MODULES AND CONFIGURATIONS OF MODULES FOR HYDROCARBON WELLS

A steam assisted gravity drainage (SAGD) system having a hub module operatively coupled to a pipe rack module. The pipe rack module having a first side and a second side. An injection module operatively coupled to the pipe rack module. The injection module providing a high pressure steam via at least one high pressure steam line to an injection well. A production module operatively coupled to the pipe rack module. The production module receiving an emulsion into a produced emulsion line from at least one production well. The hub module permits the injection module to be located on either the first side or the second side of the pipe rack module and the production module to be located on either the first side or the second side of the pipe rack module.

FIELD

This invention is in the field of oil sand wells, and more specifically to wellpads and modules for injection and production wells.

BACKGROUND

Steam-assisted gravity drainage (SAGD) is an oil recovery technology for producing heavy crude oil and bitumen. The system generally has a pair of horizontal wells drilled into an oil reservoir. The upper well is located above the lower well. A high pressure steam is continuously injected into the upper wellbore to heat the oil and reduce its viscosity resulting in the heated oil to drain into the lower wellbore.

SUMMARY

There is provided a steam assisted gravity drainage (SAGD) system that may have: a hub module operatively coupled to one or more pipe rack modules; an injection module operatively coupled to at least one of the one or more pipe rack modules; and a production module operatively coupled to at least one of the one or more pipe rack modules. The one or more pipe rack modules may have a first side and a second side. The injection module may provide a high pressure steam via one or more high pressure steam lines to one or more injection wells. The production module may receive one or more emulsions into a produced emulsion line from one or more production wells. The hub module may be configured to permit the injection module to be located on either the first side or the second side of the one or more pipe rack module and the production module to be located on either the first side or the second side of the at least one pipe rack module.

The pipe rack module may comprise: a main emulsion line, a produced gas line, a main high pressure steam line, a fuel gas line, and an instrument air line. The pipe rack module may further comprise at least one of: a test emulsion line and a test produced gas line.

The high pressure steam line may receive the high pressure steam from the main high pressure steam line via at least one pressure reduction system. The pressure reduction system may comprise a gate valve with a globe valve branching off an inlet of the gate valve and a flow return to the gate valve wherein adjusting the flow return through the globe valve results in a pressure adjustment to a supplied pressure to the injection module.

The production module may provide the at least one emulsion from the production well to a production coupling of the pipe rack module; the production coupling introducing the at least one emulsion to the emulsion line. The production module may receive at least one produced gas from the production well. The production module may provide a process fluid to the at least one production well.

A steam sweep module at an end of the pipe rack module; and the steam sweep module may provide the high pressure steam to at least one of: the emulsion line, the produced gas line, the fuel gas line, the test emulsion line, and the test produced gas line.

The injection module may receive the high pressure steam from the main high pressure steam line via a high pressure steam header. The high pressure steam line may comprise a long string high pressure steam line and a short string high pressure steam line. The injection module may separate the high pressure steam into the long string high pressure steam line and the short string high pressure steam line. The injection module is integrated into the pipe rack module. The injection module may receive a process fluid from the at least one injection well.

The long string high pressure steam line may comprise: a vortex flow meter with a flow indicator; a spring and diaphragm actuator with a flow regulator controlled by a pneumatic signal from the instrument air line; a pressure measurement system; and a fuel gas being introduced to the long string high pressure steam line via the fuel gas line.

The short string high pressure steam line may comprise: a vortex flow meter with a flow indicator; a spring and diaphragm actuator with a flow regulator controlled by a pneumatic signal from the instrument air line; and a pressure measurement system. The short string high pressure steam line further may comprise a fuel gas being introduced to the short string high pressure steam line via the fuel gas line. The short string high pressure steam line may provide a circulation steam to the production module between the spring and diaphragm actuator and the pressure measurement system.

A thermowell may measure a temperature of the at least one emulsion; and a pressure measurement system for measuring a pressure of the produced emulsion line. The circulation steam may be introduced into the produced emulsion line before the thermowell.

The pipe rack modules may comprise: a test emulsion line, and a test produced gas line. A test emulsion may be sampled from the produced emulsion line and may be provided to a test emulsion line.

DETAILED DESCRIPTION

As shown inFIG.1, a modular steam assisted gravity drainage (SAGD) system100may be operatively coupled to one or more injection wellheads600and one or more production wellheads700. In the aspect shown, the modular SAGD system100comprises an injection module200integrated with a pipe rack module200and coupled to an injection wellhead600. The production module400may be placed in a horizontal configuration along the pipe rack module200and may be coupled to a production wellhead700. The modules of the SAGD system100are described in further detail herein.

Turning toFIG.2, a plurality of the modular SAGD systems100may be operated in conjunction with a hub module800. The hub module800may provide an ability to place the production modules400and/or the injection modules200in a number of different configurations. In this aspect, six module SAGD systems100are demonstrated each comprising the injection module200, the pipe rack module300, and the production module400. Only a single pipe rack module300is labeled to improve clarity of the drawing. A pipe rack810may comprise the plurality of pipe rack modules300. In the aspect shown, all of the injection modules200are placed on one side of the pipe rack810and the production modules400are placed on the other side of the pipe rack810. Other aspects may have the injection modules200and production modules400alternate positions along the pipe rack810. All of the modular SAGD systems100may be encircled by an access road808and provided with electrical power from an electrical station802. One or more products from the production modules400may be processed in a process area804. An expansion module806may comprise a U shaped pipe, which may accommodate thermal expansion along the pipe rack810by reducing mechanical stress.

