Modular Transportable System For SAGD Process

Abstract

A transportable modular process for exploiting a remote heavy oil resource or the like using steam assisted gravity drainage technology or the like. Said process comprising transportable preassembled and commissioned modules which when interconnected adjacent said remote heavy oil resource provide the ability to exploit said heavy oil resource or the like. Each module being preassembled and commissioned at the time of manufacture with the necessary piping and electrical wiring and other essential equipment for each module prior to being transported to adjacent the resource. Each module being, when transported to adjacent said resource, able to be readily interconnected with other process modules to enable an entire SAGD process or the like to be constructed adjacent said resource.

1 . A transportable modular process for exploiting a remote heavy oil resource or the like using steam assisted gravity drainage technology or the like;
 said process comprising transportable preassembled and commissioned modules which when interconnected adjacent said remote heavy oil resource provide the ability to exploit said heavy oil resource or the like; each module being preassembled and commissioned at the time of manufacture with the necessary piping and electrical wiring and other essential equipment for each module prior to being transported to adjacent the resource,   each module being, when transported to adjacent said resource, able to be readily interconnected with other process modules to enable an entire SAGD process or the like to be constructed adjacent said resource,   wherein once said resource is depleted said modular process may be disassembled and transported to a different remote resource, and subsequently reassembled at said different remote resource in the same manner;   wherein said process comprises several transportable modules selected from the following group of modules:
 oil and water separation modules; 
 flash cooling of produced water rather than the conventional heat exchanger or the like; 
 Vapor Recovery Unit (VRU) Ejector and fuel gas system modules; 
 compact evaporator with an external demister or other evaporators available on the market and modified where necessary; 
 cooling system modules (for example glycol cooling system); 
 boiler feed water storage/supply and chemical addition modules; 
 boiler modules; 
 power Generation modules; 
   and once selected, transported, assembled and securely interconnected, providing a complete SAGD process or the like for exploiting said remote resource.   
     
     
         2 . A transportable modular system for hydrocarbon extraction using a SAGD Process, said system comprising the following interconnected modules assembled into said process at a desired site, but each module being commissioned where constructed prior to being transported:
 a) module  1  comprising inlet coolers, an inlet separator, a de-sand unit, and Free Water Knock-Out and Oil Treating vessels;   b) module  2  comprising of an Induced Gas Floatation Unit, distillate tank and Dilbit cooler;   c) module  3  comprising the evaporator exchanger;   d) module  4  comprising an evaporator compressor, evaporator recirculation pumps and chemical addition machinery;   e) module  5  comprising boiler feed water pumps, instrument air systems and electrical systems;   f) module  6  comprising a boiler;   g) module  7  comprising power generation and a Heat Recovery Steam Generator;   h) module  8  comprising a glycol cooler or other cooling system;   i) module  9  comprising a flash drum, flash drum condenser, and dump condenser;   j) module  10  comprising a glycol expansion drum, fuel gas drum, and additional heat exchangers;   
       wherein said modules or the like being assembled and interconnected into said process by the provision of the boundaries of said modules being adapted to be securely connected by mechanical means, and by connecting electrical lines and piping runs extending from module to module. 
     
     
         3 . The modular system of  claim 1  or  2  wherein said modules are interconnected and once this is done further comprising the necessary piping and tubing, fastening means, electrical lines and sets of controllers required for the operation of the modular process/system. 
     
     
         4 . The modular process of  claim 1  or  2  wherein at least one of the said modules is selected from the following list of modules:
 a) third party evaporator modified to incorporate KemeX weir and a set of controllers; and/or 
 b) compact evaporator with an external compressor suction drum; and/or 
 c) VRU Ejectors; and/or; 
 d) flash cooling system for produced water as opposed to conventional heat exchanger. 
 
     
     
         5 . A method of transporting a SAGD process or the like to a remote hydrocarbon reservoir comprising:
 defining modules which collectively substantially make up the process when assembled together to substantially form said process including preferably modules  1  to  10  of  claim 2 ,   constructing said modules adapted to be fitted on a tractor trailer, rail car, barge or the like,   transporting said modules to the remote location using trucks or other suitable means of transportation,   assembly of said modules at the remote location into said SAGD process or the like, for extraction of hydrocarbons using the SAGD process at the remote location.   
     
     
         6 . A method of constructing a modular transportable SAGD system comprising modules of  claim 1  or  2  comprising:
 a) defining modules which when assembled collectively make up the process for extraction of hydrocarbons, 
 b) constructing separate interconnecting modules adapted to be transported by a truck or other means of transportation, 
 c) commissioning of the system of the modules at the manufacturing location, 
 d) disassembling the system into the modules, 
 e) preparing the modules for transportation to the remote location. 
 
     
     
         7 . A use of a system of  claim 1  or  2  further comprising steps of:
 a) constructing and assembling the modules at a manufacturing location(s) different from the final plant site adjacent the resource; 
 b) assembling the system from the modules at the manufacturing location(s); 
 c) testing and commissioning the modules and/or the combination of modules at the manufacturing location(s); 
 d) disconnecting the modules and positioning them on tractor trailers, rail cars or other suitable means of transportation; 
 e) transporting the modules to adjacent the oil sands or heavy oil resource location; 
 f) assembling the system from the modules at the remote location; 
 g) extracting hydrocarbons from the oil sands or heavy oil deposits using the assembled system; 
 
       wherein the system can be disassembled and relocated to another remote location if necessary. 
     
     
         8 . A process comprising several modules selected from the following group of modules:
 oil and water separation modules;   flash cooling of produced water rather than the conventional heat exchanger or the like;   vapor Recovery Unit (VRU) Ejector and fuel gas system modules;   compact evaporator with an external demister or other evaporators available on the market and modified where necessary;   cooling system modules (for example glycol cooling system);   boiler feed water storage/supply and chemical addition modules;   boiler modules;   power Generation modules;   thus providing a complete SAGD process or the like for exploiting a remote resource.   
     
     
         9 . A process for hydrocarbon extraction from a resource, using an SAGD process, said process comprising the following modules:
 a) module  1  comprising inlet coolers, an inlet separator, a de-sand unit, and Free Water Knock-Out and Oil Treating vessels;   b) module  2  comprising of an Induced Gas Floatation Unit, distillate tank and Dilbit cooler;   c) module  3  comprising an evaporator exchanger;   d) module  4  comprising an evaporator compressor, evaporator recirculation pumps and chemical addition machinery;   e) module  5  comprising boiler feed water pumps, instrument air systems and electrical systems;   f) module  6  comprising a boiler;   g) module  7  comprising power generation and a Heat Recovery Steam Generator;   h) module  8  comprising a glycol cooler or other cooling system;   i) module  9  comprising a flash drum, flash drum condenser, and dump condenser;   j) module  10  comprising a glycol expansion drum, fuel gas drum, and additional heat exchangers;   
       wherein said modules or the like being interconnected into said process in order to exploit said hydrocarbon resource.