PRODUCTS
Pipe Rack Module
Process Module & Pipe Rack Module Fabrication Capability
USP has extensive experience in the design, fabrication, and assembly of process modules and pipe rack modules, offering efficient and reliable modular solutions for the petrochemical, oil & gas, and chemical industries. Our modular systems integrate equipment, piping, and electrical systems within our facility, where they are fully prefabricated, tested, and shipped to site—greatly reducing on-site work, optimizing construction timelines, and lowering overall costs.
Integrated Solutions for Process and Pipe Rack Modules
Process Modules: USP provides fully integrated process modules that combine reactors, heat exchangers, pumps, piping, instrumentation, and control systems into standardized units. Each module is prefabricated and thoroughly tested in our factory to ensure seamless installation and commissioning at site. Modular construction improves safety, shortens the project schedule, and significantly reduces construction costs.
Pipe Rack Modules: Designed to support and organize piping systems, our pipe rack modules are tailored to each project and include pipe supports, cable trays, and utility corridors. They are engineered for structural stability, safety, and easy maintenance.
Key Advantages of Process Module Fabrication
Process modules are engineered by integrating steel structures and piping systems, including thermal insulation, to accelerate site construction. Modular fabrication minimizes complexity, improves safety, shortens project timelines, reduces labor and material costs, and lowers the impact of environmental conditions and jobsite emissions.
Highlights:
- Engineering Analysis: We provide calculation and comparison services to help clients assess the benefits of modular fabrication versus traditional site construction.
- Modular Integration: Modules include in-house fabrication and assembly of structural steel, piping, equipment, supports, handrails, ladders, grating, insulation systems, and heat tracing.
- Procurement & Installation: We handle procurement and installation of valves, instrumentation, and electrical systems, ensuring a fully integrated module upon delivery.
- Testing & Quality Control: Every module undergoes hydrostatic testing, pneumatic testing, function testing, and electrical testing to meet international safety and performance standards.
- Pre-Assembly & Delivery: With deep experience in field installation, USP provides full pre-assembly, packaging, and delivery solutions—allowing modules to be largely assembled at our facility to minimize on-site work.
Fabrication & Delivery Process
- Shop Drawing & Design: Our team generates accurate shop drawings using CAD, 3D modeling, and finite element analysis (FEA) to ensure every module is tailored to project specifications.
- Factory Fabrication & Full Testing: Modules are completely fabricated, assembled, integrated, and tested in-house—including functional checks, performance validation, and quality inspections—greatly enhancing consistency and reliability.
- Roll-on/Roll-off Shipping: We support RoRo transport for oversized and heavy modules, ensuring safe and efficient delivery, especially for long-distance marine shipments.
- Seamless Site Integration: Pre-tested and pre-assembled modules are delivered ready for fast, on-site integration, reducing the need for extensive fieldwork and expediting project completion.
Project Experience
- Lubrizol Zeus Project, USA
USP delivered 1,700 tons of process and pipe rack modules to Jacobs Engineering, including integrated systems with reactors, heat exchangers, pumps, and electrical controls. All modules were fully fabricated and tested in our factory, then transported via Roll-on/Roll-off to the site for quick installation. - Oyu Tolgoi Copper Mine, Mongolia
USP supplied multiple pipe rack modules to Rio Tinto for material handling and piping support at this major mining project, ensuring robust, safe, and efficient system operation. - G3 Terminal, Canada
For Kiewit, USP provided process and pipe rack modules supporting grain handling and utility systems, enabling rapid construction at this key export terminal.
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