The configuration shown inFIG.2comprises the two well injection modules200being separate from the pipe rack modules300and placed in a perpendicular relationship to the pipe rack module300. Other aspects may have a single injection module200being integrated with the pipe rack module300and/or placed in a parallel relationship to the pipe rack module300. The production modules400may be placed in a perpendicular relationship to the pipe rack module300as shown or in a parallel relationship to the pipe rack module300. Further details of these configurations are provided with reference toFIGS.3A to3CandFIGS.4to6below.

As shown inFIGS.3A to3C, the modular SAGD system100comprises the two well injection module200, the pipe rack module300, and the two well production module400. The injection module200is described in further detail with reference toFIGS.7A to7DandFIG.10below. The production module400is described in further detail with reference toFIGS.8A to8DandFIG.11below. This first configuration of the modules200,300,400may reduce a total number of modules200,300,400and/or number of control panels. In this aspect, the SAGD system100may be configured to allow for two injector wells to be attached to the injection module200. Likewise, the SAGD system100may be configured to allow for two production wells to be attached to the production module400. In other aspects, the SAGD system100may be configured to allow for a single injector well to be attached to the injection module200and a single production well to be attached to the production module400. This SAGD system100configuration may reduce an amount of piping to the wellheads600,700as the piping to the wellheads600,700may be mirrored versus replicated. The injection module200may be coupled on an injection well side202and coupled to a rack side204on the side opposite to the injection well side202. Similarly, the production module400may be coupled to a production well side402and coupled to a rack side404on the side opposite to the production well side402. The injection wellhead600and the production wellhead700are not shown inFIGS.3A to3C.

The pipe rack module300may comprise a frame302enclosing one or more pipes500passing from one SAGD system100to another SAGD system100. The frame302may provide one or more supports for each of the one or more pipes500. In this aspect, the pipes500comprise an emulsion line502, a test emulsion line504, a produced gas line506, a steam line508, a fuel gas line510, an instrument air line512, and/or a test produced gas line514as shown inFIG.9in more detail. The frame302may comprise one or more legs308for maintaining the pipes500in an elevated position with respect to the injection module200and/or the production module400. Within the frame302, one or more injection couplings304and one or more production couplings306may couple to corresponding fittings within the injection module200and production module400respectively. The injection couplings304may comprise a steam coupling, a fuel gas coupling, and an instrument air coupling484. The production couplings306may comprise an emulsion line coupling4106, a test emulsion line coupling4104, a production gas coupling4030, a fuel gas coupling406, and an instrument air coupling484. One of more of these couplings304,306may be attached and/or removed after certain phases of the well operation. These couplings304,306may be described in further detail below.

As shown inFIG.4, a second configuration may comprise three modules (e.g. two of the production modules400and the pipe rack module300, which has a pair of integrated injection modules200) for a single double well-pair setup, or two modules (e.g. one of the production modules400and the pipe rack module300, which has a single integrated injection module200) for a single well-pair setup. The second configuration comprises a mirrored pair of the injection modules200integrated with the pipe rack module300and a mirrored pair of the production modules400. The pipe rack module300may be between the mirrored pair of the integrated injection modules200and the mirrored pair of the production modules400. The mirrored pair of the injection modules200may share a structural foundation with the pipe rack module300. The second configuration may provide access to both sides of the injection modules200and/or production modules400. The second configuration may allow for more flexibility while having smaller injection modules200and/or production modules400for easier shipment and/or installation. The second configuration may provide larger spacing from the wellheads600,700allowing easier well head access. The second configuration may have a common support structure for the piping to the wellheads600,700.

In some aspects, the mirrored pair of the injection modules200may be integrated into the pipe rack module300for a single double well-pair setup, or three modules200,300,400for a single well-pair setup. The mirrored pair of the production modules400may be off of the integrated pipe rack module300permitting access to both sides of the production modules400. The fourth configuration may have shared pipe supports and piles for the piping to the wellheads600,700.

As shown inFIG.5, a third configuration may also comprise five modules200,300,400for a single double well-pair setup, or three modules200,300,400for a single well-pair setup. The third configuration comprises the mirrored pair of the injection modules200as the second configuration. However, the third configuration comprises a mirrored pair of production modules400. The pipe rack module300may be between the mirrored pair of the injection modules200and the mirrored pair of the production modules400. The mirrored pair of the injection modules200may share a structural foundation. The third configuration may provide access to both sides of the injection modules200. The third configuration may allow for more flexibility while having smaller injection modules200for easier shipment and/or installation. The third configuration may reduce the piping necessary from the mirrored pair of the production modules400to the wellheads700.

Turning toFIG.6, a fourth configuration may comprise the injection module200integrated into the pipe rack module300for a single well-pair setup. The production module400may be off of the integrated pipe rack module300. The production modules400may be oriented along or parallel to the pipe rack module300. A pair of the fourth configuration (e.g. a pair of identical pair of injection modules200, an identical pair of production modules400) may be used for a two well-pair setup. The piping to the wellheads600,700may be separated in the fifth configuration thereby requiring more pipe supports and/or piling. Nevertheless, the fifth configuration may require less steel than compared to the other configurations.

