U.S. patent application number 15/440812 was filed with the patent office on 2017-06-08 for modular processing facility.
The applicant listed for this patent is Fluor Technologies Corporation. Invention is credited to Gary Donovan, Sean Halvorsen, Fred Haney, Alan Lowrie, Simon Lucchini, George Morlidge, Todd Roth.
Application Number | 20170159305 15/440812 |
Document ID | / |
Family ID | 58798933 |
Filed Date | 2017-06-08 |
United States Patent
Application |
20170159305 |
Kind Code |
A1 |
Haney; Fred ; et
al. |
June 8, 2017 |
MODULAR PROCESSING FACILITY
Abstract
The various processes of a plant may be segmented into separate
process blocks, which may be interconnected using fluid conduits
and/or electrical connections. These process blocks may be directly
connected, for example without an external piperack interconnecting
process blocks. In some embodiments, each process block may be
formed of one or more modules. The process-based nature of this
modular approach, along with the optional lack of an external
interconnecting piperack, may provide benefits over conventional
modular plant design.
Inventors: |
Haney; Fred; (Calgary,
CA) ; Donovan; Gary; (Canmore, CA) ; Roth;
Todd; (Calgary, CA) ; Lowrie; Alan; (Calgary,
CA) ; Morlidge; George; (Okotoks, CA) ;
Lucchini; Simon; (Calgary, CA) ; Halvorsen; Sean;
(Calgary, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Fluor Technologies Corporation |
Sugar Land |
TX |
US |
|
|
Family ID: |
58798933 |
Appl. No.: |
15/440812 |
Filed: |
February 23, 2017 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
14747727 |
Jun 23, 2015 |
|
|
|
15440812 |
|
|
|
|
14527425 |
Oct 29, 2014 |
9376828 |
|
|
14747727 |
|
|
|
|
12971365 |
Dec 17, 2010 |
8931217 |
|
|
14527425 |
|
|
|
|
62300636 |
Feb 26, 2016 |
|
|
|
61287956 |
Dec 18, 2009 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04H 5/02 20130101; E04H
1/005 20130101 |
International
Class: |
E04H 1/00 20060101
E04H001/00; E04H 5/02 20060101 E04H005/02 |
Claims
1. A modular processing facility, comprising: at least 3 process
blocks; wherein the at least 3 process blocks are non-identical
process blocks; wherein the at least 3 process blocks each comprise
one or more modules; and wherein the at least 3 process blocks are
not laid out on a piperack backbone for interconnecting process
blocks or modules, such that there is no external interconnecting
piperack interconnecting any of the 3 process blocks.
2. The facility of claim 1, wherein each of the at least 3 process
blocks comprises its own integral E+I Distribution.
3. The facility of claim 1, wherein each of the at least 3 process
blocks is configured based on a process-based approach.
4. The facility of claims 1, wherein the process blocks are close
coupled to minimize interconnects and to reduce overall footprint
of the facility.
5. The facility of claims 2, wherein each of the at least 3 process
blocks is configured to allow for independent pre-commissioning,
check-out, or commissioning of a corresponding process system.
6. The facility of claims 1, wherein each of the at least 3 process
blocks comprises integral pipeways for utility distribution.
7. The facility of claims 1, wherein each of the at least 3 process
blocks is located in proximity to one or more other of the at least
3 process blocks, without intervening process blocks, modules, or
piperacks therebetween.
8. The facility of claims 1, wherein each of the at least 3 process
blocks is interconnected to one or more other of the at least 3
process blocks, and wherein the interconnects include fluid
piping.
9. The facility of claims 1, wherein each of the at least 3 process
blocks is positioned in proximity to the other of the at least 3
process blocks to which it directly interconnects, without
intervening external piperacks or process blocks therebetween.
10. The facility of claims 1, wherein each of the at least 3
process blocks abuts at least one other of the at least 3 process
blocks.
11. The facility of claims 1, wherein the interconnections between
process blocks are disposed entirely within the envelope of
abutting process blocks.
12. A modular method of constructing a processing facility,
comprising: arranging a plurality of process blocks with respect to
one another; wherein the plurality of process blocks are
non-identical process blocks; wherein the plurality of process
blocks each comprise one or more modules; and wherein the plurality
of process blocks are not laid out on a piperack backbone for
interconnecting process blocks, such that there is no external
piperack interconnecting the plurality of process blocks.
13. The method of claim 12 further comprising providing integral
E+I distribution for each of the plurality of process blocks;
wherein each of the plurality of process blocks comprises its own
integral E+I Distribution.
14. The method of claim 12, further comprising: constructing one or
more of the plurality of process blocks at a location different
from the ultimate site of the processing facility; and
pre-commissioning, check-out, or commissioning of a corresponding
process system for the one or more process blocks constructed away
from the ultimate facility site at a location separate and apart
from the ultimate site of the facility.
15. The method of claim 13, wherein the pre-commissioning,
check-out, or commissioning for the one or more process blocks
occurs without connection of each such one or more process block to
any other of the plurality of process blocks.
16. The method of claims 14, further comprising directly
interconnecting each process block to one or more adjacent process
blocks.
17. The method of claims 12, further comprising configuring each
process block to accomplish a corresponding process.
18. A process facility constructed at least in part by coupling
first, second, and third process blocks; wherein at least 3
transportable modules are used to collectively compose the process
blocks; wherein each of the modules is fluidly and electrically
coupled to at least one other of the modules using
direct-module-to-module connections, such that no external piperack
interconnects the three process blocks; wherein the first process
block is positioned adjacent to each of the second and third
process blocks; wherein the first process block includes first and
second modules, and the second process block includes third and
fourth modules, each of which has a height greater than 4 m and a
width greater than 4 m; and wherein the first process block is
configured to carry out a first process and the second process
block is configured to carry out a second process different from
the first process.
19. The facility of claim 18, wherein each of the process blocks
comprises its own integral E+I Distribution and is configured to
allow for independent pre-commissioning, check-out, or
commissioning of a corresponding process system.
20. The facility of claim 19, wherein each of the process blocks is
positioned in proximity to and abuts the other of the process
blocks to which it directly interconnects, without intervening
external piperacks or process blocks therebetween; wherein the
interconnections between process blocks are disposed entirely
within the envelope of abutting process blocks; and wherein each
process block is configured with multiple types of equipment in
order to allow for the corresponding process system to run in an
internally self-contained manner, with no interaction with external
equipment or process blocks outside that process block to perform
any portion of the process.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent
Application No. 62/300,636 (filed Feb. 26, 2016 and entitled
"Modular Processing Facility"); this application also claims
priority as a continuation-in-part to U.S. patent application Ser.
No. 14/747,727 (filed Jun. 23, 2015 and entitled "Modular
Processing Facilities"), which claims priority as a division of
U.S. Pat. No. 9,376,828 (i.e. U.S. patent application Ser. No.
14/527,425 filed Oct. 29, 2014 and entitled "Modular Processing
Facility"), which is a division of U.S. Pat. No. 8,931,217 (i.e.
U.S. patent application Ser. No. 12/971,365 filed Dec. 17, 2010 and
entitled "Modular Processing Facility"), which claims priority to
U.S. Provisional Patent Application No. 61/287,956 (filed Dec. 18,
2009 and entitled "Modular Processing Facility"), such that this
application claims priority to all above listed patents and
applications, with the contents of each being hereby incorporated
by reference in their entireties for all purposes.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
TECHNICAL FIELD
[0004] This disclosure if generally related to the modular
construction of process facilities, with particular examples given
with respect to modular oil sand processing facilities (although
the modular construction described herein may apply to other types
of processing facilities).
BACKGROUND
[0005] 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.
[0006] 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.
Typically such 2.sup.nd Generation ("2.sup.nd Gen") modules are not
process based, but rather are equipment based, meaning that each of
the modules in a 2.sup.nd Gen Construction typically relate to a
specific equipment type (e.g., pumps, compressors, heat exchangers,
cooling towers, etc.). Several 2.sup.nd Gen 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.
