Abstract:
The various processes of a plant are segmented into separate process blocks that are connected to one another using fluid conduits or electrical connections. Each process block is specialized to perform specific tasks in an assembly line manner to achieve an overall goal. For example, multiple distillation process blocks could be daisy-chained to create fuel from crude oil. Each process block is generally small enough to be mounted on a truck or a flatbed for easy transport, allowing for an assembly line of process blocks to be transported anywhere in the world with ease.

Description:
This application claims priority to U.S. provisional application Ser. No. 61/287,956, filed Dec. 18, 2009, which along with all other references concurrently filed are incorporated herein by reference in their entirety. 
    
    
     FIELD OF THE INVENTION 
     The field of the invention is modular construction of process facilities, with particular examples given with respect to modular oil sand processing facilities. 
     BACKGROUND 
     Building large-scale processing facilities can be extraordinarily challenging in remote locations, or under adverse conditions. One particular geography that is both remote and suffers from severe adverse conditions includes the land comprising the western provinces of Canada, where several companies are now trying to establish processing plants for removing oil from oil sands. 
     Given the difficulties of building a facility entirely on-site, there has been considerable interest in what we shall call 2nd Generation Modular Construction. In that technology, 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. Several 2nd Generation Modular Construction facilities are in place in the tar sands of Alberta, Canada, and they have been proved to provide numerous advantages in terms of speed of deployment, construction work quality, reduction in safety risks, and overall project cost. There is even an example of a Modular Helium Reactor (MHR), described in a paper by Dr. Arkal Shenoy and Dr. Alexander Telengator, General Atomics, 3550 General Atomics Court, San Diego, Calif. 92121. 
     2nd Generation Modular facilities have also been described in the patent literatures, An example of a large capacity oil refinery composed of multiple, self-contained, interconnected, modular refining units is described in WO 03/031012 to Shumway. A generic 2nd Generation Modular facility is described in US20080127662 to Stanfield. 
     Unless otherwise expressly indicated herein, Shumway and all other extrinsic materials discussed herein, and in the priority specification and attachments, are incorporated by reference in their entirety. Where a definition or use of a term in an incorporated reference is inconsistent with or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply. 
     There are very significant cost savings in using 2nd Generation Modular. It is contemplated, for example, that building of a process module costs US$4 in the field for every US$1 spent building an equivalent module in a construction facility. Nevertheless, despite the many advantages of 2nd Generation Modular, there are still problems. Possibly the most serious problems arise from the ways in which the various modules are inter-connected. In the prior art 2nd Generation Modular units, the fluid, power and control lines between modules are carried by external piperacks. This can be seen clearly in FIGS. 1 and 2 of WO 03/031012. In facilities using multiple, self-contained, substantially identical production units, it is logically simple to operate those units in parallel, and to provide in feed (inflow) and product (outflow) lines along an external piperack. But where small production units are impractical or uneconomical, the use of external piperacks is a hindrance.) 
     What is needed is a new modular paradigm, in which the various processes of a plant are segmented in process blocks comprising multiple modules. We refer to such designs and implementations as 3rd Generation Modular Construction. 
     SUMMARY OF THE INVENTION 
     The inventive subject matter provides apparatus, systems and methods in which the various processes of a plant are segmented in process blocks, each comprising multiple modules, wherein at least some of the modules within at least some of the blocks are fluidly and electrically coupled to at least another of the modules using direct-module to-module connections. 
     In preferred embodiments, a processing facility is 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 comprise up to a hundred, two hundred, or even a higher number of truckable modules. All manner of industrial processing facilities are contemplated, including nuclear, gas-fired, coal-fired, or other energy producing facilities, chemical plants, and mechanical plants. 
     Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints, and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary. 
     As used herein the term “process block” means a part of a processing facility that has several process systems within a distinct geographical boundary. By way of example, a facility might have process blocks for generation or electricity or 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. 
     As used herein the term “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. From a dimensions perspective, such modules would typically measure between 15 and 30 meters long, and at least 3 meters high and 3 meters wide, but no more than 35 meters long, 8 meters wide, and 8 meters high. 
     Truckable 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 allows modules to be positioned adjacent 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 could walk from one module to another within a process block. 
     A typical truckable module might well include equipment from multiples disciplines, as for example, process and staging equipment, platforms, wiring, instrumentation, and lighting. 
     One very significant advantage of 3rd Generation Modular Construction is that process blocks are designed to have only a relatively small number of external couplings. In preferred embodiments, for example, there are at least two process blocks that are fluidly coupled by no more than three, four or five fluid lines, excluding utility lines. It is contemplated, however, that there could be two or more process blocks that are coupled by six, seven, eight, nine, ten or more fluid lines, excluding utility lines. The same is contemplated with respect to power lines, and the same is contemplated with respect to control (i.e. wired communications) lines. In each of these cases, fluid, power, and control lines, it is contemplated that 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. 
     Process blocks can be assembled in any suitable manner. It is contemplated, for example, that 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. Within each process block, the modules can also be arranged in any suitable manner, although since modules are likely much longer than they are wide, 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 modules, another process block could have two modules, and a third process block could have another two modules. In other embodiments, a first process block could have at least five modules, another process block could have at least another five modules, and a third process block could have at least another five modules. 
     In some contemplated embodiments, 3rd Generation 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 at least another one of the process blocks using fiber optics. In general, but not necessarily in all cases, the process blocks of a 3rd Generation Modular facility would collectively include at least one of a vessel, a compressor, a heat exchanger, a pump, a filter. 
     Although a 3rd Generation Modular facility might have one or more piperacks to inter-connect modules within a process block, it is not necessary to do so. Thus, it is contemplated that 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 pass do not pass through a common interconnecting piperack. 
     Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following description of exemplary embodiments and accompanying drawing figures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         FIG. 1  is a flowchart showing some of the steps involved in 3 rd  Generation Construction process. 
         FIG. 2  is an example of a 3rd Generation Construction process block showing a first level grid and equipment arrangement. 
         FIG. 3  is a simple 3rd Generation 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 3rd Generation Modular facility having four process blocks, each of which has five modules. 
     
