrosive process fluids; PVC/CPVC, PVDF, or GRP for aggressive chemical service. Skid weight: typical water treatment skid 1 to 50 tonnes; offshore process skids to 500 tonnes requiring heavy-lift crane planning; transport split for road transport restricted to 4.3 m width, 27.4 m length, 4.65 m height, and 44 tonnes gross vehicle weight (UK road haulage regulations).

    Instrumentation and control integration: process control panels mounted on skid (IP54 minimum, IP65 for washdown environments; BS EN 60529); PLC selection (Siemens S7-1200/1500, Allen-Bradley CompactLogix/ControlLogix, Schneider Modicon); SCADA interface via Profibus, Profinet, Modbus TCP/IP, or OPC-UA; HMI (7 to 21-inch touchscreen, Siemens KTP or Allen-Bradley PanelView); remote access via secure 4G/5G modem or site Ethernet; IEC 62443 cybersecurity requirements for industrial control systems on water infrastructure. Instrumentation: flow meters (electromagnetic, Coriolis, or ultrasonic, to BS EN ISO 4064 or OIML R49 for custody transfer); pressure transmitters (4 to 20 mA, SIL-rated where safety function required, BS EN 61508); analytical instruments (conductivity, pH, ORP, turbidity, dissolved oxygen, chlorine residual) with 4 to 20 mA output or digital HART/Profibus; temperature sensors (PT100 class A, BS EN 60751). Electrical design: BS 7671 (IET Wiring Regulations, 18th Edition) for UK; hazardous area classification per BS EN 60079 and IECEx if process involves flammable or explosive atmospheres; ATEX equipment selection where required; motor starters (DOL, star-delta, or variable frequency drive); power distribution within skid on DIN rail with MCB, MCCB, or fuse protection.

    Factory acceptance testing and quality assurance: FAT is conducted at the fabrication facility before dispatch, using the approved ITP (Inspection and Test Plan) witnessed by the client, third-party inspector (DNV, Bureau Veritas, Lloyds Register), or end-user representative. FAT scope: dimensional check against certified GA drawing; hydrostatic pressure test of pipework (1.5 times design pressure for ASME B31.3 Category D; 1.5 times MAWP for PED-classified pressure vessels, BS EN 13480); electrical continuity and insulation resistance test; control system function test (all I/O simulated; alarm and trip testing; SCADA communication verify); instrument calibration certificates verified; paintwork inspection (DFT measurement to specified coating system; BS EN ISO 12944 corrosivity category C2 to C5M). SAT (Site Acceptance Testing): repeat key functional tests after installation on site; production water quality verified against specification; motor rotation check; flow meter verification. Typical UK skid fabricators: WABAG, Veolia, Biwater, Arvia, Fluidity (John Crane Water), Nijhuis Saur Industries (formerly Biothane), and specialist fabrication shops (Hydro X, Keytas, Process Systems).

    Post your skid fabrication project — get matched proposals

    Frequently Asked Questions

    What standards apply to water treatment skid fabrication?

    Key standards for water treatment skid fabrication: Structural: BS EN 1993-1-1 (Eurocode 3, structural steel design); AWS D1.1 (structural welding, USA/international); DNV-OS-C401 (fabrication and testing of offshore structures). Pressure vessels: BS EN 13445 (unfired pressure vessels, EU); ASME VIII Division 1 (pressure vessels, ASME code); PED 2014/68/EU (Pressure Equipment Directive, UK retained as PSSR 2000 Pressure Systems Safety Regulations). Pipework: BS EN 13480 (metallic industrial piping); ASME B31.3 (process piping); BS EN 10357 (stainless steel tubes for food, beverage, pharmaceutical). Welding: BS EN ISO 3834 (quality requirements for fusion welding of metallic materials); BS EN ISO 15614-1 (welding procedure qualification for steel); BS EN ISO 9606-1 (qualification of welders); WRAS approval for drinking water contact materials. Electrical: BS 7671 18th Edition (IET Wiring Regulations); BS EN 60079 series (ATEX, hazardous area); IEC 62443 (cybersecurity for industrial control systems). Functional safety: IEC 61511 (safety instrumented systems, SIS) for safety-critical applications; SIL assessment (SIL 1, 2, or 3) for shutdown valves and emergency stop systems on chemical dosing or high-pressure systems. Coatings: BS EN ISO 12944 for paint systems; NACE RP 0188 for holiday testing of coatings. WRAS (Water Regulations Advisory Scheme) approval required for all wetted materials and components in contact with drinking water.

    How is a water treatment skid sized and designed?