As shown inFIG.9, the pipe rack module300comprises one or more couplings for each of the pipes500. The steam line508, the fuel gas line510, and the instrument air line512provide their respective inputs to the injection module200and/or the production module400respectively. The emulsion line502, the test emulsion line504, the produced gas line506, and the test produced gas line514may provide respective outputs from the production module400.

The test produced gas line514, the test emulsion line504, the produced gas line506, the emulsion line502, and/or the fuel gas line510may each have a gate valve304branching off of their respective lines502,504,506,510,514at a head end350of the pipe rack module300. Only one set of the valves320,304inFIG.9are numbered in order to improve clarity. The valve320may be a globe valve, while the valve304may be a gate valve. The gate valve304may act as an on/off function, while the globe valve320may gradually open and/or close to bleed off pressure. The combination of these valves304,320may reduce failure of the gate valve304. When the globe valve320fails, the gate valve304may be closed to facilitate replacement of the globe valve320. Similarly, the test produced gas line514, the test emulsion line504, the produced gas line506, the emulsion line502, and/or the fuel gas line510may each have a gate valve314branching off of their respective lines502,504,506,510,514at a tail end352of the pipe rack module300. The valve312may be a globe valve, while the valve314may be a gate valve. The gate valve314may act as an on/off function, while the globe valve312may gradually open and/or close to bleed off pressure. The combination of these valves314,312may reduce failure of the gate valve314. When the globe valve312fails, the gate valve314may be closed to facilitate replacement of the globe valve312. Each of the lines502,504,506,510,514may have a gate valve336in series with their respective line502,504,506,510,514to isolate one pipe rack module300from another pipe rack module300. Following each of these isolation gate valves336may be a spectacle blind338.

As previously mentioned, the production couplings306may comprise the emulsion line coupling4106, the test emulsion line coupling4104, the production gas coupling4030, the fuel gas coupling406, and the instrument air coupling484. Prior to connecting to the main pipes500, each of the emulsion line coupling4106, the test emulsion line coupling4104, and/or the production gas coupling4030may comprise a bleed valve310and a gate valve308. Again to improve clarity, only one set of the bleed valve310and the gate valve308are labeled inFIG.8. The fuel gas coupling406may have a bleed ball valve318and a ball valve316. In some aspects, the instrument air coupling484may not have the bleed valve310and the gate valve308.

As previously mentioned, the injection couplings304may comprise the steam coupling208, the fuel gas coupling244, and the instrument air coupling484. The fuel gas coupling244may have a bleed valve322and a gate valve320. The high pressure steam coupling208may comprise one or more pressure reduction systems324,328. The pressure reduction system324,328, shown in greater detail inFIG.9B, may comprise a gate valve330. The gate valve330may have a hand-operated globe valve332branching off an inlet of the gate valve330. Following the globe valve332, the flow returns to the gate valve330and branches to a second hand-operated globe valve334off an outlet of the gate valve330. In operation, the pressure reduction system324,328may reduce the pressure from the high pressure steam line to the injection module300. A pressure reduction may be adjusted and/or determined by increasing or decreasing a flow through each of the globe valves332,334. In this aspect, the high pressure steam coupling208may comprise a pair of pressure reduction systems324,328placed in series in order to step the pressure down twice. Other aspects may have more or less pressure reduction systems324,328depending on the pressure in the high pressure steam line. In between the pressure reduction systems324,328may be a release valve326.

According to some aspects, there may be a steam sweep module360at the end of the pipe rack modules300. The steam sweep module360enables the high pressure steam to be fed into the test produced gas line514, the test emulsion line504, the produced gas line506, the emulsion line502, and/or the fuel gas line510.

In this aspect, the production module400may be configured for a pair of production wellheads. InFIG.8, each of the lines are labeled with an “a” or “b” to denote whether the couplings306are associated with production wellhead “a” or “b”. For example, the emulsion line coupling4106ais associated with production wellhead “a” and the emulsion line coupling4106bis associated with production wellhead “b”. A common instrument air coupling484may be used for both of the production wellheads. Similarly, the injection module200may be configured for a pair of injection wellheads where each of the lines are labelled with an “a” or “b” to denote whether the couplings304are associated with injection wellhead “a” or “b”.

Turning toFIGS.7A to7D and10, the injection module200may be described in further detail. The injection module200may comprise a frame206to facilitate moving the injection module200. Fuel gas and high pressure steam may be provided to the injection module200by a high pressure steam header208and a fuel gas header244. Circulation steam214and circulation returns212may be provided to the production module400. The fuel gas line216may be insulated or not insulated. The fuel line216may start at, for example, a diameter at the fuel gas header244of 60-inches and may be reduced to 33-inches before reaching a vortex flow meter218acoupled to a flow indicator220and a bleed valve219and/or flow transmitter238. The flow transmitter238may transmit a measured fuel flow signal to a flow controller236.