    
    
     DETAILED DESCRIPTION 
     In one aspect of preferred embodiments, 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. In more preferred embodiments, the A, B, and C modules comprise at least, 5, at least 8, at least 12, or at least 15 modules. Preferably, at least two of the A, B and C process blocks are fluidly coupled by no more than five fluid lines, excluding utility lines. In still other preferred embodiments, a D module could be is stacked upon the C module, and a third fluid line could directly couple C and D modules. 
     Methods of laying out a 2nd Generation Modular facility are different in many respects from those used for laying out a 3rd Generation Modular facility. Whereas the former generally merely involves dividing up equipment for a given process among various modules, the latter preferably takes place in a five-step process as described below. It is contemplated that while traditional 2nd Generation Modular Construction can prefab about 50-60% of the work of a complex, multi-process facility, 3rd Generation Modular Construction can prefab up to about 90-95% of the work 
     Additional information for designing 3rd Generation Modular Construction facilities is included in the 3rd Generation Modular Execution Design Guide, which is included in this application. The 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. Where the 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. 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 3rd Generation Construction process facility configuration using process blocks. In this step 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 in. 
     Step  102  is to allocate a plot space for each 3rd Generation Construction process block. The plot space allocation requires the piping layout specialist to distribute the relevant equipment within each 3rd Generation Construction process block. At this phase of the project, only equipment estimated sizes and weights as provided by process/mechanical need be used to prepare each “block”. A 3rd Generation 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  102 A 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 can not fit effectively onto the module envelop needs to be evaluated by the process lead for possible resizing for effective module installation. 
     Step  102 B 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  102 C is to allocate space for the electrical and control distribution panels on the first level.  FIG. 2  is an example of a 3rd Generation Construction process block first level grid and equipment arrangement. The E&amp;I panels are sized to include the motor control centers and distributed instrument controllers and 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&amp;I panels is designated the 3rd Generation primary process block module. Refer to E&amp;I installation details for 3rd Generation module designs. 
     Step  102 D is to group the equipment and instruments by primary systems using the process block PFDs. 
     Step  102 E is to lay out each grouping of equipment by system 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&amp;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&amp;I distribution panels. In addition, equipment should be spaced to assure effective operability, maintainability and safe access and egress. 
     The use of Fluor&#39;s Optimeyes™ 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 produce an integrated 3rd Generation facility. Each process block identified from step  2  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. Traditional interconnecting piperacks are preferably no longer needed or used. Pipeways are integrated into the module. A simple, typical 3rd Generation “block” layout is illustrated in  FIG. 3 . 
     Step  104  is to develop a 3rd Generation Module Configuration Table and power and control distribution plan, which combines process blocks for the overall facility to eliminate traditional interconnecting piperacks and reduce number of interconnects. A 3rd Generation module configuration table is developed using the above data. Templates can be used, and for example, a 3rd Generation power and control distribution plan can advantageously be prepared using the 3rd Generation power and control distribution architectural template. 
     Step  105  is to develop a 3rd Generation Modular Construction plan, which includes fully detailed process block modules on integrated multi-discipline basis. The final step for this phase of a project is to prepare an overall modular 3rd Generation Modular Execution plan, which can be used for setting the baseline to proceed to the next phase. It is contemplated that a 3rd Generation Modular Execution will require a different schedule than traditionally executed modular projects. 
     Many of the differences between the traditional 1st Generation and 2nd Generation Modular Construction and the 3rd Generation Modular Construction are set forth in Table 1 below, with references to the 3rd Generation Modular Execution Design Guide, which was filed with the parent provisional application: 
     
