EP3419761A1 - Installation de traitement modulaire - Google Patents

Installation de traitement modulaire

Info

Publication number
EP3419761A1
EP3419761A1 EP17757290.6A EP17757290A EP3419761A1 EP 3419761 A1 EP3419761 A1 EP 3419761A1 EP 17757290 A EP17757290 A EP 17757290A EP 3419761 A1 EP3419761 A1 EP 3419761A1
Authority
EP
European Patent Office
Prior art keywords
process blocks
facility
blocks
modules
process block
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP17757290.6A
Other languages
German (de)
English (en)
Other versions
EP3419761A4 (fr
Inventor
Fred Haney
Gary Donovan
Todd Roth
Alan Lowrie
George Morlidge
Simon Lucchini
Sean Halvorsen
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fluor Technologies Corp
Original Assignee
Fluor Technologies Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US15/440,812 external-priority patent/US20170159305A1/en
Application filed by Fluor Technologies Corp filed Critical Fluor Technologies Corp
Publication of EP3419761A1 publication Critical patent/EP3419761A1/fr
Publication of EP3419761A4 publication Critical patent/EP3419761A4/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H5/00—Buildings or groups of buildings for industrial or agricultural purposes
    • E04H5/02—Buildings or groups of buildings for industrial purposes, e.g. for power-plants or factories

Definitions

  • 2nd Generation Modular Construction Given the difficulties of building a facility entirely on-site, there has been considerable interest in what we shall call 2nd Generation Modular Construction.
  • a facility is logically segmented into truckable modules, the modules are constructed in an established industrial area, trucked or airlifted to the plant site, and then coupled together at the plant site.
  • 2 nd Generation (“2 nd Gen”) modules are not process based, but rather are equipment based, meaning that each of the modules in a 2 nd Gen Construction typically relate to a specific equipment type (e.g., pumps, compressors, heat exchangers, cooling towers, etc.).
  • the disclosed subject matter provides apparatus, systems, and methods in which the various processes of a plant are segmented into process blocks, each process block comprising one or more (typically multiple) modules, wherein at least some of the modules within at least some of the process blocks are fluidly and electrically coupled to at least another of the modules using direct-module-to-module connections.
  • embodiments of a 3 Gen processing facility would be constructed (for example modularly) by coupling together at least two process blocks.
  • a processing facility might be constructed at least in part by coupling together three or more process blocks.
  • each of at least two of the blocks comprises at least two truckable modules, and more preferably three, four, five, or even more such modules.
  • Contemplated embodiments can be rather large, and can have four, five, ten, or even twenty or more process blocks, which collectively might comprise up to a hundred, two hundred, or even a higher number of truckable modules in some embodiments.
  • Other embodiments may have process blocks comprising one or more transportable modules.
  • process block means a part of a processing facility that has several process systems within a distinct geographical boundary. Typically, each process block is configured to achieve a single (stand-alone) process, for example of the sort that a process engineer might use in a process block layout.
  • process in this context is utilized in the manner that one of ordinary skill (e.g., a process engineer) would use the term for individual processes in a process block layout of a processing facility.
  • a process carried out within a process block may include one or more unit operations (e.g., a physical change and/or chemical transformation), and typically a process block might comprise two or more unit operations.
  • a process block includes multiple pieces and types of equipment (e.g., pumps, compressors, vessels, heat exchangers, vessels, coolers, blowers, reactors, etc., for example) for carrying out a plurality of unit operations with a contiguous, defined geographical area (i.e., the geographical area defined by the corresponding process block).
  • equipment e.g., pumps, compressors, vessels, heat exchangers, vessels, coolers, blowers, reactors, etc., for example
  • the process blocks e.g. the multiple pieces and types of equipment as well as the multiple unit operations
  • each process block would have its own self-supporting E+I.
  • each process block may be operable or configured for independent pre-commissioning, check-out, and/or commissioning.
  • Each process block typically accepts specific feed(s) and processes such feed(s) into one or more products (e.g. outputs).
  • one or more of the feed(s) for a specific process block may be provided from other process blocks(s) (e.g. the products from one or more other interconnected process blocks) in the facility, and in some instances the products from a specific process block might serve as inputs or feeds into one or more other process blocks of a facility.
  • a process block can comprise equipment, such as processing columns, reactors, vessels, drums, tanks, filters, as well as pumps or compressors to move the fluids through the processing equipment and heat exchangers and heaters for heat transfer to or from the fluid.
  • the type and arrangement of equipment within the defined geographic area of a given process block is designed to carry out the specific process(es) with the feed for that process block (i.e., the equipment arranged within the process bock is chosen and arranged to facilitate the designed process(es) of the process block and is not simply grouped by equipment type such as would be found in a 2 nd Gen modular construction).
  • a process block typically might inherently have a series of piping systems and controls to interconnect the equipment within the process block.
  • the 3 Gen approach may facilitate an efficient systems-based layout resulting in the reduction of piping quantities.
  • the piping systems described above would typically be replaced with material handling equipment (e.g., conveyors, belts, elevators, etc.).
  • material handling equipment e.g., conveyors, belts, elevators, etc.
  • a process block would include a maximum of 20 to 30 pieces of equipment, but there could be more or less pieces of equipment in some process block embodiments.
  • all equipment for a specific process would be located within a single (for example, contiguous) geographic footprint and/or envelope.
  • each such process block is configured to achieve a distinct/different process (which may include one or more unit operations as previously described). While some process facilities might comprise only two process blocks, more typical process facilities may comprise at least 3 process blocks (and in some embodiments, at least 5, at least 7, or at least 10 process blocks), with each of the at least 3 process blocks being non- identical (e.g. each of the at least 3 process blocks may be configured for a different process) (e.g.
  • 3 rd Gen processing facilities that they include at least 3 (or at least 2, at least 5, at least 7, or at least 10) different process modules, which may be interconnected (for example via piping and/or electrically) in forming the entire facility.
  • a facility might have one or more process blocks for generation of steam, for distillation, scrubbing, or otherwise separating one material from another, for crushing, grinding, or performing other mechanical operations, for performing chemical reactions with or without the use of catalysts, for cooling, and so forth.