[0007] 2.sup.nd Gen 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
2.sup.nd Gen Modular facility is described in US20080127662 to
Stanfield.
[0008] Unless otherwise expressly indicated herein, Shumway,
Stanfield, 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 and/or usage of that term provided herein, the
definition or usage of that term provided herein applies, and the
definition of that term in the reference does not apply.
[0009] There have been very significant cost savings in using
2.sup.nd Gen Modular approaches. 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 2.sup.nd Gen
Modular, there are still problems. Possibly the most serious
problems arise from the ways in which the various modules are
interconnected. In 2.sup.nd Gen 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. However,
where small production units are impractical or uneconomical, the
use of external piperacks is a hindrance. For example, not only
does the 2.sup.nd Gen usage of one or more external piperacks
typically result in the utilization of more piping and additional
work in the field to interconnect modules, external piperacks
interconnecting modules may also typically severely limit the
amount of pre-commissioning, check out, and/or commissioning of
modules individually and/or before they are installed at the
ultimate site of the facility (e.g. at a construction facility in
an industrial area remote from the ultimate site of the entire
process facility). This limitation typically arises due to the
equipment-based nature of 2.sup.nd Gen modules as described above,
which does not lend itself to stand-alone pre-commissioning,
check-out, and/or commissioning (because in order for a process to
be performed using such equipment-based 2.sup.nd Gen modules, the
modules would have to be interconnected with other modules in a way
that forms a process which can be evaluated effectively as a
whole). This may also especially be true since typical 2.sup.nd Gen
modules do not have integrated E+I (electrical and instrumentation)
systems in each module, but instead typically are connected to a
centralized E+I system (for example via home run interconnecting
cabling through traditional interconnecting racks).
[0010] What is needed is a new modular paradigm, in which the
various processes of a plant are segmented in process blocks each
comprising one or more (typically multiple) modules. This document
refers to such designs and implementations as 3rd Generation
("3.sup.rd Gen") Modular Construction or as 3.sup.rd Gen processing
facilities.
SUMMARY
[0011] The disclosed subject matter provides apparatus, systems,
and methods in which the various processes of a plant are segmented
into process blocks, each process block comprising one or more
(typically multiple) modules, wherein at least some of the modules
within at least some of the process blocks are fluidly and
electrically coupled to at least another of the modules using
direct-module-to-module connections.
[0012] Typically, embodiments of a 3.sup.rd Gen processing facility
would be constructed (for example modularly) by coupling together
at least two process blocks. In preferred embodiments, a processing
facility might be constructed at least in part by coupling together
three or more process blocks. In some embodiments, each of at least
two of the blocks comprises at least two truckable modules, and
more preferably three, four, five, or even more such modules.
Contemplated embodiments can be rather large, and can have four,
five, ten, or even twenty or more process blocks, which
collectively might comprise up to a hundred, two hundred, or even a
higher number of truckable modules in some embodiments. Other
embodiments may have process blocks comprising one or more
transportable modules. All manner of industrial processing
facilities are contemplated, including nuclear, gas-fired,
coal-fired, or other energy producing facilities, chemical plants,
and mechanical plants. And while 3.sup.rd Gen techniques might be
used for some off-shore modular construction, more often 3.sup.rd
Gen modules and construction techniques would be used to construct
on-shore processing facilities.
[0013] 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.
[0014] As used herein the term "process block" means a part of a
processing facility that has several process systems within a
distinct geographical boundary. Typically, each process block is
configured to achieve a single (stand-alone) process, for example
of the sort that a process engineer might use in a process block
layout. Thus, the term "process" in this context is utilized in the
manner that one of ordinary skill (e.g., a process engineer) would
use the term for individual processes in a process block layout of
a processing facility. A process carried out within a process block
may include one or more unit operations (e.g., a physical change
and/or chemical transformation), and typically a process block
might comprise two or more unit operations. So in at least some
embodiments, a process block includes multiple pieces and types of
equipment (e.g., pumps, compressors, vessels, heat exchangers,
vessels, coolers, blowers, reactors, etc., for example) for
carrying out a plurality of unit operations with a contiguous,
defined geographical area (i.e., the geographical area defined by
the corresponding process block). In addition, in at least some
embodiments the process blocks (e.g. the multiple pieces and types
of equipment as well as the multiple unit operations) would be
arranged and designed to support or relate to at least one common,
overarching process, for example relating to the primary process
flow of the production facility as a whole. Typically, each process
block would have its own self-supporting E+I. Due to such features,
each process block may be operable or configured for independent
pre-commissioning, check-out, and/or commissioning. Each process
block typically accepts specific feed(s) and processes such feed(s)
into one or more products (e.g. outputs). In some instances, one or
more of the feed(s) for a specific process block may be provided
from other process blocks(s) (e.g. the products from one or more
other interconnected process blocks) in the facility, and in some
instances the products from a specific process block might serve as
inputs or feeds into one or more other process blocks of a
facility. In the hydrocarbon and chemical business, a process block
can comprise equipment, such as processing columns, reactors,
vessels, drums, tanks, filters, as well as pumps or compressors to
move the fluids through the processing equipment and heat
exchangers and heaters for heat transfer to or from the fluid. The
type and arrangement of equipment within the defined geographic
area of a given process block is designed to carry out the specific
process(es) with the feed for that process block (i.e., the
equipment arranged within the process bock is chosen and arranged
to facilitate the designed process(es) of the process block and is
not simply grouped by equipment type such as would be found in a
2.sup.nd Gen modular construction). A process block typically might
inherently have a series of piping systems and controls to
interconnect the equipment within the process block. By eliminating
the traditional interconnecting piperack, the 3.sup.rd Gen approach
may facilitate an efficient systems-based layout resulting in the
reduction of piping quantities. For solid material processing
facilities, such as mineral processing, the piping systems
described above would typically be replaced with material handling
equipment (e.g., conveyors, belts, elevators, etc.). Most often, a
process block would include a maximum of 20 to 30 pieces of
equipment, but there could be more or less pieces of equipment in
some process block embodiments. Typically, all equipment for a
specific process would be located within a single (for example,
contiguous) geographic footprint and/or envelope. Thus, the
inputs/feeds for a specific process block would typically be the
inputs needed for the process (as a whole), and the outputs for the
process block would typically be the outputs resulting from the
process (as a whole). Thus, the actual process would basically be
self-contained within the corresponding process block. And
typically, each such process block is configured to achieve a
distinct/different process (which may include one or more unit
operations as previously described). While some process facilities
might comprise only two process blocks, more typical process
facilities may comprise at least 3 process blocks (and in some
embodiments, at least 5, at least 7, or at least 10 process
blocks), with each of the at least 3 process blocks being
non-identical (e.g. each of the at least 3 process blocks may be
configured for a different process) (e.g. not simply multiple,
substantially identical modules, for example in parallel). So while
there may be some amount of duplication of process blocks (for
example, for scaling purposes) in 3.sup.rd Gen, it is typically
true of 3.sup.rd Gen processing facilities that they include at
least 3 (or at least 2, at least 5, at least 7, or at least 10)
different process modules, which may be interconnected (for example
via piping and/or electrically) in forming the entire facility. By
way of example, a facility might have one or more process blocks
for generation of steam, for distillation, scrubbing, or otherwise
separating one material from another, for crushing, grinding, or
performing other mechanical operations, for performing chemical
reactions with or without the use of catalysts, for cooling, and so
forth.
[0015] 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. While some
embodiments may employ one or more truckable modules, other
embodiments may employ one or more transportable modules.
Transportable modules are modules (e.g. sections of a process block
or an entire process block including multiple pieces of equipment)
operable to be transported using one or more means for transport.
