Note: Descriptions are shown in the official language in which they were submitted.
MODULAR WELL PAD SYSTEMS AND METHODS
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The priority of U.S. Provisional Patent Application No. 62/294,418,
filed February
12, 2016, is hereby claimed.
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 an inlet module, a 2 well-pair module and a 3 well-pair module. The
inlet module, one
or more 2 well-pair modules and one or more 3 well-pair modules may be
configured to build an
interconnected well pad system for accommodating two to twelve well-pairs
wherein
standardized connections enable the 2 well-pair module and the 3 well-pair
module to be coupled
together, to the inlet module, another 2 well-pair module and/or another 3
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 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.
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[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
interconnectivity also
renders such modules significantly inflexible for expansion. As a result,
conventional SAGD well
pads remain highly customized and therefore, costly to construct.
SUMMARY
[0004a] The present invention provides modular well pad systems and methods.
In
accordance with certain embodiments there is provided 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 end of the inlet module to a central
processing facility and the
plurality of service lines is connectable at another end of the inlet module
to a respective plurality
of service lines at one end of a 2 well-pair module and a respective plurality
of services lines at
one end of a 3 well-pair module; at least one of the 2 well-pair module and
the 3 well-pair module,
wherein 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 at one end of
another 2 well-pair module and a respective plurality of service lines at the
one end of the 3 well-
pair module and the plurality of service lines at the one end of the 3 well-
pair module are
connectable at another end of the 3 well-pair module to a respective plurality
of service lines at
one end of another 3 well-pair module and a respective plurality of service
lines at the one end
of the 2 well-pair module; the 2 well-pair module connectable to two well
pairs and the 3 well-
pair module connectable to three well pairs, wherein each well pair represents
an injection well
and a production well.
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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 an inlet module, a 2 well-pair module and a 3 well-pair module for
accommodating 5
well-pairs.
[0007] FIG. 2 is a schematic sectional view of the inlet module in FIG. 1
illustrating
standardized connections to the inlet module.
[0008] FIG. 3 is a schematic sectional view of the 2 well-pair module in FIG.
1
illustrating standardized connections to the 2 well-pair module.
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[0009] FIG. 4 is a schematic sectional view of the 3 well-pair module in FIG.
1
illustrating standardized connections to the 3 well-pair module.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0010] 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.
[0011] 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
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 pipelines;
separation on or off
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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.
[0012] 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.
[0013] 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
using modularization; iii) reduces materials; and iv) provides options to
enable the design to be
customized.
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[0014] The modular well-pad thus overcomes one or more of the prior art
disadvantages with an inlet module, a 2 well-pair module and a 3 well-pair
module. The inlet
module, one or more 2 well-pair modules and one or more 3 well-pair modules
may be
configured to build an interconnected well pad system for accommodating two to
twelve
well-pairs wherein standardized connections enable the 2 well-pair module and
the 3 well-
pair module to be coupled together, to the inlet module, another 2 well-pair
module and/or
another 3 well-pair module.
[0015] 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 end of the inlet module to
a central
processing facility and the plurality of service lines is connectable at
another end of the inlet
module to a respective plurality of service lines at one end of a 2 well-pair
module and a
respective plurality of services lines at one end of a 3 well-pair module; at
least one of the
2 well-pair module and the 3 well-pair module, wherein 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 at one end of another 2 well-pair
module and a
respective plurality of service lines at the one end of the 3 well-pair module
and the plurality
of service lines at the one end of the 3 well-pair module are connectable at
another end of the
3 well-pair module to a respective plurality of service lines at one end of
another 3 well-pair
module and a respective plurality of service lines at the one end of the 2
well-pair module;
the 2 well-pair module connectable to two well pairs and the 3 well-pair
module connectable
to three well pairs, wherein each well pair represents an injection well and a
production well.
[0016] Referring now to FIG. 1, a site plan 100 illustrates one embodiment of
a
modular well-pad system comprising an inlet module 102, a 2 well-pair module
104 and a 3
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well-pair module 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 from the CPF in order to avoid the formation of
condensation in the
natural gas entering the inlet module 102. An instrument air package
(consisting of
compressor, dryer and receiver) 120 is used for providing the instrument air
entering the
inlet module 102 that controls the valves in each module. An optional start-up
package 122
may be used for providing start-up fluid entering the inlet module 102 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 building 124 to the inlet module 102.
The electric
building 124 also includes a pre-fabricated access platform and stairs (not
shown). A pre-
fabricated access platform and stairs may also be provided for each EHT panel.
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
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excess water runoff from the well-pad system.
[0017] 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
highway
transport and designed to be lowered onto piles from the bed of a transport
vehicle so that the on-
site use of cranes is no longer required. Because the modular well-pad system
and its production
is largely standardized, it is expandable from two well-pairs up to a maximum
of twelve well-
pairs within a well-pad boundary 134 using 2 and 3 well-pair modules that can
be assembled in
any configuration necessary to achieve the required count. Because module
operating platforms
are designed to mate closely field platforms or handrail construction is not
required. Field
installed stairways, however, can be provided on any module based on local
construction and
safety requirements.