A spring and diaphragm actuator224may follow the flow meter218. The spring and diaphragm actuator224may comprise a flow regulator226. The diaphragm from the spring and diaphragm actuator224may receive a pneumatic signal from a three-way solenoid valve222. An interlock228may control the three-way solenoid valve222to provide the pneumatic signal to atmosphere or to a flow converter230that may convert the pneumatic signal to an electrical signal for transmitting to a flow quantity indicator234. The flow quantity indicator234may transmit the flow measurements via one or more data links240. The flow converter230may also receive the pneumatic signal from instrument air232.

Following the spring and diaphragm actuator224, the fuel line216may increase in diameter from 33-inches back to 60-inches and then may branch into three branches. Two of the branches may produce fuel gas to a fuel gas output264to the injection well. One of these branches may comprise a gate valve242awith a bleed242b. In some aspects, a variable area flow indicator and/or a Coriolis flow meter246may be placed in the flow. This branch may terminate with another gate valve248. A bypass valve250may be on the second branch to bypass the flow indicators246. These two branches may merge together before another gate valve252. Following the gate252, the main fuel line216may have a hose branch with a hose gate254leading to a needle valve device256. The needle valve device256may comprise a needle valve receiving a pressure from the main fuel line216. A pressure transmitter258may convert the pressure into an electrical signal for transmission to a pressure indicator260and/or a flow quantity indicator266. The needle valve device256may allow an operator to confirm no pressure is trapped between valve254and the pressure transmitter258in the event that the pressure transmitter258needs to be replaced.

The third branch may provide fuel gas to a long string high pressure steam262via a check valve with a bleed and a gate valve268.

Returning to the high pressure steam header208, an insulated high pressure steam line270may have a diameter of 168-inches. The high pressure steam line270may branch into the long-string high-pressure steam output262and a short-string high-pressure steam output210, both of which may be provided to the injection well. The diameter of the insulated high pressure steam line270may be reduced from 168-inches to 89-inches. The long string branch may have a bleed ring272afollowed by a vortex flow meter272bwith a flow indicator276. The measured flow may be converted using a flow transmitter278into an electrical signal provided to a flow controller292.

Following the flow measurement, the long string branch may comprise a spring and diaphragm actuator280may comprise a flow regulator282. The diaphragm from the spring and diaphragm actuator280may receive a pneumatic signal from a three-way solenoid valve284. An interlock286may control the three-way solenoid valve284to provide the pneumatic signal to atmosphere or to a flow converter288that may convert the pneumatic signal to an electrical signal for transmitting to a flow quantity indicator294. The flow quantity indicator294may transmit the flow measurements via one or more data links296. The flow converter288may also receive the pneumatic signal from instrument air232.

Following the spring and diagram actuator280, the long string branch may expand in diameter to 114-inches. Following the expansion, the long string branch may have a hose branch with a hose gate2012leading to a pressure sampler2010. The pressure sampler2010may comprise a needle valve receiving a pressure from the long string branch. A pressure transmitter2008may convert the pressure into an electrical signal for transmission to a pressure indicator298that may transmit an override signal over a datalink to the flow quantity indicator294. Once a pressure has been measured, the pressure sampler256may vent to atmosphere. The third branch of the fuel string may provide fuel gas to the long string high pressure steam262via a check valve with a bleed and a gate valve268. In some aspect, a similar configuration2088may provide fuel gas to the short string high pressure steam210via a check valve with a bleed and gate valve2088.

Turning to the short string branch, the short string branch may have a bleed valve2015followed by a vortex flow meter2014with a flow indicator2016. The measured flow may be converted using a flow transmitter2018into an electrical signal provided to a flow controller2020.

Following the flow measurement, the short string branch may comprise a spring and diaphragm actuator2024may comprise a flow regulator2026. The diaphragm from the spring and diaphragm actuator2024may receive a pneumatic signal from a three-way solenoid valve2028. An interlock2030may control the three-way solenoid valve2028to provide the pneumatic signal to atmosphere or to a flow converter2032that may convert the pneumatic signal to an electrical signal for transmitting to a flow controller2020. The flow quantity indicator266may transmit the flow measurements via one or more data links2022. The flow converter2032may also receive the pneumatic signal from the instrument air2034.

Following the spring and diagram actuator2024, the short string branch may expand in diameter to 114-inches. Following the expansion, a branch may occur. A circulation steam branch may divert circulation steam to the production module400through a gate valve2048with a bleed2050and an open spectacle blind2052. An output branch may comprise a hose branch with a hose gate2036leading to a pressure sampler2038. The pressure sampler2038may comprise a needle valve receiving a pressure from the short string branch. A pressure transmitter2040may convert the pressure into an electrical signal for transmission to a pressure indicator242that may transmit an override signal over a datalink to the flow quantity indicator266. Once a pressure has been measured, the pressure sampler2038may vent to atmosphere.

Following the pressure sampler2038, another gate valve2044may be placed in series prior to a branch. One leg of the branch may lead directly to the short string high pressure output210to the injection well. During a brief period, the injection well may provide emulsions returned to the surface which may be via the short string high pressure output210of the injection module200. These emulsions may be diverted to the production module400. The other leg of the branch may be a circulation injection212to the production module400. The circulation injection212may comprise a gate valve2046.