"Transportable module" is intended to be a broader term than
"truckable module," such that the term typically includes truckable
modules, for example, but also includes larger modules that would
not be considered truckable. So for example, a transportable module
might be at least 30,000 Kg or at least 40,000 Kg. In some
embodiments, a transportable module might be up to 6,000,000 Kg, or
even more (for example, for very large modules). In some
embodiments, a transportable module might be between 30,000 Kg and
6,000,000 Kg, between 30,000 Kg and 500,000 Kg or between 40,000 Kg
and 350,000 Kg. From a dimensions perspective, such transportable
modules would typically measure at least 15 meters long, at least 3
meters wide, and at least 3 meters high, or in other embodiments at
least 15 meters long, at least 4 meters wide, and at least 4 meters
high.
[0016] Truckable and/or transportable modules may be closed on all
sides, and on the top and bottom, but more typically such modules
would have at least one open side, and possibly all four open
sides, as well as an open top. The open sides allow modules to be
positioned adjacent to one another at the open sides, thus creating
a large open space, comprising 2, 3, 4, 5 or even more modules,
through which an engineer operator, or other personnel could walk
from one module to another, for example within a process block.
[0017] A typical truckable and/or transportable module might well
include equipment from multiple disciplines, as for example,
process and staging equipment, platforms, wiring, instrumentation,
and lighting.
[0018] One very significant advantage of 3.sup.rd Gen 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 (3), four (4), or
five (5) fluid lines, excluding utility lines. It is contemplated,
however, that there could be two or more process blocks that are
coupled by six (6), seven (7), eight (8), nine (9), ten (10), or
more fluid lines, excluding utility lines. It is also contemplated
that each process block will include its own integrated E+I system
such that E+I lines (e.g., cables, wires, etc.) for each process
block are routed through the modules of that process block. For
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. In addition, as
used herein, "utility lines" refers to lines (e.g., pipes,
conduits, tubes, hoses, etc.) for carrying fluids (i.e., liquids
and gases) that facilitate the chemical and/or physical processes
within one or more process blocks. For example, the fluid carried
by a utility line may include air, nitrogen (N.sub.2), oxygen
(O.sub.2), water (H.sub.2O), steam, etc. The term "utility line"
does not include electrical or instrumentation cables, lines,
wires, etc. (e.g., such as would be associated within the E+I
system).
[0019] Process blocks can be assembled in any suitable manner. For
example, in some embodiments 3.sup.rd Gen process blocks are
arranged and interconnected with one another without an external
piperack (so for example, the process blocks would not be laid out
with a piperack backbone connecting the process modules, as may be
fairly typical in 2.sup.nd Gen modular design for example).
Instead, in these embodiments the 3.sup.rd Gen process blocks
typically are directly interconnected with one another in
accordance with a 3.sup.rd Gen Construction block layout, for
example. In other words, each of the process blocks typically would
be arranged/positioned in proximity (for example, oftentimes
abutting) with one or more process blocks with which it interacts
(e.g. with inputs and outputs directly interconnecting the process
blocks), without intervening external interconnecting piperack(s)
and/or process blocks therebetween. While in some embodiments all
process blocks might be positioned and/or interconnected in this
manner (e.g. in proximity with and direct interconnected with the
other process blocks with which it interacts), in some embodiments
only some of the process blocks (e.g. 3 or more, 5 or more, 8 or
more, or 10 or more process blocks) might be so arranged and/or
interconnected (and other process blocks might be arranged and/or
interconnected differently). For example, in some embodiments, the
process blocks for the primary process flow might all be so
positioned and/or interconnected, even though one or more other
process blocks might be positioned in such a way as to require
interconnection through an unrelated process block. This direct
connection between interconnected process blocks may allow for
close coupling of the process blocks, for example with each process
block abutting one or more other process blocks such that the
interconnections therebetween are located within the envelope of
those process blocks. 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. As another example, in other embodiments, the
inputs and outputs of at least some of the 3.sup.rd Gen process
blocks may optionally be coupled via an internal piping spine that
runs through at least a portion of the processing facility (and
particularly through (e.g. internally within) the corresponding
process blocks). The utility lines associated with the 3.sup.rd Gen
process blocks may also route along the piping spine so as to feed
each of the process blocks. In these embodiments (as well as in
other embodiments) the E+I lines and the fluid lines
interconnecting the equipment within each process block are not
routed through the piping spine and are instead routed
independently of the piping spine within the process block (i.e.,
within the geographic area defined by the corresponding process
block).
[0020] 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 (in some embodiments), preferred process
blocks have 3 or 4 modules arranged in a side-by-side fashion, and
abutted at one or both of their collective ends by the sides of one
or more other modules. Individual process blocks can certainly have
different numbers of modules, and for example a first process block
could have five (5) modules, another process block could have two
(2) modules, and a third process block could have another two (2)
modules. In other embodiments, a first process block could have at
least five (5) modules, another process block could have at least
another five (5) modules, and a third process block could have at
least another five (5) modules.
[0021] In some contemplated embodiments, 3.sup.rd Gen Modular
Construction facilities are those in which the process blocks
collectively include equipment configured to extract oil from oil
sands. Facilities are also contemplated in which at least one of
the process blocks produces power used by at least another one of
the process blocks, and independently wherein at least one of the
process blocks produces steam used by at least another one of the
process blocks, and independently wherein at least one of the
process blocks includes an at least two story cooling tower. It is
also contemplated that at least one of the process blocks includes
a personnel control area, which is controllably coupled to the
equipment within the at least one process block (e.g., via
electrical conductors, fiber optics cables, etc.). In general, but
not necessarily in all cases, the process blocks of a 3.sup.rd Gen
Modular facility would collectively include at least one of a
vessel, a compressor, a heat exchanger, a pump, and/or a
filter.
[0022] Although a 3.sup.rd Gen 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 do not pass through a
common interconnecting piperack.
[0023] Various objects, features, aspects and advantages will
become more apparent from the following description of exemplary
embodiments and accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] For a more complete understanding of the present disclosure,
reference is now made to the following brief description, taken in
connection with the accompanying drawings and detailed description,
wherein like reference numerals represent like parts.
[0025] FIG. 1 is a flowchart showing some of the steps involved in
a 3.sup.rd Gen Construction process.
[0026] FIG. 2 is an example of a 3.sup.rd Gen Construction process
block showing a first level grid and equipment arrangement.
[0027] FIG. 3 is a simple 3.sup.rd Gen Construction "block"
layout.
[0028] 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.
[0029] 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.
[0030] 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).
[0031] 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.
[0032] FIG. 8 is a schematic of a 3.sup.rd Gen Modular facility
having four process blocks, each of which has five modules.
[0033] FIG. 9 is a schematic of another 3rd Generation Modular
facility having a total of six interconnected process blocks.
DETAILED DESCRIPTION
[0034] It should be understood at the outset that although
illustrative implementations of one or more embodiments are
illustrated below, the disclosed systems and methods may be
implemented using any number of techniques, whether currently known
or not yet in existence. The disclosure should in no way be limited
to the illustrative implementations, drawings, and techniques
illustrated below, but may be modified within the scope of the
appended claims along with their full scope of equivalents.
[0035] The following brief definition of terms shall apply
throughout the application:
[0036] The term "comprising" means including but not limited to,
and should be interpreted in the manner it is typically used in the
patent context;
[0037] The phrases "in one embodiment," "according to one
embodiment," and the like generally mean that the particular
feature, structure, or characteristic following the phrase may be
included in at least one embodiment of the present invention, and
may be included in more than one embodiment (importantly, such
phrases do not necessarily refer to the same embodiment);
[0038] If the specification describes something as "exemplary" or
an "example," it should be understood that refers to a
non-exclusive example;
[0039] The terms "about" or "approximately" or the like, when used
with a number, may mean that specific number, or alternatively, a
range in proximity to the specific number, as understood by persons
of skill in the art field (for example, +/-10%); and
[0040] If the specification states a component or feature "may,"
"can," "could," "should," "would," "preferably," "possibly,"
"typically," "optionally," "for example," "often," or "might" (or
other such language) be included or have a characteristic, that
particular component or feature is not required to be included or
to have the characteristic. Such component or feature may be
optionally included in some embodiments, or it may be excluded.