[0018] Referring now to FIG. 2, a schematic sectional view of the inlet module
102 in
FIG. 1 illustrates standardized connections to the inlet module 102. The inlet
module 102
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 each end of the inlet module 102. Emulsion and casing gas
produced by each
production well (p) in the well-pairs 108-116 (FIG. 1) enter the inlet module
102 from the 2
well-pair module 104 or the 3 well-pair module 106 and exit the inlet module
102 to the CPF. A
steam line and a natural gas line are also connected to each end of the inlet
module 102. Steam
and natural gas enter the inlet module 102 from the CPF and exit the inlet
module 102 to the 2
well-pair module 104 or the 3 well-pair module 106. An instrument air-line and
a start-up fluid
line are connected on opposite sides of the inlet module 102 and at one end of
the inlet module
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102 that is connected to the 2 well-pair module 104 or the 3 well-pair module
106. Instrument air
and start -up fluid enter the inlet module 102 from the instrument air package
120 and the start-
up package 122, respectively, and exit the inlet module 102 to the 2 well-pair
module 104 or the
3 well-pair module 106. The instrument air entering the inlet module 102
controls any valves in
the inlet module 102 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
inlet module 102 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. A pre-fabricated metering system piping spool and
steam pressure
safety valve (PSV) piping spool (not shown) are connected to one side of the
inlet module 102
on site. The inlet module 102 minimizes the spacing required for piping,
mechanical and
electrical connections. Standardized connections allow for mating-up between
the service lines
connected to the inlet module 102 and the respective service lines connected
to the 2 well pair
module 104 or the 3 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 inlet module 102 is required.
[0019] Referring now to FIG. 3, a schematic sectional view of the 2 well-pair
module
104 in FIG. 1 illustrates standardized connections to the 2 well-pair module
104. An emulsion
line and a casing gas line are connected to each end of the 2 well-pair module
104. Alternatively,
an emulsion line and a casing gas line may be connected to only one end of the
2 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 2
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well-pair module 104 from another 2 well-pair module 104, the 3 well-pair
module 106 and/or
another emulsion line and casing gas line connected to the production side of
the 2 well-pair
module 104 from each production well. The emulsion and casing gas exit the 2
well-pair module
104 to the inlet module 102, another 2 well-pair module 104 or the 3 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 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 2 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 2 well-pair module 104 from
the inlet module 102,
another 2 well-pair module 104 or the 3 well-pair module 106. The instrument
air entering the 2
well-pair module 104 controls any valves in the 2 well-pair module 104 and
exits the 2 well-pair
module 104 to another 2 well-pair module 104 or the 3 well-pair module 106.
Steam and natural
gas exit the 2 well-pair module 104 to another 2 well-pair module 104, the 3
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 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 2 well-pair module 104 to
another 2 well-pair
module 104, the 3 well-pair module 106 and/or another start-up fluid line
connected to the
injection side of the 2 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 2 well-pair module 104 contains the process piping
and controls
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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 104 by a
respective pre-fabricated piping spool (not shown), which includes swivel
joints. The 2 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 2 well-
pair module 104 and the respective service lines connected to the inlet module
102, another 2
well-pair module 104 and/or the 3 well-pair module 106. The standardized
connections allow for
predictable connectivity in any conceivable well pad design. The 2 well pair
module 104 may
thus, be combined with the inlet module and the 3 well-par module 106 in any
quantity or
combination to achieve a modular well-pad system that can accommodate two to
twelve well-
pairs on a well pad. For example, seven well-pairs will contain a 3 well-pair
module 106 and two
2 well-pair modules 104.
[00201 Referring now to FIG. 4, a schematic sectional view of the 3 well-pair
module
106 in FIG. 1 illustrates standardized connections to the 3 well-pair module
106. An emulsion
line and a casing gas line are connected to each end of the 3 well-pair module
106. Alternatively,
an emulsion line and a casing gas line may be connected to only one end of the
3 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 3
well-pair module 106 from the 2 well-pair module 104, another 3 well-pair
module 106 and/or
another emulsion line and casing gas line connected to the production side of
the 3 well-pair
module 106 from each production well. The emulsion and casing gas exit the 3
well-pair module
106 to the inlet module 102, the 2 well-pair module 104 or another 3 well-pair
module 106. A
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steam line, a natural gas line, an instrument-air line and a start-up fluid
line are also connected to
each end of the 3 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 3 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 3 well-pair module 106 from
the inlet module 102,
the 2 well-pair module 104 or another 3 well-pair module 106. The instrument
air entering the 3
well-pair module 106 controls any valves in the 3 well-pair module 106 and
exits the 3 well-pair
module 106 to the 2 well-pair module 104 or another 3 well-pair module 106.
Steam and natural
gas exit the 3 well-pair module 106 to the 2 well-pair module 104, another 3
well-pair module
106 and/or another steam line and natural gas line connected to the injection
side and the
production side of the 3 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 3 well-pair module 106 to the 2
well-pair module
104, another 3 well-pair module 106 and/or another start-up fluid line
connected to the injection
side of the 3 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 3 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 3 well-pair module 106
by a respective
pre-fabricated piping spool (not shown), which includes swivel joints. The 3
well-pair module
106 minimizes the spacing required for piping, mechanical and electrical
connections.
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Standardized connections allow for mating-up between the service lines
connected to the 3 well-
pair module 106 and the respective service lines connected to the inlet module
102, the 2 well-
pair module 104 and/or another 3 well-pair module 106. The standardized
connections allow for
predictable connectivity in any conceivable well pad design. The 3 well pair
module 106 may
thus, be combined with the inlet module and the 2 well-par module 104 in any
quantity or
combination to achieve a modular well-pad system that can accommodate two to
twelve well-
pairs on a well pad. For example, seven well-pairs will contain a 3 well-pair
module 106 and two
2 well-pair modules 104.
[0021] Those skilled in the art will appreciate that the inlet module 102, the
2 well-pair
module 104 and the 3 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.
[0022] 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
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 appended claims and
equivalents
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thereof.
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