As the energy sector demands faster deployment and reduced site footprints, Nordstone has emerged as a premier engineering partner, delivering high-performance modular process systems and custom Oil & Gas skids across the UAE.
Backed by over 20 years of technical excellence, we specialize in the complete multi-disciplinary engineering, fabrication, and automation of plug-and-play process packages. From high-accuracy Lease Automatic Custody Transfer (LACT) and gas metering stations to high-pressure multi-phase separation modules and chemical injection skids, our custom-engineered packages are built to withstand extreme pressures, high temperatures, and highly corrosive sour service environments.
Every skid we manufacture undergoes strict 100% Factory Acceptance Testing (FAT) at our state-of-the-art facility to ensure rapid integration, cutting field installation timelines by 60% to 80% while upholding absolute structural integrity.
Engineered to strict API, ASME Section VIII, and ISO protocols, Nordstone modular assemblies seamlessly bridge complex upstream, midstream, and downstream operations with uncompromised field safety.
Frequently Asked Questions (FAQs)
1. What are Oil & Gas skids and modular process systems?
Oil & Gas process skids are pre-engineered, factory-assembled, and self-contained modular systems mounted within a structural steel frame. They integrate complex process equipment, piping, valves, instrumentation, and automated control systems into a single transportable unit. These systems allow major industrial unit operations to be built and fully tested off-site, serving as a plug-and-play solution that optimizes project timelines.
2. What types of Oil & Gas skids does Nordstone manufacture in the UAE?
Our extensive modular process system portfolio includes:
- Custody Transfer & Flow Metering: LACT skids, gas/liquid fiscal metering, and pipeline regulation systems. nordstonein.com
- Separation & Filtration Systems: Gas scrubbers, slug catchers, three-phase separators, and finger-type or vessel-type catchers.
- Fluid Conditioning & Processing: Fuel gas conditioning packages, chemical injection and dosing systems, and heavy oil viscosity control modules. nordstonein.com
- Water Treatment Skids: Produced water treatment systems featuring hydrocyclones, Induced Gas Flotation (IGF), and deep-bed walnut shell filters.
3. What design and engineering software tools does Nordstone use?
Our in-house engineering team utilizes advanced, industry-trusted tools for complete mechanical and process design validation. We use Aspen HYSYS and EES for comprehensive process simulations, thermal calculations, and hydraulic modeling. For structural and structural-frame safety, we perform 3D CAD modeling alongside Finite Element Analysis (FEA) via ANSYS, Computational Fluid Dynamics (CFD), and specialized pipeline surge and vibration analysis.
4. Which international design codes and certifications does Nordstone follow?
Every custom skid package is designed and stamped in full compliance with global regulatory standards:
- ASME: Section VIII Div 1 & 2 (Pressure Vessels) and B31.3 / B31.8 (Process and Transmission Piping).
- API: API 12J, API 12F, API 2350, and API MPMS (Manual of Petroleum Measurement Standards).
- Hazardous Area Standards: ATEX, IECEx, and NEC rules for explosion-proof electrical and instrument components. nordstonein.com
- Materials & Management: NACE MR0175/ISO 15156 for sour service and ISO 9001/14001/45001 quality frameworks.
5. What are the main advantages of modular process skids over traditional stick-built on-site construction?
Modular fabrication offers several major benefits over traditional field construction:
- Time Savings: Parallel processing allows site civil work and factory skid fabrication to happen concurrently.
- Cost Efficiency: Off-site construction minimizes field labor rates, camp overheads, and weather-related site delays. nordstonein.com
- Superior Quality Control: Fabrication occurs inside a highly controlled manufacturing facility under continuous QA/QC supervision. nordstonein.com
- Reduced Footprint: Specialized 3D layout optimization yields a significantly tighter structural footprint. nordstonein.com
- Rapid Deployment: Modular units arrive completely tested, reducing hazardous on-site hot work and shutdown windows. nordstonein.com
6. How much installation time can be saved by using Nordstone plug-and-play skids?
By executing all structural assembly, electrical wiring, instrument calibration, and initial pressure loops inside our factory, Nordstone modular packages routinely reduce site installation and commissioning timelines by 60% to 80% compared to traditional stick-built methods.