[0041] The terms "commissioning" and "pre-commissioning" refer to
processes and procedures for bringing a system, component, module,
process block, piece(s) of equipment, etc. in to working condition.
These terms may include testing to verify the function of a given
system, component, module, process block, piece(s) of equipment,
according to the design specifications and objectives.
[0042] The term "process" is used herein in the manner that one of
ordinary skill (i.e., a process engineer) would use the term for
individual processes in a process block layout of a processing
facility. In addition, a process carried out within a process block
may include one or more "unit operations" which include a physical
change and/or chemical transformation in a given process flow
(e.g., fluid or solid flow).
[0043] In one aspect of exemplary 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 may 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 may be fluidly coupled by no more than five fluid
lines, excluding utility lines. In still other preferred
embodiments, a D module could be stacked upon the C module, and a
third fluid line could directly couple C and D modules.
[0044] Methods of laying out a 2.sup.nd Gen Modular facility are
different in many respects from those used for laying out a
3.sup.rd Gen Modular facility. Whereas the former generally merely
involves dividing up equipment for a given process or unit
operation among various modules (e.g. an equipment-based approach),
the latter preferably takes place in a (process-based) five-step
process as described below. For example, in a typical 2.sup.nd Gen
Modular facility, equipment is grouped and arranged by type (e.g.,
pumps for servicing various different processes are arranged within
one or more pumping modules and lines connecting the pumps to the
various other pieces of equipment related to the various processes
and process blocks are routed through one or more external
piperacks). It is contemplated that while traditional 2.sup.nd Gen
Modular Construction can prefab about 50-60% of the work of a
complex, multi-process facility, 3.sup.rd Gen Modular Construction
can prefab up to about 90-95% of the work. 3.sup.rd Gen modular
construction can also reduce interconnecting piping and/or cabling,
(for example, due to the more direct nature of the interconnections
and/or the reduced number of inputs/outputs for each process block)
as well as reducing time in the field needed to interconnect
modules. The reduction in the length/amount of piping and/or
cabling may result in lower total installed costs (TIC) and/or
lower operating hydraulic power demand (with respect to piping)
and/or lower operating power demand (with respect to cabling).
Furthermore, the process-based nature of 3.sup.rd Gen may allow for
much more substantial pre-commissioning, check-out, and/or
commissioning (for example at the fab or mod yard, at a location
away from the ultimate site of the facility--e.g. off-site),
thereby reducing effort and time in the field to complete any
additional pre-commissioning, check-out, and/or commissioning of
process blocks and their systems. By way of example, each process
block of a facility might be fully pre-commissioned, checked-out,
and/or commissioned off-site, such that the only pre-commissioning,
check-out, and/or commissioning left for the field would be
interconnections between process blocks and/or the process facility
as a whole.
[0045] Also, in at least some embodiments, each process block in a
3.sup.rd Gen process facility disclosed herein includes its own
independent (e.g. self-supporting) power and control (i.e., E+I)
systems such that the various process blocks in the 3.sup.rd Gen
facility do not share E+I systems. As a result, each process block
may be independently installed and operated without needing to
install other process blocks making up the processing facility. In
addition, the independent E+I systems for each process block allow
for the avoidance of routing E+I lines through an external piperack
extending through the processing facility. Typically speaking, in a
2.sup.nd Gen facility, a single E+I system is shared and
distributed among all modules such that a relatively large amount
of E+I lines (e.g., cabling) must be routed between the control
station, room, etc. and the various pieces of equipment within each
module. Thus, such a typical 2.sup.nd Gen arrangement typically
requires running the shared E+I lines through one or more external
piperacks extending throughout the facility (which is clearly
different than 3.sup.rd Gen).
[0046] Additional information for designing 3.sup.rd Gen Modular
Construction facilities is included in the 3.sup.rd Gen 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,
but is merely exemplary. In the event there is a discrepancy
between the Design Guide and this specification, the specification
shall control.
[0047] 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.
[0048] Step 101 is to identify the 3.sup.rd Gen 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 herein.
[0049] Step 102 is to allocate a plot space for each 3.sup.rd Gen
Construction process block. The plot space allocation requires the
piping layout specialist to distribute the relevant equipment
within each 3.sup.rd Gen 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 3.sup.rd Gen Construction process block equipment layout
requires attention to location to assure effective integration with
the piping, electrical and control distribution. In order to
provide guidance to the layout specialist the following steps
should be followed:
[0050] Step 102A is to obtain necessary equipment types, sizes and
weights. It is important that equipment be sized so that it can fit
effectively onto a module. Any equipment that has been sized and
which cannot fit effectively onto the module envelope needs to be
evaluated by the process lead for possible resizing for effective
module installation.
[0051] Step 102B is to establish an overall geometric area for the
process block using a combination of transportable module
dimensions. A first and second level should be identified using a
grid layout where the grid identifies each module boundary within
the process block.
[0052] Step 102C is to allocate space for the electrical and
control distribution panels on the first level. FIG. 2 is an
example of a 3.sup.rd Gen Construction process block first level
grid and equipment arrangement. The E+I panels are sized to include
the motor control centers and distributed instrument controllers
and inputs/outputs (I/O) necessary to energize and control the
equipment, instrumentation, lighting and electrical heat tracing
within the process block. The module which contains the E+I panels
is designated the 3.sup.rd Gen primary process block module. Refer
to E+I installation details for 3.sup.rd Gen module designs.
[0053] Step 102D is to group the equipment and instruments by
primary systems using the process block process flow diagrams
(PFDs).
[0054] Step 102E is to lay out each grouping of equipment by system
(rather than by equipment type) onto the process block layout
assuring that equipment does not cross module boundaries. The
layout should focus on keeping the pumps located on the same module
grid and level as the E+I distribution panels. This will assist
with keeping the electrical power home run cables together. If it
is not practical, the second best layout would be to have the pumps
or any other motor close to the module with the E+I distribution
panels. In addition, equipment should be spaced to assure effective
operability, maintainability, and safe access and egress.
[0055] The use of Fluor's Optimeyes.TM. is an effective tool at
this stage of the project to assist with process block layouts.
[0056] Step 103 is to prepare a detailed equipment layout within
process blocks to produce an integrated 3.sup.rd Gen facility. Each
process block identified from step 102 is laid out onto a plot
space assuring interconnects required between blocks are minimized.
The primary interconnects are identified from the process flow
block diagram. Traditional interconnecting piperacks are preferably
no longer needed or used. A simple, typical 3.sup.rd Gen "block"
layout is illustrated in FIG. 3.
[0057] Step 104 is to develop a 3.sup.rd Gen Module Configuration
Table and power and control distribution plan, which combines
process blocks for the overall facility to eliminate traditional
interconnecting piperacks and reduce the number of interconnects. A
3.sup.rd Gen module configuration table is developed using the
above data. Templates can be used, and for example, a 3.sup.rd Gen
power and control distribution plan can advantageously be prepared
using the 3.sup.rd Gen power and control distribution architectural
template.
[0058] Step 105 is to develop a 3.sup.rd Gen Modular Construction
plan, which includes fully detailed process block modules on an
integrated multi-discipline basis. The final step for this phase of
a project is to prepare an overall modular 3.sup.rd Gen Modular
Execution plan, which can be used for setting the baseline to
proceed to the next phase. It is contemplated that a 3.sup.rd Gen
Modular Execution will require a different schedule than
traditionally executed modular projects.