  • truckable module means a section of a process block that includes multiple pieces of equipment and has a transportation weight between 20,000 Kg and 200,000 Kg.
  • the concept is that a commercially viable subset of truckable modules would be large enough to practically carry the needed equipment and support structures, but would also be suitable for transportation on commercially-used roadways in a relevant geographic area, for a particular time of year. It is contemplated that a typical truckable module for the Western Canada tar sands areas would be between 30,000 Kg and 180,000 Kg, and more preferably between 40,000 Kg and 160,000 Kg.
  • Transportable modules are modules (e.g. sections of a process block or an entire process block including multiple pieces of equipment) operable to be transported using one or more means for transport.
  • Transportable module is intended to be a broader term than "truckable module,” such that the term typically includes truckable modules, for example, but also includes larger modules that would not be considered truckable. So for example, a transportable module might be at least 30,000 Kg or at least 40,000 Kg.
  • a transportable module might be up to 6,000,000 Kg, or even more (for example, for very large modules). In some embodiments, a transportable module might be between 30,000 Kg and 6,000,000 Kg, between 30,000 Kg and 500,000 Kg or between 40,000 Kg and 350,000 Kg. From a dimensions perspective, such transportable modules would typically measure at least 15 meters long, at least 3 meters wide, and at least 3 meters high, or in other embodiments at least 15 meters long, at least 4 meters wide, and at least 4 meters high.
  • Truckable and/or transportable modules may be closed on all sides, and on the top and bottom, but more typically such modules would have at least one open side, and possibly all four open sides, as well as an open top.
  • the open sides allow modules to be positioned adjacent to one another at the open sides, thus creating a large open space, comprising 2, 3, 4, 5 or even more modules, through which an engineer operator, or other personnel could walk from one module to another, for example within a process block.
  • a typical truckable and/or transportable module might well include equipment from multiple disciplines, as for example, process and staging equipment, platforms, wiring, instrumentation, and lighting.
  • process blocks are designed to have only a relatively small number of external couplings.
  • each process block will include its own integrated E+I system such that E+I lines (e.g., cables, wires, etc.) for each process block are routed through the modules of that process block.
  • a given line coming into a process block will "fan out” to various modules within the process block.
  • the term “fan out” is not meant in a narrow literal sense, but in a broader sense to include situations where, for example, a given fluid line splits into smaller lines that carry a fluid to different parts of the process block through orthogonal, parallel, and other line orientations.
  • "utility lines” refers to lines (e.g., pipes, conduits, tubes, hoses, etc.) for carrying fluids (i.e., liquids and gases) that facilitate the chemical and/or physical processes within one or more process blocks.
  • the fluid carried by a utility line may include air, nitrogen (N 2 ), oxygen ((1 ⁇ 2), water (H 2 O), steam, etc.
  • the term "utility line” does not include electrical or instrumentation cables, lines, wires, etc. (e.g., such as would be associated within the E+I system).
  • Process blocks can be assembled in any suitable manner.
  • 3 Gen process blocks are arranged and interconnected with one another without an external piperack (so for example, the process blocks would not be laid out with a piperack backbone connecting the process modules, as may be fairly typical in 2 nd Gen modular design for
  • the 3 Gen process blocks typically are directly interconnected with one another in accordance with a 3 rd Gen Construction block layout, for example.
  • each of the process blocks typically would be arranged/positioned in proximity (for example, oftentimes abutting) with one or more process blocks with which it interacts (e.g. with inputs and outputs directly interconnecting the process blocks), without intervening external interconnecting piperack(s) and/or process blocks therebetween.
  • all process blocks might be positioned and/or interconnected in this manner (e.g. in proximity with and direct interconnected with the other process blocks with which it interacts), in some embodiments only some of the process blocks (e.g.
  • process blocks for the primary process flow might all be so positioned and/or interconnected, even though one or more other process blocks might be positioned in such a way as to require interconnection through an unrelated process block.
  • This direct connection between interconnected process blocks may allow for close coupling of the process blocks, for example with each process block abutting one or more other process blocks such that the interconnections therebetween are located within the envelope of those process blocks.
  • process blocks can be positioned end-to-end and/or side-to-side and/or above- below one another.
  • Contemplated facilities include those arranged in a matrix of x by y blocks, in which x is at least 2 and y is at least 3.
  • the inputs and outputs of at least some of the 3 rd Gen process blocks may optionally be coupled via an internal piping spine that runs through at least a portion of the processing facility (and particularly through (e.g. internally within) the corresponding process blocks).
  • the E+I lines and the fluid lines interconnecting the equipment within each process block are not routed through the piping spine and are instead routed independently of the piping spine within the process block (i.e., within the geographic area defined by the corresponding process block).
  • the modules can also be arranged in any suitable manner, although since modules are likely much longer than they are wide (in some embodiments), preferred process blocks have 3 or 4 modules arranged in a side-by-side fashion, and abutted at one or both of their collective ends by the sides of one or more other modules.
  • Individual process blocks can certainly have different numbers of modules, and for example a first process block could have five (5) modules, another process block could have two (2) modules, and a third process block could have another two (2) modules. In other embodiments, a first process block could have at least five (5) modules, another process block could have at least another five (5) modules, and a third process block could have at least another five (5) modules.
  • 3 Gen Modular Construction facilities are those in which the process blocks collectively include equipment configured to extract oil from oil sands. Facilities are also contemplated in which at least one of the process blocks produces power used by at least another one of the process blocks, and independently wherein at least one of the process blocks produces steam used by at least another one of the process blocks, and independently wherein at least one of the process blocks includes an at least two story cooling tower. It is also contemplated that at least one of the process blocks includes a personnel control area, which is controllably coupled to the equipment within the at least one process block (e.g., via electrical conductors, fiber optics cables, etc.). In general, but not necessarily in all
  • the process blocks of a 3 Gen Modular facility would collectively include at least one of a vessel, a compressor, a heat exchanger, a pump, and/or a filter.
  • a 3 rd Gen Modular facility might have one or more piperacks to interconnect modules within a process block, it is not necessary to do so.