       
         
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                   
                 Traditional Truckable Modular 
                   
               
               
                 Activities 
                 Execution 
                 3 rd  Gen Modular Execution 
               
               
                   
               
             
             
               
                 Layout &amp; 
                 Steps are: 
                 Utilize structured work process to 
               
               
                 Module 
                 1. Develop Plot Plan using 
                 develop plot layout based on 
               
               
                 Definition 
                    equipment dimensions and 
                 development of Process Blocks with 
               
               
                   
                    Process Flow Diagrams 
                 fully integrated equipment, piping, 
               
               
                   
                    (PFDs). Optimize 
                 electrical and instrumentation/ 
               
               
                   
                    interconnects between 
                 controls, including the following 
               
               
                   
                    equipment. 
                 steps: 
               
               
                   
                 2. Develop module boundaries 
                 1. Identify the 3rd Generation 
               
               
                   
                    using Plot Plan and Module 
                    process facility configuration 
               
               
                   
                    Transportation Envelop. 
                    using process blocks using PFDs. 
               
               
                   
                 3. Develop detailed module 
                 2. Allocate plot space for each 3rd 
               
               
                   
                    layouts and interconnects 
                    Generation process block. 
               
               
                   
                    between modules and stick- 
                 3. Detailed equipment layout within 
               
               
                   
                    built portions of facilities 
                    Process Blocks using 3 rd   
               
               
                   
                    utilizing a network of 
                    Generation methodology to 
               
               
                   
                    piperack/sleeperways and 
                    eliminate traditional 
               
               
                   
                    misc. supports. 
                    interconnecting piperack and 
               
               
                   
                 4. Route electrical and controls 
                    minimize or reduce interconnects 
               
               
                   
                    cabling through 
                    within Process Block modules. 
               
               
                   
                    interconnecting racks and misc. 
                    The layout builds up the Process 
               
               
                   
                    supports to connect various 
                    Block based on module blocks 
               
               
                   
                    loads and instruments with 
                    that conform to the 
               
               
                   
                    satellite substation and racks. 
                    transportation envelop. 
               
               
                   
                 Note: This results in a combination 
                 4. Combine Process Blocks for 
               
               
                   
                 of 1 st  generation (piperack) and 2 nd   
                    overall facility to eliminate 
               
               
                   
                 generation (piperack with selected 
                    traditional interconnecting 
               
               
                   
                 equipment) modules that fit the 
                    piperacks and reduce number of 
               
               
                   
                 transportation envelop. 
                    interconnects. 
               
               
                   
                 Ref.: Section 1.4 A 
                 5. Develop a 3rd Generation 
               
               
                   
                   
                    Modular Construction plan, 
               
               
                   
                   
                    which includes fully detailed 
               
               
                   
                   
                    process block modules on 
               
               
                   
                   
                    integrated multi-discipline basis 
               
               
                   
                   
                 Note: This results in an integrated 
               
               
                   
                   
                 overall plot layout fully built up 
               
               
                   
                   
                 from Module blocks that conform to 
               
               
                   
                   
                 the transportation envelop. 
               