[0059] Many of the differences between the traditional 1.sup.st
Generation and 2.sup.nd Gen Modular Construction and the 3.sup.rd
Gen Modular Construction are set forth in Table 1 below, with
references to the 3.sup.rd Gen Modular Execution Design Guide,
which was filed in U.S. Provisional application No. 61/287,956, the
entire contents of which being previously incorporated by reference
above:
TABLE-US-00001 TABLE 1 Activities Traditional Truckable Modular
Execution 3.sup.rd Gen Modular Execution Layout & Module Steps
are: Utilize structured work process to develop plot layout based
Definition Develop Plot Plan using equipment dimensions and Process
Flow on development of Process Blocks with fully integrated
Diagrams (PFDs). Optimize interconnects between equipment.
equipment, piping, electrical and instrumentation/controls, Develop
module boundaries using Plot Plan and Module including the
following steps: Transportation Envelope Identify the 3.sup.rd Gen
process facility configuration using Develop detailed module
layouts and interconnects between process blocks using PFDs.
modules and stick-built portions of facilities utilizing a network
of Allocate plot space for each 3.sup.rd Gen Process Block.
piperack/sleeperways and misc. supports Detailed equipment layout
within Process Blocks using 3.sup.rd Route electrical and controls
cabling through Gen methodology to eliminate traditional
interconnecting interconnecting racks and misc. supports to connect
various loads piperack and minimize or reduce interconnects within
and instruments with satellite substation and racks. Process Block
modules. The layout builds up the Process Note: This results in a
combination of 1'' generation (piperack) Block based on module
blocks that conform to the and 2' generation (piperack with
selected equipment) modules that transportation envelope. fit the
transportation envelope. Combine Process Blocks for overall
facility to eliminate Ref.: Section 1.4A traditional
interconnecting piperacks and reduce number of interconnects. 5.
Develop a 3.sup.rd Gen 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
envelope. Ref.: Section 2.2 thru 2.4 Piperacks/ Modularized
piperacks and sleeperways, including cable tray for Eliminates the
traditional modularized piperacks and Sleeperways field
installation of interconnects and home-run cables sleeperways.
Interconnects are integrated into Process Block Ref.: Section 2.5
modules for shop installation. Ref.: Section 2.2 Buildings Multiple
standalone pre-engineered and stick built buildings Buildings are
integrated into Process Block modules. based on discrete equipment
housing. Ref: Section 3.3D Power Distribution Centralized
switchgear and MCC at main and satellite Decentralized MCC &
switchgear integrated into Process Architecture substations. Blocks
located in Primary Process Block module. Individual home run
feeders run from satellite substations to Feeders to loads are
directly from decentralized MCCs drivers and loads via
interconnecting piperacks. and switchgears located in the Process
Block without Power cabling installed and terminated at site. the
need 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 and Control cabinets are either
centralized in satellite substations or Control cabinets are
decentralized and integrated into Control Systems randomly
distributed throughout process facility. the Primary Process Block
module. Instrument locations are fallout of piping and mechanical
Close coupling of instruments to locate all instruments layout. for
a system on a single Process Block module to Vast majority of
instrument cabling and termination is done in maximum extent
practical. field for multiple cross module boundaries and
stick-built Instrumentation cabling installed and terminated in
portions via cable tray or misc. supports installed on module shop.
interconnecting piperacks. Process Block module interconnects
utilize pre-installed cabling pre-coiled at module boundary for
site connection using pre-terminated cable connectors. Ref.:
Section 3.3F
[0060] A typical 3.sup.rd Gen modular processing facility/system
might typically include at least 3 (typically modular, such as
being formed of one or more transportable modules) process blocks
(although other embodiments could comprise at least 2, at least 5,
at least 7, or at least 10 process blocks). The at least 3 process
blocks typically would be non-identical process blocks (e.g. each
process block configured for a different process and/or having
different structure and/or equipment and/or layout). In this way,
3.sup.rd Gen modular construction may be quite different from
typical 2.sup.nd Gen construction approaches, since the 3.sup.rd
Gen facility typically would not simply be multiple, substantially
identical modules, for example in parallel (as may be typical of
2.sup.nd Gen modular construction, for example).
[0061] Typically, the at least 3 process blocks of an exemplary
3.sup.rd Gen facility would each comprise one or more transportable
modules (which typically would be configured to jointly achieve the
process of the corresponding process block, if the corresponding
process block is made up of multiple modules). 3.sup.rd Gen modular
facilities typically employ a different layout (of modular
elements) than conventional 2.sup.nd Gen facilities. For example,
typically the at least 3 process blocks of an exemplary 3.sup.rd
Gen modular facility would not be laid out on an (external)
piperack backbone for interconnecting process blocks (or modules).
In other words, in at least some embodiments there typically would
be no external interconnecting piperack
between/linking/interconnecting the at least 3 process blocks of
such a 3.sup.rd Gen facility (for at least the process blocks
associated with the primary process fluid flow through the
production facility). Instead, the 3.sup.rd Gen process blocks
would be adjacent one another and directly interconnected (for
example, without intervening external piperack or other equipment
therebetween). This may mean that in some 3.sup.rd Gen embodiments,
for example, the interconnections between process blocks would be
disposed entirely within an envelope of the process blocks. Thus,
interconnections between a first and a second of the at least 3
process blocks of an exemplary 3.sup.rd Gen modular facility might
be located entirely within the envelopes of the first and second
process blocks. Oftentimes, such process blocks would be close
coupled to minimize interconnects and/or to reduce overall
footprint of the facility (for example, with interconnecting
process blocks abutting one another). While there may not be
interconnecting external piperack(s) in typical 3.sup.rd Gen
modular construction, each of the at least 3 process blocks may
optionally comprise integral pipeways for utility distribution
within the process block (and in some instances for process block
interconnects).
[0062] Typically, each of the at least 3 process blocks of a
3.sup.rd Gen facility would be configured based on a process-based
approach or layout (e.g. with each process block configured to
achieve a specific stand-alone process, which may be operable to
run without accessing equipment from other modules outside the
process block (e.g. other than inputs and outputs from the process
block as a whole--such that a process block merely takes its
inputs, for example, from one or more other process blocks,
performs an integral process or unit operation using those inputs,
and then provides or emits the outputs from the integral process
(for example, to one or more other process blocks))). Each process
block typically accepts specific feed(s) and processes such feed(s)
into one or more products (e.g. outputs). In some instances, one or
more of the feed(s) for a specific process block may be provided
from other process blocks(s) (e.g. the products from one or more
other interconnected process blocks) in the facility, and in some
instances the products from a specific process block might serve as
inputs or feeds into one or more other process blocks of a
facility. In the hydrocarbon and chemical business, a process block
can comprise equipment, such as processing columns, reactors,
vessels, drums, tanks, filters, as well as pumps or compressors to
move the fluids through the processing equipment and heat
exchangers and heaters for heat transfer to or from the fluid. A
process block typically might inherently have a series of piping
systems and controls to interconnect the equipment within the
block. By eliminating the traditional interconnecting piperack, the
3rd Gen approach may facilitate an efficient systems-based layout
resulting in the reduction of piping quantities. For solid material
processing facilities, such as mineral processing, the piping
systems described above would typically be replaced with material
handling equipment (e.g., conveyors, belts, etc.). Most often, a
process block would include a maximum of 20 to 30 pieces of
equipment, but there could be more or less equipment in some
process block embodiments. Typically, all equipment for a specific
process would be located within a single (for example, contiguous)
geographic footprint and/or envelope. Thus, the inputs/feeds for a
specific process block would typically be the inputs needed for the
process (as a whole), and the outputs for the process block would
typically be the outputs resulting from the process (as a whole).
Thus, the actual process would basically be self-contained
(physically) within the corresponding process block. This may
differ from conventional 2.sup.nd Gen approaches, which may
typically use an equipment-based approach (such that typical
2.sup.nd Gen modules may be required to interact with equipment
from several modules being needed to perform a specific process).