    Water treatment skid sizing and design process: (1) Process design basis: source water quality (flow rate in m3/h, quality parameters, variability); product water quality requirement; operating hours per day and year; chemical dose requirements; backwash or regeneration flows and volumes. (2) Mass balance and hydraulic calculations: flow balances (feed, product, reject, recycle streams); sizing of pumps (Q-H curve; NPSH available vs NPSH required; BS EN ISO 9906 hydraulic performance); sizing of vessels (contact time calculation for DAF - 10 to 20 minutes; filter bed depth and EBCT for carbon contactors; membrane system flux and recovery). (3) Piping and instrument diagram (P&ID): developed to ANSI/ISA 5.1 symbols; reviewed by process engineer, instrument engineer, and control system engineer; issued as IFR (Issued for Review) then IFC (Issued for Construction) after client approval. (4) 3D modelling: Autodesk Plant 3D, AVEVA E3D, or PDMS used for skid layout; minimum clearances: 600 mm on pump seal side; 1,000 mm on valve actuator operating side; 750 mm between parallel pipe runs; headroom for overhead maintenance. (5) Structural sizing: skid weight (operating, hydro-test, and empty weights calculated); skid stiffness check; lifting lug design (4-point lift standard; 2:1 safety factor minimum on each lug at worst-case lift angle 45 degrees). (6) Design review: HAZOP for safety-critical skids; HAZOP report with action register resolved before FAT.

    What materials are used in skid pipework for water treatment?

    Skid pipework material selection for water treatment: (1) 316L stainless steel: standard for drinking water contact (BS EN 10357, smooth bore, orbital welded to Ra less than 0.8 um hygienic standard); pharmaceutical purified water and WFI systems (passivated to ASTM A380, electropolished interior); food and beverage (EHEDG guidelines; 3-A Sanitary Standards). (2) 304 stainless steel: lower-cost alternative to 316L for non-aggressive water applications; not suitable for chloride-containing water above 200 mg/L Cl- (pitting corrosion risk) or seawater service. (3) Duplex 2205 (UNS S31803): higher corrosion resistance and strength than 316L; selected for seawater, high-chloride brackish water, or sodium hypochlorite service above 2 percent concentration; 20 to 40 percent premium over 316L but eliminates stress corrosion cracking risk. (4) Carbon steel ASTM A106 Grade B / BS EN 10216-2: for service water, cooling water, and raw water where corrosion is managed by chemical treatment or internal coating; hot-dip galvanised (BS EN ISO 1461) or epoxy-coated internally for potable water contact (DWI/WRAS approved coatings). (5) PVDF (polyvinylidene fluoride): chemical resistance to acids, alkalis, and halogens; used in ozone, chlorine, and chemical dosing pipework; rated to 140 degrees C; electrofusion or butt-welded joints. (6) CPVC: lower cost than PVDF; suitable to 93 degrees C; common for chemical dosing pipework up to 200 mm diameter. (7) GRP (glass reinforced plastic, filament wound to BS EN 1120 or AWWA C950): large diameter corrosion-resistant pipework for aggressive chemical service at lower cost than metallic alternatives.

    What is a factory acceptance test for a water treatment skid?

    A factory acceptance test (FAT) is a formal, witnessed test of a water treatment skid at the fabrication facility before dispatch to site, verifying that the unit meets contract specifications, design documents, and applicable codes. FAT participants: client's project engineer and instrument/control engineer; third-party inspection body (DNV GL, Bureau Veritas, SGS, TUV) if specified in contract; equipment vendors for specialist items (membrane manufacturer, analyser supplier). FAT procedure document: issued by fabricator 4 to 6 weeks before FAT date; client review and approval; specifies each test, acceptance criterion, and hold point (HP - fabricator must wait for client sign-off before proceeding) vs witness point (WP - client should attend but fabricator may proceed if client gives written waiver). Typical FAT checks: dimensional verification (skid footprint, nozzle positions vs certified GA drawing; tolerance plus or minus 5 mm for pipework nozzles); pipe hydrostatic test (1.5 times design pressure, 30 minutes, no visible leaks; BS EN 13480 or ASME B31.3); instrument loop checks (all I/O signals verified from field instrument to PLC/SCADA; simulated signals for 4 to 20 mA transmitters; valve travel and position feedback verified); alarm and trip testing (every high/high and low/low trip function activated and PLC response verified); control logic function test (automatic sequences run through in simulation mode). FAT punch list: deficiencies categorised as A (must fix before dispatch), B (fix before SAT), or C (cosmetic, acceptable on delivery); A-items closed and re-inspected before skid shipped.

    Case Study·Pharmaceutical manufacturing
    Challenge

    A sterile injectables manufacturer in Staffordshire required a replacement purified water skid to BS EN 13480 hygienic standard within a 14-week programme to avoid a planned line shutdown overrun. The previous skid was carbon steel with polyethylene liners that had failed a DWI extraction test, prompting a compliance notice from their site quality team ahead of an MHRA inspection.

