Note: Descriptions are shown in the official language in which they were submitted.
MODULAR WELL PAD SYSTEMS AND METHODS
FIELD OF THE DISCLOSURE
[0002] The present disclosure generally relates to modular well pad systems
and methods.
More particularly, the present disclosure relates to a modular well pad
system, which includes a
first inlet module, a second inlet module, a 1 well-pair module and a 2 well-
pair module. The
first and second inlet modules, one or more 1 well-pair modules and one or
more 2 well-pair
modules may be configured to build an interconnected well pad system for
accommodating one
to twelve well-pairs wherein standardized connections enable the 1 well-pair
module and the 2
well-pair module to be coupled together, to the second inlet module, another 1
well-pair module
and/or another 2 well-pair module.
BACKGROUND
[0003] Steam Assisted Gravity Drainage (SAGD) is a methodology of oil
extraction
where steam is injected into the underground oil reservoir through an
injection well and
bituminous product is collected though a production well. The steam is
injected downhole to
melt bitumen trapped within a sand layer, typically anywhere from 200 to 500
meters below
grade. The resultant mixture of bitumen and water (hereinafter referred to as
a production
emulsion) flows up through the production well, potentially with some free
gas, where a well
pad and surface facilities handle the transfer of the production emulsion to a
central processing
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facility (CPF). Because the production emulsion is a multiphase product, the
liquid and gases
are separated and sent to the CPF. Conventional SAGD well pads thus, require
the use of
separator vessels.
[0004] Conventional SAGD well pads are often constructed in a way that allows
for
much of the construction and fabrication work to be performed offsite, in a
more controlled
environment, and then assembled on-site. Each well pad thus, may include
multiple modules that
can be shipped by highway on a flatbed trailer of a transport truck and then
lowered or lifted into
place for assembly on-site. Such modules, however, still lack the requisite
standardization
necessary to permit simple interconnectivity between the modules regardless of
the module type,
well pad location and design parameters. Moreover, the lack of simple
intercormectivity also
renders such modules significantly inflexible for expansion. As a result,
conventional SAGD
well pads remain highly customized and therefore, costly to construct.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The present disclosure is described with reference to the accompanying
drawings,
in which like elements are referenced with like reference numbers, and in
which:
[0006] FIG. 1 is a site plan illustrating one embodiment of a modular well-pad
system
comprising a first inlet module, a second inlet module, a 1 well-pair module
and two 2 well-pair
modules for accommodating 5 well-pairs.
[0007] FIG. 2 is a schematic view of the first inlet module in FIG. 1
illustrating
standardized connections to the first inlet module.
[0008] FIG. 3 is a schematic view of the second inlet module in FIG. 1
illustrating
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standardized connections to the second inlet module.
[0009] FIG. 4 is a schematic view of the 1 well-pair module in FIG. 1
illustrating
standardized connections to the 1 well-pair module.
[0010] FIG. 5 is a schematic view of the 2 well-pair module in FIG. 1
illustrating
standardized connections to the 2 well-pair module.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0011] The subject matter of the present disclosure is described with
specificity,
however, the description itself is not intended to limit the scope of the
disclosure. The subject
matter thus, might also be embodied in other ways, to include different
structures, steps and/or
combinations similar to and/or fewer than those described herein, in
conjunction with other
present or future technologies. Moreover, although the term "step" may be used
herein to
describe different elements of methods employed, the term should not be
interpreted as implying
any particular order among or between various steps herein disclosed unless
otherwise expressly
limited by the description to a particular order. Other features and
advantages of the disclosed
embodiments will be or will become apparent to one of ordinary skill in the
art upon examination
of the following figures and detailed description. It is intended that all
such additional features
and advantages be included within the scope of the disclosed embodiments.
Further, the
illustrated figures are only exemplary and are not intended to assert or imply
any limitation with
regard to the environment, architecture, design, or process in which different
embodiments may
be implemented.
[0012] The pressure profile for a well-pad cannot be standardized because the
location of
each well pad in relation to the CPF is unique to each project. Similarly, the
topography along
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the right of way is also unique to each project. Due to these factors, the
selection of some well-
pad design parameters (e.g. single phase pipelines vs multi-phase pipeline;
separation on or off
the well pad; pipeline size (internal diameter); and pumping configuration ¨
pumps in series,
multi-phase pumps), based on costs, cannot be easily made using a standardized
design. As used
herein, the terms "pipeline" and "pipelines" may also be referred to as
piping, line or lines.