In other words, 3.sup.rd Gen process block embodiments may not have
an equipment-based approach or layout.
[0063] In at least some embodiments of a 3.sup.rd Gen modular
processing facility, each process block includes multiple pieces
and types of equipment for carrying out one or more (e.g.,
multiple) unit operations within the contiguous geographic region
defined by the process block. The unit operations and associated
equipment may be arranged to carry out, or relate to one or more
common, overarching processes within the 3.sup.rd Gen modular
processing facility.
[0064] In at least some of these embodiments, the equipment
disposed within the process block may be grouped by type within a
given process block. For example, within a given process block,
each of the units or pieces of equipment of one type (e.g., each of
the pumps within the process block) may be disposed together within
a first defined geographic envelope or space within the overall
geographic boundary of the process block and each of the units or
pieces of equipment of another type (e.g., each of the heat
exchangers within the process block) may be disposed together
within a second defined geographic envelope or space within the
overall geographic boundary of the process block. Within this
example, the first defined region may be separate (e.g., not
overlapping) with the second defined region with the given process
block. In some embodiments, such geographical grouping of a
specific type of equipment may only occur for one type of equipment
within the process block (such as E+I equipment, which typically
might all be grouped or located together within a process block),
or it may occur for multiple (or even all) types of equipment
within the process block.
[0065] In a typical exemplary 3.sup.rd Gen modular processing
facility, each of the at least 3 process blocks may comprise its
own integral E+I system and distribution (e.g. electrical control
and instrument system). As a result, each process block in a
3.sup.rd Gen modular processing facility disclosed herein may
include its own integral (e.g. self-supporting) power supply and
control systems for operating that process block (and the equipment
disposed therein). This may eliminate home run interconnecting
cabling through traditional interconnecting racks (of the sort
which typically may be used in conventional 2.sup.nd Gen modular
approaches). In addition, this may be beneficial for allowing each
process block to operate as a stand-alone process (as described
above, for example), and may provide commissioning benefits. So,
for example, each of the at least 3 process blocks may be
configured to allow for independent pre-commissioning, check-out,
and/or commissioning of its corresponding process system (for
example, without connection to any other of the at least 3 process
blocks). This may allow for separate/independent pre-commissioning,
check-out, and/or commissioning of its corresponding process
system, for example, at a location geographically separate and
apart (e.g. distant) from the ultimate site of the facility (such
as a fab or mod yard). The ability to perform separate/independent
pre-commissioning, check-out, and/or commissioning for each
3.sup.rd Gen process block may be due to integral E+I (within each
process block), the process block design approach, and/or lack of
external interconnecting piperack (which, for example, may allow
for fewer connections which can be more easily connected for
simulation and/or testing). Moreover, because of the independent,
integral E+I system and distribution within each process block, as
each process block is installed at the production facility, it may
be independently operated for its intended function or process
while other process blocks are either not yet operational or are
not yet even installed (assuming that the operating process block's
feed is available and other necessary utility services to the
operating process block have been connected and are operating).
Such independent operation of process blocks was not available in a
2.sup.nd Gen production facility since operation of any one process
required the installation of the shared E+I system and distribution
to the entire production facility. As a result, the total time to
production from a 3.sup.rd Gen production facility may be greatly
shortened from that typically experienced in a 2.sup.nd Gen
production facility.
[0066] The arrangement/layout of process blocks in exemplary
3.sup.rd Gen modular facilities may also be distinct. For example,
each of the at least 3 process blocks may be located/arranged in
proximity to one or more other of the at least 3 process blocks
(e.g. without intervening process blocks, modules, and/or piperacks
therebetween). Typically, each of the at least 3 process blocks
would be interconnected to one or more other of the at least 3
process blocks (and, for example, the interconnects might include
fluid (e.g. piping), solids (e.g., conveyors), etc.). Typically,
each of the at least 3 process blocks would be positioned/arranged
in proximity to the other of the at least 3 process blocks to which
it directly interconnects, for example, without intervening
external piperacks and/or process blocks therebetween. While not
required in all 3.sup.rd Gen embodiments, often the at least 3
process blocks would abut at least one other of the at least 3
process blocks (for example, interconnected process blocks might
typically abut one another--for example, forming a contiguous
geographic footprint and/or envelope). For such abutting process
blocks, interconnections between such process blocks might
typically be disposed entirely within the envelope of abutting
process blocks. And in some 3.sup.rd Gen embodiments, all process
blocks might abut the other process blocks to which they
interconnect (or at least might directly abut the other process
blocks with which it interacts with respect to the primary process
flow), such that the facility as a whole might have a contiguous
geographic footprint and/or envelope (in which case, all
interconnections between process blocks might be within the
contiguous envelope of the facility process blocks as a whole (e.g.
jointly), such that no external piperacks would be necessary).
[0067] Typical process blocks would each have feed input piping (or
solid material transfer), product output piping (or solid material
transfer), and utility support inputs and outputs. As previously
described, utility support inputs and outputs might include one or
more one or more inputs for fluid lines (e.g., pipes, conduits,
hoses, etc.) that carry fluids (e.g., liquids and/or gases) to
support the systems operation within a process block. For example,
such liquids and gases carried by the utility pipes include, steam,
water, N.sub.2, O.sub.2, air, etc. Process blocks would typically
be arranged to efficiently interconnect to each other based on the
process flow through the facility. Utilities may also be
interconnected between process blocks in a similar design for
efficient flow.
[0068] Each process block may be formed of one or more
transportable modules (thereby allowing construction of such
modules off-site at locations distant from the final site for the
process facility). Typically, each of the transportable modules for
the process blocks might be sized as discussed above with respect
to transportable modules. And in some embodiments, one or more of
the modules might be sized to be truckable, as described above. So,
a process block can be formed of (e.g. comprise) one to several
modules, for example, depending on the maximum module size and/or
weight the local site infrastructure will allow for transport. The
use of smaller truckable modules might result in several modules
per process block, while the use of VLMs (very large modules) could
allow for one module per process block. The modules making up each
process block would typically be configured with equipment so that,
when interconnected, the modules would jointly perform the process
of the corresponding process block (for example, with the equipment
in a plurality of related modules for a corresponding process block
working together (e.g. interlinked) to accomplish the overall
process of the process block). In laying out modules (in forming a
corresponding process block), each module would typically be
arranged in proximity (typically abutting) with the one or more
modules with which it interconnects (e.g. without any intervening
external piperack and/or module). So typically, the modules for a
process block would not interconnect via a piperack (for example,
an interconnecting piperack located external to the modules), but
might rather be directly interconnected. And most often, the
modules associated with a specific (corresponding) process block
would abut to form a contiguous footprint and/or envelope for the
process block as a whole. As otherwise described herein, such
abutment of modules and/or process blocks may be side-by-side,
end-to-end, and/or stacked, for example.