Turning toFIGS.8A to8D and11, the production module400may be provided with a bubble gas from a fuel gas header406. The bubble gas line may be insulated and may have a diameter of 33-inches. The bubble gas line may break into two branches. The first branch may comprise a gate valve408followed by a vortex flow meter410. Both the gate valve408and the flow meter410may be placed in a flanged configuration with the bubble gas line. A measured flow from the vortex flow meter410may be converted using a flow transducer416into an electrical signal to be received by a flow controller414with a flow quantity indicator412. The flow quantity indicator412may transmit the flow quantity via a data link438.

In some aspects, following the vortex flow meter410may be a spring and diaphragm actuator418also placed in a flanged configuration with the bubble gas line. The spring and diaphragm actuator418may be controlled by a three way solenoid valve422. The solenoid valve422may in turn be controlled by an interlock428. A pneumatic signal may be supplied by instrument air424to the diaphragm of the spring and diaphragm actuator418in order to control the flow of bubble gas therethrough. A flow measurement of the instrument air424may be transmitted by electrical signal to the flow controller414by a flow transducer426.

The second branch may have a ball valve430with a quarter turn actuator. The actuator may receive a pneumatic signal from a solenoid valve436supplied by industrial air434and controlled by an electrical signal from an interlock432. Following the ball valve430may be a needle valve428threaded in line with the branch. The flow from this branch may then rejoin the previously described branch.

Following the merging of the two branches, a pressure of the bubble gas may be measured prior to the bubble gas452being supplied to the production well. A ball valve440may be socket welded off of the bubble gas line. The ball valve440may enable and/or disable the measurement of the pressure and/or facilitate replacement of the remaining pressure measurement elements. Following the ball valve440, the pressure sampler442may comprise a needle valve receiving a pressure from the bubble gas line. A pressure transmitter444may convert the pressure into an electrical signal for transmission to a pressure indicator446. A temperature indicator448may also provide an electrical signal corresponding to the temperature to the pressure indicator446. The pressure and/or temperature may then be transmitted via a short string steam data link450. Once a pressure has been measured, the pressure sampler442may vent to atmosphere via a second needle valve.

Produced gas454may be received from the production well by the production module400via a production gas line. The production gas line may have a diameter of 114-inches and/or may be insulated. Circulation steam214from the injection module200may be introduced into the production gas near the production side402of the production module400. The circulation steam214may be introduced by a gate valve456during a circulation phase. A gate valve420in a flanged configuration may be placed following the introduction of the circulation steam214, which is closed during the circulation phase. During the circulation phase, the produced gas454may be circulation steam. Following the gate valve420, circulation returns212from the injection module200may be introduced into the production gas line. A gate valve4034in flanged configuration on the circulation return line may be used to enable or disable the circulation returns212. The circulation return line may also have a bleed4032socket welded off of the circulation return line.

A thermowell458may retrieve a temperature of the mixture of the production gas, the circulation returns, and/or the circulation steam. A temperature transmitter460may convert the temperature into an electrical signal for display on a temperature indicator462.

A gate valve464may be socket welded off of the production gas line. The gate valve464may enable and/or disable the measurement of the pressure and/or facilitate replacement of the remaining pressure measurement elements. Following the gate valve464, a pressure sampler466may comprise a needle valve receiving a pressure from the production gas line. A pressure transmitter468may convert the pressure into an electrical signal for transmission to a pressure indicator470. The pressure measurement may be transmitted by a datalink to a pressure controller480.

A bleed472may be socket welded off of the production gas line following the pressure sampler466and before a spring and diaphragm actuator474, which may be in a flanged configuration on the production gas line. An interlock476may control a solenoid valve478that may provide industrial air484to the diaphragm of the spring and diaphragm actuator474. A pressure converter482may be controlled by the pressure controller480in order to control the pressure supplied by the industrial air484. Following the spring and diaphragm actuator474may be a check valve486in a flanged configuration and a bleed488socket welded off of the production gas line.

A test produced gas4028may be sampled from the production gas line. In this aspect, a ball valve490may be placed in a flanged configuration on the production gas line. A corresponding ball valve4020may be placed in a flanged configuration on the test produced gas line. Each of the ball valves490,4020may be controlled by a quarter turn actuator. The production gas line ball valve490may have the quarter turn actuator receive a pneumatic signal from a solenoid valve4004. The solenoid valve4004may be controlled by an interlock4006to provide industrial air4008to the quarter turn actuator of the production gas line ball valve490. A position of the quarter turn actuator may be indicated by a position indicator498that may transmit the position over a datalink to an alarm4010. When the ball valve490is enabled, the produced gas4030is provided. Following the ball valve490may be a pair of bleed valves492,494. One of the bleed valves492may be configured to bleed liquids and the other bleed valve494may be configured to bleed gases from the produced gas line.

Similarly on the test production gas line, the ball valve4020may have the quarter turn actuator receive a pneumatic signal from a solenoid valve4018. The solenoid valve4018may be controlled by an interlock4016to provide industrial air4014to the quarter turn actuator of the test production gas line ball valve4020. A position of the quarter turn actuator may be indicated by a position indicator4024that may transmit the position over a datalink to the alarm4010. When the ball valve4020is enabled, the test produced gas4028may be provided. When the production ball valve490is open, then the test ball valve4020is closed. Likewise, when the production ball valve490is closed, then the test ball valve4020is open.