[0013] Other parameters of the well pad design and its production
(engineering,
procurement, fabrication, installation and construction), however, may be
standardized to
achieve substantial production savings. The modular well pad described herein
employs carefully
controlled reservoir pressure and temperature conditions along with the use of
submersible
downhole pumps that produce a product with a single liquid phase, thereby
eliminating the
requirement for separator vessels and a costly gas pipeline back to the CPF.
The modular well
pad and its production may thus, be standardized by (i) removing separators
(group and test)
from the design by raising the product pressure to above the bubble point
using electric
submersible pumps (ESPs); (ii) providing an option to connect to a multi-phase
pump to boost
the pressure further if need be to remain a single phase (liquid) for the
product; and iii) providing
an option to connect to a separation building if required to enable two single
phase pipelines (1
gas, 1 liquid emulsion) for the product.
[0014] Because the modular well-pad connections between modules are
standardized, the
modular well-pad allows for increased flexibility and repeatability without
any additional
engineering. Moreover, production costs for the modular well-pad are lowered
because the
modular well-pad is based on a design that: i) reduces the scope of a well-pad
to the maximum
possible extent without sacrificing life cycle cost; ii) reduces the scope of
on-site field production
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using modularization; iii) reduces materials; iv) provides options to enable
the design to be
customized and v) expands potential production locations by reducing the
module size.
[0015] The modular well-pad thus overcomes one or more of the prior art
disadvantages with a first inlet module, a second inlet module, a 1 well-pair
module and a 2
well-pair module. The first and second inlet modules, one or more 1 well-pair
modules and
one or more 2 well-pair modules may be configured to build an interconnected
well pad
system for accommodating one to twelve well-pairs wherein standardized
connections enable
the 1 well-pair module and the 2 well-pair module to be coupled together, to
the second inlet
module, another 1 well-pair module and/or another 2 well-pair module.
[0016] In one embodiment the present disclosure includes a modular well-pad
system,
comprising: an inlet module comprising a plurality of service lines, wherein
one or more of
the plurality of service lines is connected at one side of the inlet module to
a central
processing facility and the plurality of service lines is connected at another
end of the inlet
module to a respective plurality of service lines at one end of another inlet
module, the
plurality of service lines connected at the one end of the another inlet
module connectable at
another end of the another inlet module to a respective plurality of service
lines at one end of
a 1 well-pair module and a respective plurality of service lines at one end of
a 2 well-pair
module; at least one of the 1 well-pair module and the 2 well-pair module,
wherein the
plurality of service lines at the one end of the 1 well-pair module are
connectable at another
end of the 1 well-pair module to a respective plurality of service lines at
one end of amother 1
well-pair module and a respective plurality of service lines at one end of the
2 well-pair
module and the plurality of service lines at the one end of the 2 well-pair
module are
connectable at another end of the 2 well-pair module to a respective plurality
of service lines
AMENDED SHEET
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at one end of another 2 well-pair module and a respective plurality of service
lines at the one
end of the 1 well-pair module; and the 1 well-pair module connectable to one
well pair and the
2 well-pair module connectable to two well pairs, wherein each well pair
represents an
injection well and a production well.
[0017] Referring now to FIG. 1, a site plan 100 illustrates one embodiment of
a
modular well-pad system comprising a first inlet module 102a, a second inlet
module 102b,
a 1 well-pair module 104 and two 2 well-pair modules 106 for accommodating
five well-
pairs 108-116. Each well pair represents one production well (p) and one steam
injection
well (i). The modular well-pad system may also include various support
structures. A
natural gas heater 118 is used for heating the natural gas in order to avoid
the formation of
condensation in the natural gas entering the first inlet module 102a. An
instrument air
package (consisting of compressor, dryer and receiver) 120 is used for
providing the
instrument air entering the first inlet module 102a that controls the valves
in each module.