[0069] Such 3.sup.rd Gen modular process facilities may be
constructed uniquely, due to the 3.sup.rd Gen nature of the process
blocks and/or modules and/or the process-based approach. For
example, a typical exemplary 3.sup.rd Gen modular method of
constructing a processing facility (for example, of the sort
described above) might comprise arranging a plurality of process
blocks (e.g. at least 3 process blocks) with respect to one
another, wherein the at least 3 process blocks are non-identical
process blocks (e.g. each configured for a different process) (e.g.
not simply multiple, substantially identical modules, for example
in parallel), wherein the at least 3 process blocks each comprise
one or more transportable modules (which are configured to jointly
achieve the process of the corresponding process block); and
wherein the at least 3 process blocks are not laid out on an
(external) piperack backbone for interconnecting process blocks (or
modules) (e.g. no external interconnecting piperack
between/linking/interconnecting the 3 process blocks) (e.g. process
blocks are directly interconnected (without intervening piperack
therebetween, for example, such that the interconnections between
process blocks are disposed entirely within an envelope of the
process blocks--for example, with interconnections between a first
and a second of the at least 3 process blocks being located
entirely within the envelopes of the first and second process
blocks). Such a method might also and/or further comprise
constructing one or more (e.g., each or all) of the at least 3
process blocks at (one or more location) different (remote/away)
from the ultimate site of the processing facility (e.g., a fab or
mod yard); and pre-commissioning, check-out, and/or commissioning
of a corresponding process system for the one or more process
blocks constructed away from the ultimate facility site (e.g., at
the fab or mod yard) (e.g., without connection to any other of the
at least 3 process blocks) (e.g., at a location separate and apart
from the ultimate site of the facility, such as a mod yard) (e.g.,
due to integral E+I, process block design approach, and/or lack of
external interconnecting piperack). In some embodiments, such
methods might further comprise directly interconnecting (e.g.
without an external interconnecting piperack) each process block
(which might be pre-commissioned, checked out, or commissioned
previously) to one or more adjacent process blocks (e.g. without
intervening external piperacks and/or other process blocks
therebetween). In some such methods, the arrangement of process
blocks might also include close coupling one or more (e.g., all) of
the at least 3 process blocks (e.g., to reduce overall footprint of
the facility and/or reduce/minimize interconnects). Some method
embodiments might further comprise designing/configuring each
process block to accomplish a corresponding process, which in some
embodiments might include laying out equipment in the modules
making up each process block accordingly. Also, some method
embodiments might further comprise the step of providing integral
E+I distribution for each of the at least 3 process blocks (e.g.,
to eliminate home run interconnecting cabling). The modular nature
of 3.sup.rd Gen construction may also allow for more efficient
construction and/or implementation, for example, using integrated
execution to support the modular implementation with reduced
scheduling versus traditional/conventional stick build or 2.sup.nd
Gen (e.g., equipment only modules).
[0070] In some embodiments, two or more of the process blocks to be
interconnected may not able to be placed adjacent one another such
that one or more fluid lines interconnecting the inputs and outputs
of the two or more process blocks must be routed through another
geographically intervening process block or other equipment.
However, this sort of arrangement is not required, and in at least
some embodiments, such a routing of the one or more fluid lines
does not occur. If such routing becomes necessary, design efforts
(regarding placement of process blocks and/or interconnections
between process blocks) would typically seek to minimize this type
of indirect routing or interconnection as much as possible (e.g.
most process blocks should preferably be directly interconnected
and located adjacent to the other process blocks with which it
interacts, especially with respect to the primary process flow). So
for at least some embodiments, the primary flow (i.e., the primary
process flow through the 3.sup.rd Gen production facility) would
typically flow between adjacent and directly interconnected process
blocks. Stated another way, the process blocks in a 3.sup.rd Gen
production facility that are associated with the main or primary
process flow are typically positioned geographically adjacent one
another such that each of these process blocks is directly
interconnected with no intervening piperacks or other equipment or
modules therebetween. So while there may be process blocks in a
3.sup.rd Gen facility that are not adjacent and/or interconnected
with one or more other process blocks with which it interacts, in a
3.sup.rd Gen facility typically at least 3, at least 5, at least 8,
or at least 10 process blocks (for example, relating to the main or
primary process flow) would be adjacent (or abutting) and/or
directly interconnected with the other such of the at least 3, at
least 5, at least 9 or at least 10 process blocks with which it
interacts.
[0071] In addition, in some embodiments, one or more of the fluid
lines interconnecting the inputs and outputs of the 3.sup.rd Gen
process blocks are routed through a central piping spine that runs
through at least a portion of the (and in some instances, through
the entire) processing facility (and particularly through at least
some of the process blocks, with the spine located internally
within at least some of the process blocks). In addition, in at
least some of these embodiments, the utility lines (e.g., carrying
steam, water, air, N.sub.2, O.sub.2, etc.) associated with the
process blocks may also route along the piping spine so as to
access each of the process blocks. In these embodiments (as well as
in other embodiments) the E+I lines and the fluid lines
interconnecting the equipment within each process block are not
routed through the piping spine and are instead routed within each
individual process block (i.e., within the geographic area defined
by the corresponding process block) as described above. Such an
optional spine might serve to line up inputs and outputs for
multiple process blocks (for example regarding the primary process
flow and/or utilities), thereby optimizing layout of a facility.
So, typically such a spine would not be used for equipment
connections within a process blocks, but would instead typically be
focused on inputs and outputs between interconnected process
blocks.
[0072] 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, FIG. 1 shows
only one electrical line connection and one fluid line connection
between modules #1 and #2. Similarly, FIG. 1 shows no electrical
line connections between process blocks #1 and #2, and only a
single fluid line connection between those process blocks. Further,
FIG. 1 shows utility lines (shown as "Steam Coupling" and "Treated
Water Coupling") extending between module #3 of Water treatment
process Block #2 and module #5 of Steam Generation Process Block
#3.
[0073] Still further, FIG. 1 shows that each process block (process
blocks #1, #2, #3) each have their own Power and Control Area. In
at least some embodiments, each Power and Control Area is a
designated location (which in some embodiment comprises an
enclosure or room, or simply one or more control panels) within the
corresponding process block (e.g., process blocks #1, #2, #3) that
operating personnel may direct, monitor, initiate, and/or control
(collectively "control operations") the operation of the process
block and any and all equipment contained therein. Typically, the
integrated E+I system and distribution is coupled to and includes
the Power and Control area to facilitate the control operations
described above. While FIG. 1 shows a fiber optic coupling
extending between each of the Power and Control Areas, it should be
appreciated that such a coupling is not required and may not be
included in other embodiments (i.e., in some embodiments, the Power
and Control Areas of each process block are not coupled to one
another--e.g., as shown in FIG. 6).
[0074] FIG. 5 is a schematic of a process block module layout
elevation view, in which modules C, B, and A are on one level, most
likely ground level, with a fourth module D disposed atop module C.
Although only two fluid couplings are shown, FIG. 5 should be
understood to potentially include one or more additional fluid
couplings, and one or more electrical and control couplings.
[0075] FIG. 6 is a schematic of an alternative embodiment of a
portion of an oil separation facility in which there are again
three process blocks (#1, #2 and #3). But here, process block #1
has three modules (#1, #2, and #3), process block #2 has two
modules (#1 and #2), and process block #3 has two additional
modules (#1 and #2). Also, it should be appreciated that each of
the Power and Control Areas of process blocks #1, #2, and #3 of
FIG. 6 are not coupled or interconnected (e.g., with a fiber
optical cable or the like).
[0076] 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.
[0077] FIG. 8 is a schematic of a 3rd Generation Modular facility
having four process blocks, each of which has five modules.
Although dimensions are not shown, each of the modules should be
interpreted as having (a) a length of at least 15 meters, (b) a
height greater than 4 meters, (c) a width greater than 4 meters,
and (d) having open sides and/or ends where the modules within a
given process block are positioned adjacent to one another. In this
particular example, the first and second process blocks are fluidly
coupled by no more than four fluid lines, excluding utility lines,
four electrical lines, and two control lines. The first and third
process blocks are connected by six fluid lines, excluding utility
lines, and by one electrical and one control line.
[0078] 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.