               
                   
                   
                 Ref.: Section 2.2 thru 2.4 
               
               
                 Piperacks/ 
                 Modularized piperacks and 
                 Eliminates the traditional 
               
               
                 Sleeperways 
                 sleeperways, including cable tray 
                 modularized piperacks and 
               
               
                   
                 for field installation of 
                 sleeperways. Interconnects are 
               
               
                   
                 interconnects and home-run 
                 integrated into Process Block 
               
               
                   
                 cables. 
                 modules for shop installation. 
               
               
                   
                 Ref.: Section 2.5 
                 Ref.: Section 2.2 
               
               
                 Buildings 
                 Multiple standalone pre- 
                 Buildings are integrated into Process 
               
               
                   
                 engineered and stick built 
                 Block modules. 
               
               
                   
                 buildings based on discrete 
                 Ref: Section 3.3D 
               
               
                   
                 equipment housing. 
               
               
                 Power 
                 Centralized switchgear and 
                 Decentralized MCC &amp; 
               
               
                 Distribution 
                 MCC at main and satellite 
                 switchgear integrated into 
               
               
                 Architecture 
                 substations. 
                 Process Blocks located in 
               
               
                   
                 Individual home run feeders 
                 Primary Process Block module. 
               
               
                   
                 run from satellite substations to 
                 Feeders to loads are directly 
               
               
                   
                 drivers and loads via 
                 from decentralized MCCs and 
               
               
                   
                 interconnecting piperacks. 
                 switchgears located in the 
               
               
                   
                 Power cabling installed and 
                 Process Block without the need 
               
               
                   
                 terminated at site. 
                 for interconnecting piperack. 
               
               
                   
                   
                 Power distribution cabling is 
               
               
                   
                   
                 installed and terminated in 
               
               
                   
                   
                 module shop for Process Block 
               
               
                   
                   
                 interconnects with pre- 
               
               
                   
                   
                 terminated cable connectors, or 
               
               
                   
                   
                 coiled at module boundary for 
               
               
                   
                   
                 site interconnection of cross 
               
               
                   
                   
                 module feeders to loads within 
               
               
                   
                   
                 Process Blocks using pre- 
               
               
                   
                   
                 terminated cable connectors. 
               
               
                   
                   
                 Ref.: Section 3.3E 
               
               
                 Instrument 
                 Control cabinets are either 
                 Control cabinets are 
               
               
                 and control 
                 centralized in satellite 
                 decentralized and integrated into 
               
               
                 systems 
                 substations or randomly 
                 the Primary Process Block 
               
               
                   
                 distributed throughout process 
                 module. 
               
               
                   
                 facility. 
                 Close coupling of instruments to 
               
               
                   
                 Instrument locations are fallout 
                 locate all instruments for a 
               
               
                   
                 of piping and mechanical 
                 system on a single Process Block 
               
               
                   
                 layout. 
                 module to maximum extent 
               
               
                   
                 Vast majority of instrument 
                 practical. 
               
               
                   
                 cabling and termination is done 
                 Instrumentation cabling installed 
               
               
                   
                 in field for multiple cross 
                 and terminated in module shop. 
               
               
                   
                 module boundaries and stick- 
                 Process Block module 
               
               
                   
                 built portions via cable tray or 
                 interconnects utilize pre-installed 
               
               
                   
                 misc. supports installed on 
                 cabling pre-coiled at module 
               
               
                   
                 interconnecting piperacks. 
                 boundary for site connection 
               
               
                   
                   
                 using pre-terminated cable 
               
               
                   
                   
                 connectors. 
               
               
                   
                   
                 Ref.: Section 3.3F 
               
               
                   
               
             
          
         
       
     
       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. Here, process block # 1  has two modules (# 1  and # 2 ), process block # 2  has two modules (# 3  and # 4 ), and 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. Thus, Drawing  1  shows only two one electrical line connection and one fluid line connection between modules # 1  and # 2 . Similarly, Drawing  1  shows no electrical line connections between process blocks # 1  and  2 , and only a single fluid line connection between those process blocks. 
       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, the Drawing 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 ). 
       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 one another. In this particular example, the first and second process blocks are fluidly coupled by no more 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. 
     Also in  FIG. 8 , a primary electrical supply from process block  1  fans out to three of the four modules of process block  3 , and a control line from process block  1  fans out to all four of the modules of process block  3 . 
     It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.