An optional start-up package 122 may be used for providing start-up fluid
entering the first
inlet module 102a that supports the formation of a steam chamber below each
injection
well as part of the SAGD process. An electrical building 124 is used for
transmitting power
to i) each ESP below each production well; ii) each electrical heat tracing
(EHT) panel for
freeze protection on the piping in each module; and iii) general utilities
(e.g. lighting) in
each module. A stick built cable tray and pipe (not shown) connects the
electrical
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building 124 to the first inlet module 102a. The electric building 124 also
includes a pre-
fabricated access platform and stairs (not shown). An ATCO transformer 126 is
used for
supplying power to the electrical building 124 and variable frequency drive
(VFD) skids 128 are
used for controlling the power to each ESP. A stock pile may be used for
storing excess soil and
a storm water pond may be used for collecting excess water runoff from the
well-pad system.
[0018] The modular well-pad system is based on receiving a pre-drilled well-
pad to
rough grade with an installed power transformer 126. Each module is sized for
international
transport by sea, rail and/or road and designed to be lowered onto piles so
that the on-site use of
cranes is minimized. Because the modular well-pad system and its production is
largely
standardized, it is expandable from one well-pair up to a maximum of twelve
well-pairs within a
well-pad boundary 134 using I and 2 well-pair modules that can be assembled in
any
configuration necessary to achieve the required count. Module access is at
grade, removing the
requirement for a platform.
[0019] Referring now to FIG. 2, a schematic sectional view of the first inlet
module 102a
in FIG. 1 illustrates standardized connections to the first inlet module 102a.
The first inlet
module 102a functions as the interface between the interconnecting pipelines
to and from the
CPF and interconnecting pipelines from other support structures. An emulsion
line and a casing
gas line are connected to one end and one side of the first inlet module 102a.
Emulsion and
casing gas produced by each production well (p) in the well-pairs 108-116
(FIG. 1) enter one
end of the first inlet module 102a from the second inlet module 102b and exit
one side of the
first inlet module 102a to the CPF. A steam line and a natural gas line are
also connected to one
end and one side of the first inlet module 102a. Steam and natural gas enter
one side of the first
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inlet module 102a from the CPF and exit one end of the first inlet module 102a
to the second
inlet module 102b. An instrument air-line and a start-up fluid line are
connected to one end and
opposite sides of the first inlet module 102a. Instrument air and start -up
fluid enter opposite
sides of the first inlet module 102a from the instrument air package 120 and
the start-up package
122, respectively, and exit one end of the first inlet module 102a to the
second inlet module
102a. The instrument air entering the first inlet module 102a controls any
valves in the first inlet
module 102a such as the emergency shutdown valves for the critical steam,
emulsion, natural
gas, casing gas, and start-up fluid lines at the well pad limits. The first
inlet module 102a also
includes the required metering for process measurement of steam, emulsion,
natural gas, casing
gas, instrument air and start-up fluid lines (hereinafter collectively
referred to as service lines)
and regulatory purposes. The first inlet module 102a minimizes the spacing
required for piping,
mechanical and electrical connections. Standardized connections allow for
mating-up between
the service lines connected to the first inlet module 102a and the respective
service lines
connected to the second inlet module 102b. The standardized connections thus,
allow for
predictable connectivity in any conceivable well pad design. In any
combination of the well-pad
system modules, only one first inlet module 102a is required.
[0020] Referring now to FIG. 3, a schematic sectional view of the second inlet
module
102b in FIG. 1 illustrates standardized connections to the second inlet module
102b. An
emulsion line and a casing gas line are connected each end of the second inlet
module 102b.
Emulsion and casing gas produced by each production well (p) in the well-pairs
108-116 (FIG.
1) enter one end of the second inlet module 102b from the 1 well-pair module
104 or the 2 well-
pair module 106 and exit the other end of the second inlet module 102b to the
first inlet module
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102a. A steam line, a natural gas line, an instrument-air line and a start-up
fluid line are also
connected to each end of the second inlet module 102b. Steam, natural gas,
instrument air and
start-up fluid enter one end of the second inlet module 102b from the first
inlet module 102a and
exit the other end of the second inlet module 102b to the 1 well-pair module
104 or the 2 well-
pair module 106. The instrument air entering the first second module 102b
controls any valves in
the second inlet module 102b such as the emergency shutdown valves for the
critical steam,
emulsion, natural gas, casing gas, and start-up fluid lines at the well pad
limits. The second inlet
module 102b also includes the required metering for process measurement of
steam, emulsion,
natural gas, casing gas, instrument air and start-up fluid lines and
regulatory purposes. The
second inlet module 102b minimizes the spacing required for piping, mechanical
and electrical
connections. Standardized connections allow for mating-up between the service
lines connected
to the second inlet module 102b and the respective service lines connected to
the first inlet
module 102a and the 1 well-pair module 104 or the 2 well-pair module 106. The
standardized
connections thus, allow for predictable connectivity in any conceivable well
pad design. In any
combination of the well-pad system modules, only one second inlet module 102b
is required.