  • a modular building system could comprise A, B, and C modules juxtaposed in a side-to-side fashion, each of the modules having (a) a height greater than 4 meters and a width greater than 4 meters, and (b) at least one open side; and a first fluid line coupling the A and B modules; a second fluid line coupling the B and C modules; and wherein the first and second fluid lines do not pass through a common interconnecting piperack.
  • FIG. 1 is a flowchart showing some of the steps involved in a 3 Gen Construction process.
  • FIG. 2 is an example of a 3 Gen Construction process block showing a first level grid and equipment arrangement.
  • FIG. 3 is a simple 3 rd Gen Construction "block” layout.
  • FIG. 4 is a schematic of three exemplary process blocks (#1, #2 and #3) in an oil separation facility designed for the oil sands region of western Canada.
  • FIG. 5 is a schematic of a process block module layout elevation view, in which modules C, B and A are on one level, most likely ground level, with a fourth module D disposed atop module C.
  • FIG. 6 is a schematic of an alternative embodiment of a portion of an oil separation facility in which there are again three process blocks (#1, #2 and #3).
  • FIG. 7 is a schematic of the oil treating process block #1 of FIG. 3, showing the three modules described above, plus two additional modules disposed in a second story.
  • FIG. 8 is a schematic of a 3 Gen Modular facility having four process blocks, each of which has five modules.
  • FIG. 9 is a schematic of another 3rd Generation Modular facility having a total of six interconnected process blocks.
  • component or feature may,” “can,” “could,” “should,” “would,” “preferably,” “possibly,” “typically,” “optionally,” “for example,” “often,” or “might” (or other such language) be included or have a characteristic, that particular component or feature is not required to be included or to have the characteristic. Such component or feature may be optionally included in some embodiments, or it may be excluded.
  • transmissioning and “pre-commissioning” refer to processes and procedures for bringing a system, component, module, process block, piece(s) of equipment, etc. in to working condition. These terms may include testing to verify the function of a given system, component, module, process block, piece(s) of equipment, according to the design specifications and objectives.
  • process is used herein in the manner that one of ordinary skill (i.e., a process engineer) would use the term for individual processes in a process block layout of a processing facility.
  • a process carried out within a process block may include one or more "unit operations" which include a physical change and/or chemical transformation in a given process flow (e.g., fluid or solid flow).
  • the modular building system would further comprise a first command line coupling the A and B modules; a second command line coupling the B and C modules; and wherein the first and second command lines do not pass through the common piperack.
  • the A, B, and C modules may comprise at least, 5, at least 8, at least 12, or at least 15 modules.
  • at least two of the A, B and C process blocks may be fluidly coupled by no more than five fluid lines, excluding utility lines.
  • a D module could be stacked upon the C module, and a third fluid line could directly couple C and D modules.
  • Methods of laying out a 2 nd Gen Modular facility are different in many respects from those used for laying out a 3 Gen Modular facility.
  • the former generally merely involves dividing up equipment for a given process or unit operation among various modules (e.g. an equipment-based approach), the latter preferably takes place in a (process-based) five- step process as described below.
  • equipment is grouped and arranged by type (e.g., pumps for servicing various different processes are arranged within one or more pumping modules and lines connecting the pumps to the various other pieces of equipment related to the various processes and process blocks are routed through one or more external piperacks).
  • type e.g., pumps for servicing various different processes are arranged within one or more pumping modules and lines connecting the pumps to the various other pieces of equipment related to the various processes and process blocks are routed through one or more external piperacks.
  • traditional 2 nd Gen Modular Construction can prefab about 50-60% of the work of a complex, multi-process facility, 3 Gen rd
  • Modular Construction can prefab up to about 90-95% of the work.
  • 3 Gen modular construction can also reduce interconnecting piping and/or cabling, (for example, due to the more direct nature of the interconnections and/or the reduced number of inputs/outputs for each process block) as well as reducing time in the field needed to interconnect modules.
  • the reduction in the length/amount of piping and/or cabling may result in lower total installed costs (TIC) and/or lower operating hydraulic power demand (with respect to piping) and/or lower operating power rd
  • process-based nature of 3 Gen may allow for much more substantial pre-commissioning, check-out, and/or commissioning (for example at the fab or mod yard, at a location away from the ultimate site of the facility - e.g. off-site), thereby reducing effort and time in the field to complete any additional pre-commissioning, check-out, and/or commissioning of process blocks and their systems.
  • each process block of a facility might be fully pre-commissioned, checked-out, and/or commissioned off-site, such that the only pre-commissioning, check-out, and/or commissioning left for the field would be interconnections between process blocks and/or the process facility as a whole.
  • each process block in a 3 rd Gen process facility disclosed herein includes its own independent (e.g. self-supporting) power and control (i.e., E+I) systems such that the various process blocks in the 3 rd Gen facility do not share E+I systems.
  • E+I independent power and control
  • each process block may be independently installed and operated without needing to install other process blocks making up the processing facility.
  • the independent E+I systems for each process block allow for the avoidance of routing E+I lines through an external piperack extending through the processing facility.
  • a single E+I system is shared and distributed among all modules such that a relatively large amount of E+I lines (e.g., cabling) must be routed between the control station, room, etc. and the various pieces of equipment within each module.
  • E+I lines e.g., cabling
  • Design Guide should be interpreted as exemplary of one or more preferred embodiments, and language indicating specifics (e.g. "shall be” or “must be”) should therefore be viewed merely as suggestive of one or more preferred embodiments.
  • Design Guide refers to confidential software, data or other design tools that are not included in this application, such software, data or other design tools are not deemed to be incorporated by reference, but is merely exemplary. In the event there is a discrepancy between the Design Guide and this specification, the specification shall control.
  • FIG. 1 is a flow chart 100 showing steps in production of a 3rd Generation Construction process facility. In general there are three steps, as discussed below.
  • Step 101 is to identify the 3 Gen Construction process facility configuration using process blocks.
  • the process lead typically separates the facilities into process "blocks". This is best accomplished by developing a process block flow diagram.
  • Each process block contains a distinct set of process systems.
  • a process block will have one or more feed streams and one or more product streams. The process block will process the feed into different products as shown herein.