The production module400may receive an emulsion4036from the production well. A thermowell4038may retrieve a temperature of the mixture of the emulsion and/or the circulation steam. A temperature transmitter4108may convert the temperature into an electrical signal for display on a temperature indicator4040.

A gate valve4042may be socket welded off of the emulsion line. The gate valve4042may enable and/or disable the measurement of the pressure and/or facilitate replacement of the remaining pressure measurement elements. Following the gate valve4042, a needle valve device4044may comprise a needle valve receiving a pressure from the produced emulsion line. A pressure transmitter4046may convert the pressure into an electrical signal for transmission to a pressure indicator4048. The pressure measurement may be transmitted by a datalink to a pressure controller4062. The pressure measurement may be transmitted by a datalink to a pressure difference indicator4050. The needle valve device256may allow an operator to confirm no pressure is trapped between valve4042and the pressure transmitter4046in the event that the pressure transmitter4046needs to be replaced.

Following the gate valve4042may be a gate valve4052in a flanged configuration off of the emulsion line along a line to the circulation steam line214. The gate valve4052may be closed during an ESP production phase and may be open during the circulation phase. Also along the line to the circulation steam line214may be a check valve4054in a flanged configuration. A gate valve4056on the emulsion line may follow the line to the circulation steam line214. Following the gate valve4056may be a pair of bleed valves4058,4076socket welded off the emulsion line. One of the bleed valves4076may be configured to bleed liquids and the other bleed valve4058may be configured to bleed gases from the emulsion line.

A spring and diaphragm actuator4060may follow the bleed valves4058,4076and may be in a flanged configuration on the emulsion line. An interlock4066may control a solenoid valve4064that may provide industrial air4068to the diaphragm of the spring and diaphragm actuator4064. A pressure converter4069may be controlled by the pressure controller4062in order to control the pressure supplied by the industrial air4068. Following the spring and diaphragm actuator4060may be a check valve4070in a flanged configuration and a bleed4072socket welded off of the production gas line.

A line may branch off the emulsion line to the produced gas line following the bleed4072. The line may have a gate valve4110.

A test emulsion4104may be sampled from the produced emulsion line. In this aspect, a ball valve4076may be placed in a flanged configuration on the emulsion line. A corresponding ball valve4096may be placed in a flanged configuration on the test emulsion line. Each of the ball valves4076,4096may be controlled by a quarter turn actuator. The test emulsion line and the emulsion line may each have a bleed valve4074,4112before each of the ball valves4076,4096. The emulsion line ball valve4076may have the quarter turn actuator receive a pneumatic signal from a solenoid valve4078. The solenoid valve4078may be controlled by an interlock4082to provide industrial air4080to the quarter turn actuator of the emulsion line ball valve4076. A position of the quarter turn actuator may be indicated by a position indicator4088that may transmit the position over a datalink to an alarm4090. When the ball valve4076is enabled, the emulsion4106is provided.

Similarly on the test emulsion line, the ball valve4096may have the quarter turn actuator receive a pneumatic signal from a solenoid valve4098. The solenoid valve4098may be controlled by an interlock4102to provide industrial air4100to the quarter turn actuator of the test emulsion line ball valve4096. A position of the quarter turn actuator may be indicated by a position indicator4092that may transmit the position over a datalink to the alarm4090. When the ball valve4096is enabled, the test emulsion4104may be provided. When the emulsion ball valve4076is open, then the test ball valve4096is closed. Likewise, when the emulsion ball valve4076is closed, then the test ball valve4096is open.

Turning toFIGS.12A and12B, the hub module800may permit the number of module configurations, as previously described, without requiring any substantial changes to the injection module200, the production module400, and/or the pipe rack module300. The configuration of the hub module800, as described herein, may be such that inlets and outlets of the hub module800may accommodate reversing an orientation of the pipe rack module300thereby allowing for well types to be on either side of the pipe rack module300. The configuration of the hub module800may allow for surface pipeline into the site from any direction.

With particular reference toFIG.12A, the hub module800may comprise an emulsion line503from a group header. A pair of Hastelloy injection quills902may facilitate injection of chemicals into the emulsion line503. Following the injection quills902may be a gate valve904to vent any gas in the emulsion line503. A gate valve906may be coupled between the emulsion line503and a gauge valve908having a diaphragm coupled to a pressure transmitter910, which may transmit the pressure measurements to a pressure indicator912. The gate valve906may be closed in order to allow for replacement of the pressure transmitter910and/or the pressure indicator912. A gate valve914may be used to drain the emulsion line503. An emergency shutdown valve916may comprise a ball valve916that closes the emulsion line503on a failure. A quarter-turn actuator on the ball valve916may be activated by a pneumatic signal from a solenoid valve918that is supplied with industrial air232. The solenoid valve918may be opened by an interlock920when a failure condition is determined. A position indicator921may indicate whether the emergency shutdown valve916is open or closed. The main emulsion line503may receive test emulsion504from the test separator module. A gate valve934may be closed to prevent test emulsion504from entering the main emulsion line503.

A gate valve922may be coupled between the emulsion line503and a gauge valve924having a diaphragm coupled to a pressure transmitter926, which may transmit the pressure measurements to a pressure indicator928. The gate valve922may be closed in order to allow for replacement of the pressure transmitter926and/or the pressure indicator928. This pressure indicator928may measure the pressure in the emulsion line503following the introduction of the test emulsion. The emulsion line503may comprise a gate valve930inline to stop emulsion from entering the emulsion pipeline502. A vent valve932may vent gas following the inline gate valve930.