[0021] Referring now to FIG. 4, a schematic sectional view of the 1 well-pair
module
104 in FIG. 1 illustrates standardized connections to the 1 well-pair module
104. An emulsion
line and a casing gas line are connected to each end of the 1 well-pair module
104. Alternatively,
an emulsion line and a casing gas line may be connected to only one end of the
1 well-pair
module 104 when it is the last module on the end of a modular well-pad system.
Emulsion and
casing gas produced by each production well (p) in the well-pairs 108-116
(FIG. 1) enter the 1
well-pair module 104 from another 1 well-pair module 104, the 2 well-pair
module 106 and/or
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another emulsion line and casing gas line connected to the production side of
the 1 well-pair
module 104 from each production well. The emulsion and casing gas exit the 1
well-pair module
104 to the second inlet module 102b, another 1 well-pair module 104 or the 2
well-pair module
106. A steam line, a natural gas line, an instrument-air line and a start-up
fluid line are also
connected to each end of the 1 well-pair module 104. Alternatively, a steam
line, a natural gas
line, an instrument-air line and a start-up fluid line may be connected to
only one end of the 1
well-pair module 104 when it is the last module on the end of a modular well-
pad system. Steam,
natural gas, instrument air and start-up fluid enter the 1 well-pair module
104 from the second
inlet module 102b, another 1 well-pair module 104 or the 3 well-pair module
106. The
instrument air entering the 1 well-pair module 104 controls any valves in the
1 well-pair module
104 and exits the 1 well-pair module 104 to another 1 well-pair module 104 or
the 2 well-pair
module 106. Steam and natural gas exit the 1 well-pair module 104 to another 1
well-pair
module 104, the 2 well-pair module 106 and/or another steam line and natural
gas line connected
to the injection side and the production side of the 1 well-pair module 104
from each respective
injection well and production well. Steam is used to form a steam chamber
below each injection
well and each production well as part of the SAGD process. Natural gas is used
as blanket gas
for each injection well and each production well. Start-up fluid also exits
the 1 well-pair module
104 to another 1 well-pair module 104, the 2 well-pair module 106 and/or
another start-up fluid
line connected to the injection side of the 1 well-pair module 104 from each
respective injection
well. The start-up fluid may be used to support the formation of a steam
chamber below each
injection well as part of the SAGD process. The 1 well-pair module 104
contains the process
piping and controls necessary to supply steam to each injection well and
receive emulsion from
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each production well. Each injection well and production well are connected to
the 1 well-pair
module 104 by a respective pre-fabricated piping spool (not shown), which
includes swivel
joints. The 1 well-pair module 104 minimizes the spacing required for piping,
mechanical and
electrical connections. Standardized connections allow for mating-up between
the service lines
connected to the 1 well-pair module 104 and the respective service lines
connected to the second
inlet module 102b, another 1 well-pair module 104 and/or the 2 well-pair
module 106. The
standardized connections allow for predictable connectivity in any conceivable
well pad design.
The 1 well pair module 104 may thus, be combined with the first inlet module
102a, the second
inlet module 102b and the 2 well-par module 106 in any quantity or combination
to achieve a
modular well-pad system that can accommodate one to twelve well- pairs on a
well pad. For
example, five well-pairs may contain five 1 well-pair modules 104, one 2 well-
pair module 106
and three 1 well-pair modules 104 or two 2 well-pair modules 106 and one 1
well-pair module
104 as illustrated in FIG. 1.