  • Step 102 is to allocate a plot space for each 3 Gen Construction process block.
  • the plot space allocation requires the piping layout specialist to distribute the relevant equipment
  • block A 3 Gen Construction process block equipment layout requires attention to location to assure effective integration with the piping, electrical and control distribution. In order to provide guidance to the layout specialist the following steps should be followed:
  • Step 102A is to obtain necessary equipment types, sizes and weights. It is important that equipment be sized so that it can fit effectively onto a module. Any equipment that has been sized and which cannot fit effectively onto the module envelope needs to be evaluated by the process lead for possible resizing for effective module installation.
  • Step 102B is to establish an overall geometric area for the process block using a combination of transportable module dimensions.
  • a first and second level should be identified using a grid layout where the grid identifies each module boundary within the process block.
  • Step 102C is to allocate space for the electrical and control distribution panels
  • FIG. 2 is an example of a 3 Gen Construction process block first level grid and equipment arrangement.
  • the E+I panels are sized to include the motor control centers and distributed instrument controllers and inputs/outputs (I/O) necessary to energize and control the equipment, instrumentation, lighting and electrical heat tracing within the process block.
  • the module which contains the E+I panels is designated the 3 r Gen primary process block module.
  • Step 102D is to group the equipment and instruments by primary systems using the process block process flow diagrams (PFDs).
  • Step 102E is to lay out each grouping of equipment by system (rather than by equipment type) onto the process block layout assuring that equipment does not cross module boundaries.
  • the layout should focus on keeping the pumps located on the same module grid and level as the E+I distribution panels. This will assist with keeping the electrical power home run cables together. If it is not practical, the second best layout would be to have the pumps or any other motor close to the module with the E+I distribution panels.
  • equipment should be spaced to assure effective operability, maintainability, and safe access and egress.
  • Fluor's OptimeyesTM is an effective tool at this stage of the project to assist with process block layouts.
  • Step 103 is to prepare a detailed equipment layout within process blocks to rd
  • Each process block identified from step 102 is laid out onto a plot space assuring interconnects required between blocks are minimized.
  • the primary interconnects are identified from the process flow block diagram.
  • piperacks are preferably no longer needed or used.
  • a simple, typical 3 Gen "block” layout is illustrated in FIG. 3.
  • Step 104 is to develop a 3 Gen Module Configuration Table and power and control distribution plan, which combines process blocks for the overall facility to eliminate rd
  • a 3 Gen module configuration table is developed using the above data. Templates can be used, and for example, a 3 r Gen power and control distribution plan can advantageously be prepared using the 3 rd Gen power and control distribution architectural template.
  • Step 105 is to develop a 3 rd Gen Modular Construction plan, which includes fully detailed process block modules on an integrated multi-discipline basis.
  • the final step for this phase of a project is to prepare an overall modular 3 rd Gen Modular Execution plan, which rd can be used for setting the baseline to proceed to the next phase. It is contemplated that a 3 Gen Modular Execution will require a different schedule than traditionally executed modular projects.
  • a typical 3 r Gen modular processing facility/system might typically include at least 3 (typically modular, such as being formed of one or more transportable modules) process blocks (although other embodiments could comprise at least 2, at least 5, at least 7, or at least 10 process blocks).
  • the at least 3 process blocks typically would be non-identical process blocks (e.g. each process block configured for a different process and/or having different structure and/or equipment and/or layout).
  • 3 Gen modular construction may be quite different from typical 2 nd Gen construction approaches, since the 3 rd Gen facility typically would not simply be multiple, substantially identical modules, for example in parallel (as may be typical of 2 nd Gen modular construction, for example).
  • the at least 3 process blocks of an exemplary 3 Gen facility would each comprise one or more transportable modules (which typically would be configured to jointly achieve the process of the corresponding process block, if the corresponding process rd
  • 3 Gen modular facilities typically employ a different layout (of modular elements) than conventional 2 nd Gen facilities.
  • typically the at least 3 process blocks of an exemplary 3 rd Gen modular facility would not be laid out on an (external) piperack backbone for interconnecting process blocks (or modules).
  • interconnections between process blocks would be disposed entirely within an envelope of the process blocks.
  • each of the at least 3 process blocks may optionally comprise integral pipeways for utility distribution within the process block (and in some instances for process block interconnects).
  • each of the at least 3 process blocks of a 3 Gen facility would be configured based on a process-based approach or layout (e.g. with each process block configured to achieve a specific stand-alone process, which may be operable to run without accessing equipment from other modules outside the process block (e.g. other than inputs and outputs from the process block as a whole - such that a process block merely takes its inputs, for example, from one or more other process blocks, performs an integral process or unit operation using those inputs, and then provides or emits the outputs from the integral process (for example, to one or more other process blocks))).
  • Each process block typically accepts specific feed(s) and processes such feed(s) into one or more products (e.g. outputs).
  • one or more of the feed(s) for a specific process block may be provided from other process blocks(s) (e.g. the products from one or more other interconnected process blocks) in the facility, and in some instances the products from a specific process block might serve as inputs or feeds into one or more other process blocks of a facility.
  • a process block can comprise equipment, such as processing columns, reactors, vessels, drums, tanks, filters, as well as pumps or compressors to move the fluids through the processing equipment and heat exchangers and heaters for heat transfer to or from the fluid.
  • a process block typically might inherently have a series of piping systems and controls to interconnect the equipment within the block.
  • the 3rd Gen approach may facilitate an efficient systems-based layout resulting in the reduction of piping quantities.
  • the piping systems described above would typically be replaced with material handling equipment (e.g., conveyors, belts, etc.).
  • material handling equipment e.g., conveyors, belts, etc.
  • a process block would include a maximum of 20 to 30 pieces of equipment, but there could be more or less equipment in some process block embodiments.
  • all equipment for a specific process would be located within a single (for example, contiguous) geographic footprint and/or envelope.
  • the inputs/feeds for a specific process block would typically be the inputs needed for the process (as a whole), and the outputs for the process block would typically be the outputs resulting from the process (as a whole).
  • the actual process would basically be self-contained (physically) within the corresponding process block.
