Biotech Modules Superskid represents a notable challenge from an engineering point of view. The Modular Approach requires to envision the whole plant as a structure of big building blocks. When the plant is disassembled, you will not disassemble and separate each component but the building blocks – aka the modules. Thus, each module has to be designed baring in mind it has to be organized as standalone sub-systems (a skid), where multiple components will be collocated on and it should be easily disconnected and reconnected with other modules to be operative at customer’s site.

Modular Approach is not always applicable, but it is recommended for large plants. The benefits of this method are several, as the reduction of field activities, re-works, commissioning and on-site tests; a shorter project schedule; a faster response to inconveniences. The result is a substantial cost control.

The giant plant for media and buffer is composed of two macro areas – that correspond to two different rooms at customer’s site, subdivided into 18 modules. The Buffer Room is designed to position three Buffer Hold Tanks, 15.000 L each; the Media Preparation Room two Media Prep Tank, 10.000 L each. 

The geometry of the process led to concentrate process equipment just on the upper and lower parts of the plant, in this way the operator has easy access to process equipment on lids. Also, the middle part is the one with the greatest handling complexity, therefore process equipment is more likely to be damaged. The shell frame in fact hangs and encloses the tank, allowing horizontal positioning for easier transportation. 

Lastly, to reduce operator’s intervention time, the transfer panel applies normally closed valves, which block flows allowing to work safely. In fact, valves are usually in a different grade room and the operator can avoid undressing and dressing multiple times just to take action on the valves.