[0022] Referring now to FIG. 5, a schematic sectional view of the 2 well-pair
module
106 in FIG. 1 illustrates standardized connections to the 2 well-pair module
106. An emulsion
line and a casing gas line are connected to each end of the 2 well-pair module
106. Alternatively,
an emulsion line and a casing gas line may be connected to only one end of the
2 well-pair
module 106 when it is the last module on the end of a modular well-pad system.
Emulsion and
casing gas produced by each production well (p) in the well-pairs 108-116
(FIG. 1) enter the 2
well-pair module 106 from the 1 well-pair module 104, another 2 well-pai2
module 106 and/or
another emulsion line and casing gas line connected to the production side of
the 2 well-pair
module 106 from each production well. The emulsion and casing gas exit the 2
well-pair module
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106 to the second inlet module 102b, the I well-pair module 104 or another 2
well-pair module
106. A steam line, a natural gas line, an instrument-air line and a start-up
fluid line are also
connected to each end of the 2 well-pair module 106. Alternatively, a steam
line, a natural gas
line, an instrument-air line and a start-up fluid line may be connected to
only one end of the 2
well-pair module 106 when it is the last module on the end of a modular well-
pad system. Steam,
natural gas, instrument air and start-up fluid enter the 2 well-pair module
106 from the second
inlet module 102b, the I well-pair module 104 or another 2 well-pair module
106. The
instrument air entering the 2 well-pair module 106 controls any valves in the
2 well-pair module
106 and exits the 2 well-pair module 106 to the I well-pair module 104 or
another 2 well-pair
module 106. Steam and natural gas exit the 2 well-pair module 106 to the 1
well-pair module
104, another 2 well-pair module 106 and/or another steam line and natural gas
line connected to
the injection side and the production side of the 2 well-pair module 106 from
each respective
injection well and production well. Steam is used to form a steam chamber
below each injection
well and each production well as part of the SAGD process. Natural gas is used
as blanket gas
for each injection well and each production well. Start-up fluid also exits
the 2 well-pair module
106 to the 1 well-pair module 104, another 2 well-pair module 106 and/or
another start-up fluid
line connected to the injection side of the 2 well-pair module 106 from each
respective injection
well. The start-up fluid may be used to support the formation of a steam
chamber below each
injection well as part of the SAGD process. The 2 well-pair module 106
contains the process
piping and controls necessary to supply steam to each injection well and
receive emulsion from
each production well. Each injection well and production well are connected to
the 2 well-pair
module 106 by a respective pre-fabricated piping spool (not shown), which
includes swivel
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joints. The 2 well-pair module 106 minimizes the spacing required for piping,
mechanical and
electrical connections. Standardized connections allow for mating-up between
the service lines
connected to the 2 well-pair module 106 and the respective service lines
connected to the second
inlet module 102b, the 1 well-pair module 104 and/or another 2 well-pair
module 106. The
standardized connections allow for predictable connectivity in any conceivable
well pad design.
The 2 well pair module 106 may thus, be combined with the first inlet module
102a, the second
inlet module 102b, and the 1 well-par module 104 in any quantity or
combination to achieve a
modular well-pad system that can accommodate one to twelve well- pairs on a
well pad. For
example, five well-pairs may contain five 1 well-pair modules 104, one 2 well-
pair module 106
and three I well-pair modules 104 or two 2 well-pair modules 106 and one 1
well-pair module
104 as illustrated in FIG. 1.
[0023] Those skilled in the art will appreciate that the first inlet module
102a, the second
inlet module 102b, the 1 well-pair module 104 and the 2 well-pair module 106
may include
many possible different internal configurations of piping, mechanical and
electrical components.
If, for example, these modules needed to support a water flood reservoir
support design (high
pressure water injection downhole), then each steam line would be replaced
with high pressure
water line (with suitable controls) and each emulsion line would be replaced
with another
reservoir production fluid line such as a water, solution gas or oil line.
Suitable controls for these
new lines may require electrical actuation in which the instrument-air line
may be replaced with
an electrical line. In these cases the piping may vary at the Christmas tree
accordingly.
[0024] While the present disclosure has been described in connection with
presently
preferred embodiments, it will be understood by those skilled in the art that
it is not intended to
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limit the disclosure to those embodiments. It is therefore, contemplated that
various alternative
embodiments and modifications may be made to the disclosed embodiments without
departing
from the spirit and scope of the disclosure defined by the equivalents
thereof.
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