7. Can Nordstone build skids designed for highly corrosive and sour service (H2S) environments?
Yes. We have specialized, long-standing expertise in sour service material engineering according to NACE compliance protocols. Depending on the exact process composition, we design and manufacture skid internals and pressure loops using corrosion-resistant alloys (CRAs), including Duplex and Super Duplex stainless steels, Inconel claddings, and Hastelloy variations.
8. What automation, control, and electrical integration options are available?
Our modular process packages are delivered fully automation-ready. We provide seamlessly integrated control packages featuring local programmable logic controllers (PLCs), Human-Machine Interfaces (HMIs), or full Supervisory Control and Data Acquisition (SCADA) hooks into overarching Distributed Control Systems (DCS). These packages include built-in Emergency Shutdown (ESD) valves, fire and gas safety detection arrays, power management distributions, and dedicated continuous un-interruptible power supplies (UPS).
9. What testing procedures do your skids undergo before being shipped to site?
Every single module goes through a comprehensive Factory Acceptance Testing (FAT) protocol before dispatch. This includes:
- 100% Non-Destructive Testing (NDT) such as radiography and ultrasonic testing on critical welds.
- Hydrostatic pressure loop verification and pneumatic leak testing. nordstonein.com
- Electrical continuity, loop checks, and control logic validation.
- Full physical and mechanical operational checkouts of rotating assets and automated valves.
10. Does Nordstone offer completely custom specialized skids for unique site parameters?
Yes. When standard process footprints do not match restricted plot layouts, complex retrofits, or unusual operating parameters, our team builds custom skids completely from scratch. We integrate multiple discrete unit operations (such as combined filtration, precise blending, and chemical dosing) into single compact, multi-functional process platforms.
11. What upstream oil and gas modules do you provide?
Our upstream portfolio primarily addresses wellhead management and initial fluid conditioning. We supply wellhead production skids, robust multi-phase test separators, and high-volume produced water treatment blocks engineered to remove sands, free hydrocarbons, and chemical residuals prior to safe environmental disposal or subterranean reinjection.
12. Do you manufacture gas custody transfer and regulation stations?
Yes, gas processing and fiscal metering are central to our capabilities. We manufacture highly accurate, multi-run gas metering skids that comply with AGA standards, incorporating ultrasonic, turbine, or orifice meters paired with redundant flow computers. We also supply integrated pressure reduction and gas conditioning skids equipped with safety shut-off systems and inline pre-heaters to mitigate the Joule-Thomson cooling effect.
13. How does Nordstone optimize the layout of a modular skid system?
We execute comprehensive spatial optimization using intelligent 3D layout software. This allows our design team to arrange pressure vessels, pumps, valving manifolds, and structural steel beams to guarantee maximum ergonomic space for maintenance technicians, straightforward access to instrumentation points, and optimal Net Positive Suction Head (NPSH) parameters for pumps, all while minimizing the ultimate transport size.
14. What support documentation does Nordstone deliver with each system?
We provide an exhaustive engineering and data book with every skid package delivered. This comprehensive handover package includes certified P&IDs, as-built mechanical drawings, calculations (ASME and FEA), structural weld logs, material test certificates (MTCs), NDT validation reports, ATEX/IECEx electrical classification dossiers, FAT logs, and step-by-step installation, operation, and maintenance (IOM) manuals.
15. How can I request a quote or connect with Nordstone’s engineering team for an upcoming project in the UAE?
For targeted technical proposals, process feasibility consults, or specific manufacturing timelines for your modular skid configurations, you can submit your detailed Data Sheets, P&IDs, and tender requirements directly to our regional technical specialists through our dedicated communication channel by visiting our Contact Us page.