  • This may differ from conventional 2 nd Gen approaches, which may typically use an equipment-based approach (such that typical 2 nd Gen modules may be required to interact with equipment from several modules being needed to perform a specific process).
  • 3 rd Gen process block embodiments may not have an equipment-based approach or layout.
  • each process block includes multiple pieces and types of equipment for carrying out one or more (e.g., multiple) unit operations within the contiguous geographic region defined by the process block.
  • the unit operations and associated equipment may be arranged to carry out, or relate to one or
  • the equipment disposed within the process block may be grouped by type within a given process block.
  • each of the units or pieces of equipment of one type e.g., each of the pumps within the process block
  • each of the units or pieces of equipment of another type e.g., each of the heat exchangers within the process block
  • the first defined region may be separate (e.g., not overlapping) with the second defined region with the given process block.
  • such geographical grouping of a specific type of equipment may only occur for one type of equipment within the process block (such as E+I equipment, which typically might all be grouped or located together within a process block), or it may occur for multiple (or even all) types of equipment within the process block.
  • each of the at least 3 process blocks may comprise its own integral E+I system and distribution (e.g. electrical control and instrument system).
  • each process block in a 3 Gen modular processing facility disclosed herein may include its own integral (e.g. self-supporting) power supply and control systems for operating that process block (and the equipment disposed therein). This may eliminate home run interconnecting cabling through traditional interconnecting racks (of the sort which typically may be used in conventional 2 nd Gen modular approaches). In addition, this may be beneficial for allowing each process block to operate as a stand-alone process (as described above, for example), and may provide commissioning benefits.
  • each of the at least 3 process blocks may be configured to allow for independent pre-commissioning, checkout, and/or commissioning of its corresponding process system (for example, without connection to any other of the at least 3 process blocks). This may allow for separate/independent pre- commissioning, check-out, and/or commissioning of its corresponding process system, for example, at a location geographically separate and apart (e.g. distant) from the ultimate site of the facility (such as a fab or mod yard).
  • the ability to perform separate/independent pre- commissioning, check-out, and/or commissioning for each 3 rd Gen process block may be due to integral E+I (within each process block), the process block design approach, and/or lack of external interconnecting piperack (which, for example, may allow for fewer connections which can be more easily connected for simulation and/or testing).
  • integral E+I within each process block
  • the process block design approach and/or lack of external interconnecting piperack (which, for example, may allow for fewer connections which can be more easily connected for simulation and/or testing).
  • the independent, integral E+I system and distribution within each process block as each process block is installed at the production facility, it may be independently operated for its intended function or process while other process blocks are either not yet operational or are not yet even installed (assuming that the operating process block's feed is available and other necessary utility services to the operating process block have been connected and are operating).
  • each of the at least 3 process blocks may be located/arranged in proximity to one or more other of the at least 3 process blocks (e.g. without intervening process blocks, modules, and/or piperacks therebetween).
  • each of the at least 3 process blocks would be interconnected to one or more other of the at least 3 process blocks (and, for example, the interconnects might include fluid (e.g. piping), solids (e.g., conveyors), etc.).
  • each of the at least 3 process blocks would be positioned/arranged in proximity to the other of the at least 3 process blocks to which it directly interconnects, for example, without intervening external piperacks and/or process blocks therebetween. While not required in all 3 rd Gen embodiments, often the at least 3 process blocks would abut at least one other of the at least 3 process blocks (for example, interconnected process blocks might typically abut one another - for example, forming a contiguous geographic footprint and/or envelope). For such abutting process blocks, interconnections between such process blocks might typically be
  • all process blocks might abut the other process blocks to which they interconnect (or at least might directly abut the other process blocks with which it interacts with respect to the primary process flow), such that the facility as a whole might have a contiguous geographic footprint and/or envelope (in which case, all interconnections between process blocks might be within the contiguous envelope of the facility process blocks as a whole (e.g. jointly), such that no external piperacks would be necessary).
  • Typical process blocks would each have feed input piping (or solid material transfer), product output piping (or solid material transfer), and utility support inputs and outputs.
  • utility support inputs and outputs might include one or more one or more inputs for fluid lines (e.g., pipes, conduits, hoses, etc.) that carry fluids (e.g., liquids and/or gases) to support the systems operation within a process block.
  • fluid lines e.g., pipes, conduits, hoses, etc.
  • fluids e.g., liquids and/or gases
  • Such liquids and gases carried by the utility pipes include, steam, water, N 2 , 0 2 , air, etc.
  • Process blocks would typically be arranged to efficiently interconnect to each other based on the process flow through the facility. Utilities may also be interconnected between process blocks in a similar design for efficient flow.
  • Each process block may be formed of one or more transportable modules (thereby allowing construction of such modules off-site at locations distant from the final site for the process facility).
  • each of the transportable modules for the process blocks might be sized as discussed above with respect to transportable modules.
  • one or more of the modules might be sized to be truckable, as described above.
  • a process block can be formed of (e.g. comprise) one to several modules, for example, depending on the maximum module size and/or weight the local site infrastructure will allow for transport.
  • the use of smaller truckable modules might result in several modules per process block, while the use of VLMs (very large modules) could allow for one module per process block.
  • each process block would typically be configured with equipment so that, when interconnected, the modules would jointly perform the process of the corresponding process block (for example, with the equipment in a plurality of related modules for a corresponding process block working together (e.g. interlinked) to accomplish the overall process of the process block).
  • each module In laying out modules (in forming a corresponding process block), each module would typically be arranged in proximity (typically abutting) with the one or more modules with which it interconnects (e.g. without any intervening external piperack and/or module). So typically, the modules for a process block would not interconnect via a piperack (for example, an interconnecting piperack located external to the modules), but might rather be directly interconnected.
  • modules associated with a specific (corresponding) process block would abut to form a contiguous footprint and/or envelope for the process block as a whole.
  • abutment of modules and/or process blocks may be side-by-side, end-to-end, and/or stacked, for example.
  • Such 3 rd Gen modular process facilities may be constructed uniquely, due to the 3 rd Gen nature of the process blocks and/or modules and/or the process-based approach.