The fuel gas line510may comprise a ball valve936prior to a self-actuated pressure reducing regulator938set to 3000 kPag. Following the pressure reducing regulator938may be a pressure indicator940. A pressure safety valve942set to 3500 kPag may vent the fuel gas to atmosphere at excess pressure. Otherwise, the fuel gas may be introduced into the test emulsion line504via a check valve944and a gate valve946, which may be closed for maintenance of either the fuel gas line510and/or the test emulsion line504. The fuel gas may be introduced to sweep the test line clear of emulsion in order to reduce plugging.

Following the introduction of fuel gas to the test emulsion line504, the test emulsion line504may branch into two lines, each line may reach a three-way valve948,958. One branch from the three-way valve948may comprise a temperature indicator950to determine the temperature of the test emulsion. Following the temperature indicator950may be a gate valve952leading to a gauge valve954where a pressure indicator956may provide the pressure of the test emulsion. This branch may then join the three-way valve958. The other branch of the three-way valve958may join the larger test emulsion line504via a gate valve960.

The other branch from the three-way valve948may comprise a gate valve962and a ball valve964leading to a sample box966. The sample box966may be configured to receive a beaker and/or jar to be inserted to take a manual liquid sample from the sample line. The liquid sample may then be analyzed for certain key characteristics. The sample box966may vent to atmosphere with a fan972that may have a capacity greater than or about 10,000 CFM. The fan972may be rotated using a motor974provided with full voltage non-reversing supply and controlled by a hand switch978. One or more samples from the sample box966may be provided to a drain tank970for each client via a ball valve968.

Turning toFIG.12B, the produced gas line506, the high pressure steam line508, and the fuel gas510of the hub module800are described. A pair of Hastelloy injection quills980,982may facilitate injection of chemicals into the produced gas line507from the produced gas header. Following the injection quills980,982may be a gate valve988may be coupled between the produced gas line507and a gauge valve990having a diaphragm coupled to a pressure transmitter992, which may transmit the pressure measurements to a pressure indicator994. The gate valve988may be closed in order to allow for replacement of the pressure transmitter992and/or the pressure indicator994. A gate valve996may be used to drain the produced gas line996. An emergency shutdown valve998may comprise a ball valve998that closes the produced gas line507on a failure. A quarter-turn actuator on the ball valve998may be activated by a pneumatic signal from a solenoid valve9100that is supplied with industrial air232. The solenoid valve9100may be opened by an interlock9106when a failure condition is determined. A position indicator9108may indicate whether the emergency shutdown valve998is open or closed. The main produced gas line507may receive test fluids from the test separator module via a gate valve984.

A gate valve9110may be coupled between the produced gas line507and a gauge valve9112having a diaphragm coupled to a pressure transmitter9114, which may transmit the pressure measurements to a pressure indicator9116. The gate valve9110may be closed in order to allow for replacement of the pressure transmitter9114and/or the pressure indicator9116. This pressure indicator9116may measure the pressure in the produced gas line507following the introduction of the test fluids from the test separator. A redundant pressure measurement structure9118may be present in order to provide redundancy in case the previously described pressure measurement structure must go offline for maintenance or malfunctions.

Turning to the high pressure steam line509, the high pressure steam line509may comprise a gate valve9126may be coupled between the high pressure steam line509and a gauge valve9128having a diaphragm coupled to a pressure transmitter9130, which may transmit the pressure measurements to a pressure indicator9132. The gate valve9126may be closed in order to allow for replacement of the pressure transmitter9130and/or the pressure indicator9132. The pressure indicator9132may transmit the pressure measurements to a pressure controller9134. A pressure differential indicator9136may display a pressure differential between a head end of the high pressure steam line509and a tail end of the high pressure steam line508.

An emergency shutdown valve9138may comprise a quarter-turn actuator to halt high pressure steam flow on a fault condition. The valve9138may be activated by a pneumatic signal from a solenoid valve9140that is supplied with industrial air232. The solenoid valve9140may be opened by an interlock9144when a failure condition is determined. A position indicator9146may indicate whether the emergency shutdown valve9138is open or closed.

The high pressure steam line509may branch into three branches. A first branch may comprise a globe valve9148and a gate valve9150. A second branch may comprise a pressure regulation valve9152that may be provided with a pneumatic signal from a solenoid valve9154controlled by an interlock. The solenoid valve9154may be provided with industrial air232via a pressure converter9155. The pressure converter9155may be controlled via an electrical signal from a position controller9164. The third branch may comprise a pressure regulation valve9156that may be provided with a pneumatic signal from a solenoid valve9158controlled by an interlock. The solenoid valve9158may be provided with industrial air232via a pressure converter9160. The pressure converter9160may provide an electrical signal from the pressure converter9162. The position controller9164may in turn receive a pressure converter signal from the pressure converter9162. The pressure converter9162may be coupled to a datalink receiving pressure signals from the pressure differential indicator9136and a pressure indicator9188. All three branches may then return to the high pressure steam line508. In this manner, the three branches may be used to regulate and/or reduce the pressure from the high pressure steam line509to the high pressure steam line508provided to the pipe rack module300.