    Approach

    A specialist skid fabricator delivered a 316L stainless steel, orbital-welded, double-pass RO plus continuous electrodeionisation (CEDI) skid with Ra less than 0.8 um electropolished wetted surfaces. The P&ID was issued for HAZOP review at week two; FAT was completed at the fabricator's Coventry facility at week 10 using simulated SCADA I/O and witnessed by the client's QA manager and a Lloyds Register inspector. All A-category punch items were closed within 48 hours of FAT.

    Outcome

    The skid was delivered and installed on time in week 13 and passed SAT (site acceptance test) including a 72-hour production water quality verification run showing conductivity 0.08 uS/cm and TOC 28 ppb, well within USP Purified Water limits. The MHRA inspection found the installation compliant with GAMP5 documentation requirements. Total skid supply cost was GBP 285,000 against a project budget of GBP 310,000.

    Questions to Ask Shortlisted Providers

    1. 1

      What welding qualification records and weld procedure specifications (WPS) will you provide for all process pipework joints?

      For pharmaceutical and food-grade 316L pipework, BS EN ISO 9606-1 welder qualification and BS EN ISO 15614-1 WPS are mandatory; without them, the skid will fail MHRA or FDA inspection.

    2. 2

      Is the control system designed to IEC 62443 security levels and does the SCADA interface use an OPC-UA encrypted protocol?

      Water infrastructure skids connecting to plant SCADA must comply with NIS Regulations 2018 cybersecurity obligations; an insecure OPC-DA legacy connection will trigger a corrective action during an OT security audit.

    3. 3

      How is the skid hydrostatic test pressure determined and will you provide a traceable pressure gauge calibration certificate?

      BS EN 13480 requires 1.5 times maximum allowable operating pressure; using an uncalibrated gauge invalidates the test certificate and creates a PSSR 2000 compliance gap.

    4. 4

      What is your minimum order value for WRAS-approved wetted component substitutions and how do you handle late specification changes?

      WRAS substitutions midway through fabrication trigger a re-extraction test and can add 4 to 6 weeks to the programme; the contract must clarify who bears this cost and time.

    5. 5

      Will you provide as-built documentation including a final updated P&ID, instrument calibration certificates, and ATEX declarations of conformity as part of the delivery package?

      Without a complete as-built dossier, the client cannot fulfil CDM 2015 Health and Safety File obligations or complete PSSR written scheme of examination for the skid's pressure vessels.

    What Drives Cost in This Category

    Material specification and alloy grade

    Upgrading from 304 to 316L stainless for chloride-containing water service adds 15 to 25 percent to pipework material cost; specifying duplex 2205 for seawater service doubles the pipework material cost versus 316L.

    Hygienic finish and orbital welding

    Orbital welded, internally electropolished pipework (Ra less than 0.8 um) for pharmaceutical applications costs 40 to 60 percent more than standard manual-welded carbon steel pipework; this is non-negotiable for USP Purified Water compliance.

    Control system complexity and safety integrity level

    A simple PLC with standalone HMI costs GBP 15,000 to 30,000; a SIL 2-rated safety instrumented system with dual-redundant PLCs, remote SCADA, and IEC 62443 cybersecurity architecture costs GBP 80,000 to 200,000 for a medium-complexity process skid.

    Third-party inspection and FAT witnessing

    A Lloyds Register or Bureau Veritas FAT witness adds GBP 3,000 to 8,000 in inspection fees plus travel; radiographic weld examination (RT, 10 percent spot check) adds GBP 2,000 to 6,000 for a medium-size skid.

    Key Regulations & Standards

    PSSR 2000 (Pressure Systems Safety Regulations)

    Water treatment skids containing pressure vessels above the Article 4 PED threshold must have a written scheme of examination (WSE) prepared by a competent person before the skid is brought into use; WSE defines inspection intervals and maximum allowable working pressure.

    WRAS Approval for Drinking Water Contact

    All wetted materials and components on skids producing water for human consumption must be WRAS-approved (BS 6920 extraction test); WRAS approval is a material-specific and product-specific certification, not a company-level approval.

    BS EN ISO 9606-1 Welder Qualification

    All fusion welds on process pipework must be made by welders qualified to BS EN ISO 9606-1; welder qualification certificates must be current (typically 2-year renewal with ongoing production test) and provided in the FAT documentation package.

    ATEX Directive (Equipment and Protective Systems Regulations 2016)

    Skids installed in ATEX Zone 1 or Zone 2 classified areas (chemical dosing rooms, biogas handling) must use ATEX-rated electrical equipment (Category 2G or 3G); ATEX declarations of conformity for each item must be included in the as-built dossier.

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