  • a typical exemplary 3 rd Gen modular method of constructing a processing facility might comprise arranging a plurality of process blocks (e.g. at least 3 process blocks) with respect to one another, wherein the at least 3 process blocks are non-identical process blocks (e.g. each configured for a different process) (e.g.
  • the at least 3 process blocks each comprise one or more transportable modules (which are configured to jointly achieve the process of the corresponding process block); and wherein the at least 3 process blocks are not laid out on an (external) piperack backbone for interconnecting process blocks (or modules) (e.g. no external interconnecting piperack between/linking/interconnecting the 3 process blocks) (e.g. process blocks are directly interconnected (without intervening piperack therebetween, for example, such that the interconnections between process blocks are disposed entirely within an envelope of the process blocks - for example, with interconnections between a first and a second of the at least 3 process blocks being located entirely within the envelopes of the first and second process blocks).
  • interconnecting process blocks or modules
  • process blocks are directly interconnected (without intervening piperack therebetween, for example, such that the interconnections between process blocks are disposed entirely within an envelope of the process blocks - for example, with interconnections between a first and a second of the at least 3 process blocks being located entirely within the envelopes of the first
  • Such a method might also and/or further comprise constructing one or more (e.g.,, each or all) of the at least 3 process blocks at (one or more location) different (remote/away) from the ultimate site of the processing facility (e.g., a fab or mod yard); and pre-commissioning, check-out, and/or commissioning of a corresponding process system for the one or more process blocks constructed away from the ultimate facility site (e.g., at the fab or mod yard) (e.g., without connection to any other of the at least 3 process blocks) (e.g., at a location separate and apart from the ultimate site of the facility, such as a mod yard) (e.g., due to integral E+I, process block design approach, and/or lack of external interconnecting piperack).
  • constructing one or more e.g., each or all of the at least 3 process blocks at (one or more location) different (remote/away) from the ultimate site of the processing facility (e.g., a
  • such methods might further comprise directly interconnecting (e.g. without an external interconnecting piperack) each process block (which might be pre- commissioned, checked out, or commissioned previously) to one or more adjacent process blocks (e.g. without intervening external piperacks and/or other process blocks therebetween).
  • the arrangement of process blocks might also include close coupling one or more (e.g., all) of the at least 3 process blocks (e.g., to reduce overall footprint of the facility and/or reduce/minimize interconnects).
  • Some method embodiments might further comprise designing/configuring each process block to accomplish a corresponding process, which in some embodiments might include laying out equipment in the modules making up each process block accordingly.
  • some method embodiments might further comprise the step of providing integral E+I distribution for each of the at least 3 process blocks (e.g., to eliminate home run interconnecting cabling).
  • the modular nature of 3 rd Gen construction may also allow for more efficient construction and/or implementation, for example, using integrated execution to support the modular implementation with reduced scheduling versus traditional/conventional stick build or 2 nd Gen (e.g., equipment only modules).
  • two or more of the process blocks to be interconnected may not able to be placed adjacent one another such that one or more fluid lines interconnecting the inputs and outputs of the two or more process blocks must be routed through another geographically intervening process block or other equipment.
  • this sort of arrangement is not required, and in at least some embodiments, such a routing of the one or more fluid lines does not occur. If such routing becomes necessary, design efforts (regarding placement of process blocks and/or interconnections between process blocks) would typically seek to minimize this type of indirect routing or interconnection as much as possible (e.g. most process blocks should preferably be directly interconnected and located adjacent to the other process blocks with which it interacts, especially with respect to the primary process flow). So for at least some embodiments, the primary flow (i.e., the primary process flow through the 3 Gen production facility) would typically flow between adjacent and directly interconnected process rd
  • process blocks in a 3 Gen production facility that are associated with the main or primary process flow are typically positioned geographically adjacent one another such that each of these process blocks is directly interconnected with no intervening piperacks or other equipment or modules therebetween. So while there may be process blocks in a 3 rd Gen facility that are not adjacent and/or interconnected with one or more other process rd
  • a 3 Gen facility typically at least 3, at least 5, at least 8, or at least 10 process blocks (for example, relating to the main or primary process flow) would be adjacent (or abutting) and/or directly interconnected with the other such of the at least 3, at least 5, at least 9 or at least 10 process blocks with which it interacts.
  • interconnecting the inputs and outputs of the 3 Gen process blocks are routed through a central piping spine that runs through at least a portion of the (and in some instances, through the entire) processing facility (and particularly through at least some of the process blocks, with the spine located internally within at least some of the process blocks).
  • the utility lines e.g., carrying steam, water, air, N 2 , 0 2 , etc.
  • associated with the process blocks may also route along the piping spine so as to access each of the process blocks.
  • the E+I lines and the fluid lines interconnecting the equipment within each process block are not routed through the piping spine and are instead routed within each individual process block (i.e., within the geographic area defined by the corresponding process block) as described above.
  • Such an optional spine might serve to line up inputs and outputs for multiple process blocks (for example regarding the primary process flow and/or utilities), thereby optimizing layout of a facility. So, typically such a spine would not be used for equipment connections within a process blocks, but would instead typically be focused on inputs and outputs between interconnected process blocks.
  • FIG. 4 is a schematic of three exemplary process blocks (#1, #2, and #3) in an oil separation facility designed for the oil sands region of western Canada.
  • process block #1 has two modules (#1 and #2)
  • process block #2 has two modules (#3 and #4)
  • process block #3 has only one module (#5).
  • the dotted lines between modules indicate open sides of adjacent modules, whereas the solid lines around the modules indicate walls.
  • the arrows show fluid and electrical couplings between modules.
  • FIG. 1 shows only one electrical line connection and one fluid line connection between modules #1 and #2.
  • FIG. 1 shows no electrical line connections between process blocks #1 and #2, and only a single fluid line connection between those process blocks.
  • FIG. 1 shows utility lines (shown as "Steam Coupling” and "Treated Water Coupling") extending between module #3 of Water treatment process Block #2 and module #5 of Steam Generation Process Block #3.
  • FIG. 1 shows that each process block (process blocks #1, #2, #3) each have their own Power and Control Area.