Following the merging of the three branches may be a pair of redundant pressure measurement structures, each comprising a gate valve9166,9176, a gauge valve9168,9178, a pressure transmitter9170,1971, and a pressure indicator9172,9180. The signals from the pressure indicators9172,9180may be provided to a pressure indicator9174of a safety instrumentation system.

Following the redundant pressure measurement structures may be another pressure measurement structure comprising a gate valve9182, a gauge valve9184, a pressure transmitter9186providing an electrical signal to a pressure indicator9188. This pressure indicator9188may provide pressure measurements via a datalink to the pressure converter9162and to temperature converter9190. The temperature converter9190may provide temperature data to a temperature differential indicator9196, which may display a temperature difference between the temperature converter9190and a temperature indicator9198. The temperature indicator9198receives a temperature signal from a temperature transmitter and thermowell9200. In some aspects, a reduntant temperature differential indicator9202may also receive a temperature signal from a redundant temperature indicator9204receiving a temperature signal from a temperature transmitter and thermowell9206.

A condensate drain may comprise a gate valve9194and a globe valve9192prior to the high pressure steam header506.

A fuel gas line511may have a vent valve9208prior to an emergency shutdown ball valve9210. The emergency shutdown valve9210may comprise a quarter-turn actuator to halt fuel gas flow on a fault condition. The valve9210may be activated by a pneumatic signal from a solenoid valve9212that is supplied with industrial air232. The solenoid valve9212may be opened by an interlock9216when a failure condition is determined. A position indicator9216may indicate whether the emergency shutdown valve9210is open or closed.

Following the emergency shutdown valve9210may be a pressure measurement structure comprising a gate valve9218, a gauge valve9220and a pressure transmitter9222. The pressure transmitter9222may receive a pressure measurement from the gauge valve9220and provide the measurement to a pressure controller9224.

According to some aspects, the fuel gas line511may comprise a line heater9234. The line heater9234may receive fuel gas from the fuel gas line511via a pair of gate valves9228,9232. The main fuel gas line511may comprise a gate valve9230separating the pair of gate valves9228,9232. A pressure safety valve9226may vent the fuel gas to atmosphere in the event of a fire. The pressure safety valve9226may have a set pressure of 9930 kPag. The line heater may comprise a gas heating element with a local control panel that may measure a temperature and have a temperature indicator. Following the line heater9234may be a Hastelloy quill9236reserved for methanol injection.

According to some aspects, a pressure regulator9238may regulate a pressure within the fuel gas line511. The pressure regulator9238may receive a pneumatic signal from a solenoid valve9240. The solenoid valve9240may be provided with instrument air232via a pressure converter9242and the solenoid valve9240may be controlled with an interlock9244. The pressure converter9242may receive an electrical signal from a pressure controller9254in order to control the pressure provided to the pressure regulator9238.

Following the pressure regulator9238may be a pressure measurement structure comprising a gate valve9248and a gauge valve9250. A pressure transmitter9252may measure the pressure and provide an electrical signal to a pressure indicator9253, which in turn may provide the pressure measurements to the pressure controller9254.

Following the pressure measurement structure may be a thermowell and temperature transmitter9256providing a temperature measurement to a temperature indicator9257of the safety instrumentation system. The temperature indicator9257may provide the temperature measurements to a temperature converter9260that may convert the electrical temperature measurement signal into a signal suitable for a data link. Similarly, a redundant thermowell and temperature transmitter9258may provide a temperature indicator9259.

The fuel gas line may then split into three branches. One branch may provide fuel gas to the sample station510as previously described. A second branch may provide make-up gas to a test separator module. A third branch may provide fuel gas to the fuel gas header via a ball valve9268. Prior to the ball valve9268may be a pressure safety valve9266that may vent the fuel gas to atmosphere at a safe location. The pressure safety valve9266may have a setpoint pressure of 7960 kPag. The pressure safety valve9266may be bypassed by a ball valve9262and a globe valve9264in order to manually vent fuel gas to atmosphere or other venting requirements.

Although the description herein describes a particular order for each of the elements, one of skill in the art upon review of the present disclosure would know that certain connections may be reordered without departing from the function of the modules.

Although single or dual well pair modules have been described and shown herein, one of skill in the art on review of the present disclosure would consider that triple or quadruple well pair modules would fall within the teachings of the present disclosure.

According to another aspect, a process fluid, such as the bubble gas or the high pressure steam, may be provided to the producer well700via the production module400. Another process fluid, such as the circulation returns212, may be retrieved from the injection well600via the injection module200.

In some aspects, the high pressure steam may be provided into the production well700via the production module400during a startup phase (e.g. first 3-months of operation). The emulsion may then be retrieved from the production well700via the production module400. Similarly during the startup phase, the emulsion may be retrieved from the injection well600via the injection module200during injection of the high pressure steam.

Although particular pipe and/or valve sizes may be described and/or demonstrated in the drawings, the pipe and/or valve sizes may be modified to satisfy different sizes and/or numbers of wells. Although particular valve types may be described, other valves may be substituted for similar functionality valves.

According to aspects herein, the frame206,302may facilitate moving the module by jacking and sliding the module and/or moving the module by crane.