  • each Power and Control Area is a designated location (which in some embodiment comprises an enclosure or room, or simply one or more control panels) within the corresponding process block (e.g., process blocks #1, #2, #3) that operating personnel may direct, monitor, initiate, and/or control (collectively "control operations") the operation of the process block and any and all equipment contained therein.
  • the integrated E+I system and distribution is coupled to and includes the Power and Control area to facilitate the control operations described above. While FIG.
  • FIG. 1 shows a fiber optic coupling extending between each of the Power and Control Areas, it should be appreciated that such a coupling is not required and may not be included in other embodiments (i.e., in some embodiments, the Power and Control Areas of each process block are not coupled to one another - e.g., as shown in FIG. 6).
  • FIG. 5 is a schematic of a process block module layout elevation view, in which modules C, B, and A are on one level, most likely ground level, with a fourth module D disposed atop module C. Although only two fluid couplings are shown, FIG. 5 should be understood to potentially include one or more additional fluid couplings, and one or more electrical and control couplings.
  • FIG. 6 is a schematic of an alternative embodiment of a portion of an oil separation facility in which there are again three process blocks (#1, #2 and #3). But here, process block #1 has three modules (#1, #2, and #3), process block #2 has two modules (#1 and #2), and process block #3 has two additional modules (#1 and #2). Also, it should be appreciated that each of the Power and Control Areas of process blocks #1, #2, and #3 of FIG. 6 are not coupled or interconnected (e.g., with a fiber optical cable or the like).
  • FIG. 7 is a schematic of the oil treating process block #1 of FIG. 3, showing the three modules described above, plus two additional modules disposed in a second story.
  • FIG. 8 is a schematic of a 3rd Generation Modular facility having four process blocks, each of which has five modules. Although dimensions are not shown, each of the modules should be interpreted as having (a) a length of at least 15 meters, (b) a height greater than 4 meters, (c) a width greater than 4 meters, and (d) having open sides and/or ends where the modules within a given process block are positioned adjacent to one another.
  • the first and second process blocks are fluidly coupled by no more than four fluid lines, excluding utility lines, four electrical lines, and two control lines.
  • the first and third process blocks are connected by six fluid lines, excluding utility lines, and by one electrical and one control line.
  • FIG. 9 is a schematic of a 3 rd Gen Modular facility having six process blocks 110a- 11 Of.
  • one or more of the fluid lines interconnecting the inputs and outputs of the 3 rd Gen process blocks are routed through a central piping spine that runs through at least portions of the processing facility (and particularly through and within at least some of the plurality of the process blocks).
  • piping spine 150 also carries a plurality of interconnecting fluid lines (not specifically shown) that connect the ultimate inputs and outputs of each process block 110a- 11 Of.
  • piping spine 150 carries pipes or other conduits that interconnect the output of process block 110a to the input of process block 110b, the output of process block 110b to the input of process block 110c, the output of process block 110c to the input of process block 1 lOd, the output of process block 1 lOd to the input of process block l lOe, and finally the output of process block l lOe to the input of process block 11 Of.
  • piping spine 150 provides a main corridor for interconnecting the inputs and outputs for each of the adjacent process blocks 110a- 11 Of, for at least the main processing flow.
  • piping spine 150 carries a plurality of utility lines (not specifically shown) that are coupled to the process blocks 110a- 11 Of (and therefore carry various utility fluids to process blocks 110a- 11 Of as previously described above).
  • each of the fluid lines e.g., pipes, conduits, etc. - not shown
  • the E+I lines also not shown
  • routed throughout each process block 110a- 1 lOf are not routed through the piping spine 150 and are instead routed exclusively within the corresponding process block itself (i.e., within the geographic boundary defined by the corresponding process block 110a- 1 1 Of), typically in a more direct manner.
  • a modular processing facility/system comprising: a plurality (for example, at least 3) (modular) process blocks; wherein the plurality of (e.g. at least 3) process blocks are non-identical process blocks (e.g. each configured for a different process) (e.g. not simply multiple, substantially identical modules, for example in parallel); wherein the at plurality of (e.g. least 3) process blocks each comprise one or more transportable modules (which are configured to jointly achieve the process of the corresponding process block); and wherein the plurality of (e.g.
  • process blocks are not laid out on a (common) (external) piperack backbone for interconnecting process blocks (or modules) (e.g. no external interconnecting piperack between/linking/interconnecting the process blocks) (e.g. the process blocks are directly interconnected (without intervening piperack therebetween, for example, such that the interconnections between process blocks are disposed entirely within an envelope of the process blocks - for example, with interconnections between a first and a second of the at least 3 process blocks being located entirely within envelopes of the first and second process blocks).
  • process blocks or modules
  • the process blocks are directly interconnected (without intervening piperack therebetween, for example, such that the interconnections between process blocks are disposed entirely within an envelope of the process blocks - for example, with interconnections between a first and a second of the at least 3 process blocks being located entirely within envelopes of the first and second process blocks.
  • system/facility of the first embodiment wherein each of the plurality of (e.g.
  • process blocks is configured based on a process-based approach (e.g. to achieve a specific stand-alone process) (e.g. not equipment-based).
  • system/facility of embodiments 1-2 wherein the process blocks are close coupled to minimize interconnects and/or to reduce overall footprint of the facility.
  • system/facility of embodiments 1-3 wherein each of the plurality of (e.g. at least 3) process blocks comprises its own integral E+I Distribution (for example, thereby eliminating home run interconnecting cabling through traditional interconnecting racks).
  • system/facility of embodiments 1-4 wherein each of the plurality of (e.g.
  • process blocks is configured to allow for independent pre-commissioning, check-out, and/or commissioning of a corresponding process system (for example, without connection to any other of the at least 3 process blocks) (for example, at a location separate and apart from the ultimate site of the facility, such as a mod yard) (for example, due to integral E+I, process block design approach, and/or lack of external interconnecting piperack).
  • the system/facility of embodiments 1-5 wherein each of the plurality of (e.g. at least 3) process blocks comprises integral pipeways for utility distribution (and process block interconnects).
  • the system/facility of embodiments 1-6 wherein each of the plurality of (e.g.
  • process blocks is located/arranged in proximity to (e.g. without intervening process blocks, modules, and/or piperacks therebetween) one or more other of the at least 3 process blocks.
  • system/facility of embodiments 1-7 wherein each of the plurality of (e.g. at least 3) process blocks is interconnected to one or more other of the at least 3 process blocks, and wherein the interconnects include fluid (e.g. piping).
  • system/facility of embodiments 1-8 wherein each of the plurality of (e.g. at least 3) process blocks is positioned/arranged in proximity to the other of the plurality of (e.g.
  • each of the plurality of process blocks comprises a plurality of transportable or truckable modules, which jointly may be configured to achieve the process for the corresponding process block.
  • the system/facility of embodiments l-13 wherein each process block is configured to allow for independent pre-commissioning, check-out, and/or commissioning (e.g. without being connected to another one or more of the process blocks)(e.g. at a site separate and apart from the ultimate facility site).
  • a modular method of constructing a processing facility comprising: arranging a plurality of process blocks (e.g. at least 3 process blocks) with respect to one another; wherein the plurality of (e.g. at least 3) process blocks are non-identical process blocks (e.g. each configured for a different process) (e.g. not simply multiple, substantially identical modules, for example in parallel); wherein the plurality of (at least 3) process blocks each comprise one or more transportable modules (e.g. typically a plurality of transportable or truckable modules for each process block)(e.g. which are configured to jointly achieve the process of the corresponding process block); and wherein the plurality of (e.g.
  • process blocks are not laid out on an (external) piperack backbone for interconnecting process blocks (or modules) (e.g. no external interconnecting piperack between/linking/interconnecting the 3 process blocks) (e.g. process blocks are directly interconnected (without intervening piperack therebetween, for example such that the interconnections between process blocks are disposed entirely within an envelope of the process blocks - for example, with the interconnections between a first and a second of the at least 3 process blocks being located entirely within the envelopes of the first and second process blocks)).
  • the method of embodiment 15 further comprising: constructing one or more (for example, each or all) of the plurality of (e.g.
  • process blocks at one or more location different (remote/away) from the ultimate site of the processing facility (for example, a fab or mod yard); and pre-commissioning, check-out, and/or commissioning of a corresponding process system for the one or more process block(s) constructed away from the ultimate facility site (e.g. at the site of construction for such one or more process blocks)(for example, at the fab or mod yard) (for example, without connection to any other of the at least 3 process blocks) (for example at a location separate and apart from the ultimate site of the facility, such as a mod yard) (for example, due to integral E+I, process block design approach, and/or lack of the external interconnecting piperack).
  • the method of embodiments 15-16 further comprising directly interconnecting (e.g. without the external interconnecting piperack) each process block to one or more adjacent process blocks (e.g. without intervening external piperacks and/or other process blocks therebetween).
  • the method of embodiments 15-17 further comprising, close coupling one or more (for example, all) of the at least 3 process blocks (for example, to reduce overall footprint of the facility and/or reduce/minimize interconnects).
  • the method of embodiments 15-18 further comprising designing/configuring each process block to accomplish a corresponding process (and laying out equipment in the modules making up each process block accordingly).
  • the method of embodiments 1-19 further comprising providing (e.g. at the one or more location different (remote/away) from the ultimate site of the processing facility (for example, a fab or mod yard)) integral E+I distribution for each of the at least 3 process blocks (e.g. to eliminate home run interconnecting cabling).
  • each of the process blocks comprises its own integral E+I Distribution.
  • the method of embodiments 15-21 wherein arranging a plurality of process blocks (e.g. at least 3 process blocks) with respect to one another comprises positioning each process block so that it abuts any of the other process blocks to which it is connected.
  • each of the plurality of (e.g. at least 3) process blocks is configured to allow for independent pre-commissioning, check-out, or commissioning of a corresponding process system (for example, with each such process block being configured with multiple types of equipment in order to allow for the corresponding process system to run independently of the other process blocks (e.g. without interacting with other, outside equipment in the midst of performing the process) to perform its process, for example using only feeds into the process (e.g. process block) for the process block to perform its corresponding process system (e.g. with no interaction with equipment or process blocks outside the process block to perform any portion of the process (e.g.
  • each process block may be configured with multiple types of equipment in order to allow for the corresponding process system to run in an internally self-contained manner, with no interaction with external equipment or process blocks outside that process block to perform any (internal) portion of the process.))).
  • the method of embodiments 15-23 further comprising beginning partial operation of the facility before all of the process blocks for the full facility are provided at the ultimate facility site and/or are interconnected (for example, operating a first process block independently while awaiting installation of a second process block; or operating a first and second (interconnected) process block while awaiting installation of a third process block; or operating a first, second, and third (interconnected) process block while awaiting installation of a fourth process block; etc.).

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Abstract

Selon l'invention, les différents processus d'une installation peuvent être segmentés en blocs de processus séparés, qui peuvent être interconnectés grâce à des conduites de fluide et/ou des connexions électriques. Ces blocs de processus peuvent être connectés directement, par exemple sans nappe de tubes extérieure interconnectant des blocs de processus. Dans certains modes de réalisation, chaque bloc de processus peut être formé d'un ou plusieurs modules. Le caractère centré sur le processus de cette approche modulaire, avec l'absence facultative de nappe de tubes extérieure d'interconnexion, peut offrir des avantages par rapport à une conception d'installation modulaire classique.
EP17757290.6A 2016-02-26 2017-02-24 Installation de traitement modulaire Withdrawn EP3419761A4 (fr)

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US201662300636P 2016-02-26 2016-02-26
US15/440,812 US20170159305A1 (en) 2009-12-18 2017-02-23 Modular processing facility
PCT/US2017/019329 WO2017147405A1 (fr) 2016-02-26 2017-02-24 Installation de traitement modulaire

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US10458140B2 (en) 2009-12-18 2019-10-29 Fluor Technologies Corporation Modular processing facility
US10787890B2 (en) 2017-10-20 2020-09-29 Fluor Technologies Corporation Integrated configuration for a steam assisted gravity drainage central processing facility

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