[0079] FIG. 9 is a schematic of a 3.sup.rd Gen Modular facility
having six process blocks 110a-110f. As previously described, in
some embodiments, one or more of the fluid lines interconnecting
the inputs and outputs of the 3.sup.rd Gen process blocks are
routed through a central piping spine that runs through at least
portions of the processing facility (and particularly through and
within at least some of the plurality of the process blocks). The
embodiment of FIG. 9 shows a piping spine 150 that extends through
each of the process blocks 110a-110f of a=n exemplary 3.sup.rd Gen
modular facility. In this embodiment, piping spine 150 also carries
a plurality of interconnecting fluid lines (not specifically shown)
that connect the ultimate inputs and outputs of each process block
110a-110f. Specifically, in this embodiment, piping spine 150
carries pipes or other conduits that interconnect the output of
process block 110a to the input of process block 110b, the output
of process block 110b to the input of process block 110c, the
output of process block 110c to the input of process block 110d,
the output of process block 110d to the input of process block
110e, and finally the output of process block 110e to the input of
process block 110f. As a result, piping spine 150 provides a main
corridor for interconnecting the inputs and outputs for each of the
adjacent process blocks 110a-110f, for at least the main processing
flow. In addition, in this embodiment piping spine 150 carries a
plurality of utility lines (not specifically shown) that are
coupled to the process blocks 110a-110f (and therefore carry
various utility fluids to process blocks 110a-110f as previously
described above). Further, in the embodiment of FIG. 9, each of the
fluid lines (e.g., pipes, conduits, etc.--not shown)
interconnecting the equipment within each process block 110a-110f
and the E+I lines (also not shown) routed throughout each process
block 110a-110f are not routed through the piping spine 150 and are
instead routed exclusively within the corresponding process block
itself (i.e., within the geographic boundary defined by the
corresponding process block 110a-110f), typically in a more direct
manner.
[0080] Having described above various system/facility and method
embodiments, various additional embodiments may include, but are
not limited to the following:
[0081] In a first embodiment, a modular processing facility/system,
comprising: a plurality (for example, at least 3) (modular) process
blocks; wherein the plurality of (e.g. at least 3) process blocks
are non-identical process blocks (e.g. each configured for a
different process) (e.g. not simply multiple, substantially
identical modules, for example in parallel); wherein the at
plurality of (e.g. least 3) process blocks each comprise one or
more transportable modules (which are configured to jointly achieve
the process of the corresponding process block); and wherein the
plurality of (e.g. at least 3) process blocks are not laid out on a
(common) (external) piperack backbone for interconnecting process
blocks (or modules) (e.g. no external interconnecting piperack
between/linking/interconnecting the process blocks) (e.g. the
process blocks are directly interconnected (without intervening
piperack therebetween, for example, such that the interconnections
between process blocks are disposed entirely within an envelope of
the process blocks--for example, with interconnections between a
first and a second of the at least 3 process blocks being located
entirely within envelopes of the first and second process blocks).
In a second embodiment, the system/facility of the first
embodiment, wherein each of the plurality of (e.g. at least 3)
process blocks is configured based on a process-based approach
(e.g. to achieve a specific stand-alone process) (e.g. not
equipment-based). In a third embodiment, the system/facility of
embodiments 1-2, wherein the process blocks are close coupled to
minimize interconnects and/or to reduce overall footprint of the
facility. In a fourth embodiment, the system/facility of
embodiments 1-3, wherein each of the plurality of (e.g. at least 3)
process blocks comprises its own integral E+I Distribution (for
example, thereby eliminating home run interconnecting cabling
through traditional interconnecting racks). In a fifth embodiment,
the system/facility of embodiments 1-4, wherein each of the
plurality of (e.g. at least 3) process blocks is configured to
allow for independent pre-commissioning, check-out, and/or
commissioning of a corresponding process system (for example,
without connection to any other of the at least 3 process blocks)
(for example, at a location separate and apart from the ultimate
site of the facility, such as a mod yard) (for example, due to
integral E+I, process block design approach, and/or lack of
external interconnecting piperack). In a sixth embodiment, the
system/facility of embodiments 1-5, wherein each of the plurality
of (e.g. at least 3) process blocks comprises integral pipeways for
utility distribution (and process block interconnects). In a
seventh embodiment, the system/facility of embodiments 1-6, wherein
each of the plurality of (e.g. at least 3) process blocks is
located/arranged in proximity to (e.g. without intervening process
blocks, modules, and/or piperacks therebetween) one or more other
of the at least 3 process blocks. In an eighth embodiment, the
system/facility of embodiments 1-7, wherein each of the plurality
of (e.g. at least 3) process blocks is interconnected to one or
more other of the at least 3 process blocks, and wherein the
interconnects include fluid (e.g. piping). In a ninth embodiment,
the system/facility of embodiments 1-8, wherein each of the
plurality of (e.g. at least 3) process blocks is
positioned/arranged in proximity to the other of the plurality of
(e.g. at least 3) process blocks to which it directly
interconnects, without intervening external piperacks and/or
process blocks therebetween. In a tenth embodiment, the
system/facility of embodiments 1-9, wherein each of the plurality
of (e.g. at least 3) process blocks abuts at least one other of the
process blocks. In an eleventh embodiment, the system/facility of
embodiments 1-10, wherein the interconnections between process
blocks are disposed entirely within the envelope of abutting
process blocks. In a twelfth embodiment, the system/facility of
embodiments 1-11, wherein each (or alternatively, some) of the
transportable modules for the process blocks is sized as a
truckable module. In a thirteenth embodiment, the system/facility
of embodiments 1-12, wherein each of the plurality of process
blocks comprises a plurality of transportable or truckable modules,
which jointly may be configured to achieve the process for the
corresponding process block. In a fourteenth embodiment, the
system/facility of embodiments 1-13,wherein each process block is
configured to allow for independent pre-commissioning, check-out,
and/or commissioning (e.g. without being connected to another one
or more of the process blocks) (e.g. at a site separate and apart
from the ultimate facility site).
[0082] In a fifteenth embodiment, a modular method of constructing
a processing facility, comprising: arranging a plurality of process
blocks (e.g. at least 3 process blocks) with respect to one
another; wherein the plurality of (e.g. at least 3) process blocks
are non-identical process blocks (e.g. each configured for a
different process) (e.g. not simply multiple, substantially
identical modules, for example in parallel); wherein the plurality
of (at least 3) process blocks each comprise one or more
transportable modules (e.g. typically a plurality of transportable
or truckable modules for each process block) (e.g. which are
configured to jointly achieve the process of the corresponding
process block); and wherein the plurality of (e.g. at least 3)
process blocks are not laid out on an (external) piperack backbone
for interconnecting process blocks (or modules) (e.g. no external
interconnecting piperack between/linking/interconnecting the 3
process blocks) (e.g. process blocks are directly interconnected
(without intervening piperack therebetween, for example such that
the interconnections between process blocks are disposed entirely
within an envelope of the process blocks--for example, with the
interconnections between a first and a second of the at least 3
process blocks being located entirely within the envelopes of the
first and second process blocks)). In a sixteenth embodiment, the
method of embodiment 15, further comprising: constructing one or
more (for example, each or all) of the plurality of (e.g. at least
3) process blocks at one or more location different (remote/away)
from the ultimate site of the processing facility (for example, a
fab or mod yard); and pre-commissioning, check-out, and/or
commissioning of a corresponding process system for the one or more
process block(s) constructed away from the ultimate facility site
(e.g. at the site of construction for such one or more process
blocks) (for example, at the fab or mod yard) (for example, without
connection to any other of the at least 3 process blocks) (for
example at a location separate and apart from the ultimate site of
the facility, such as a mod yard) (for example, due to integral
E+I, process block design approach, and/or lack of the external
interconnecting piperack). In a seventeenth embodiment, the method
of embodiments 15-16, further comprising directly interconnecting
(e.g. without the external interconnecting piperack) each process
block to one or more adjacent process blocks (e.g. without
intervening external piperacks and/or other process blocks
therebetween). In an eighteenth embodiment, the method of
embodiments 15-17, further comprising, close coupling one or more
(for example, all) of the at least 3 process blocks (for example,
to reduce overall footprint of the facility and/or reduce/minimize
interconnects). In a nineteenth embodiment, the method of
embodiments 15-18, further comprising designing/configuring each
process block to accomplish a corresponding process (and laying out
equipment in the modules making up each process block accordingly).
In a twentieth embodiment, the method of embodiments 1-19, the
method further comprising providing (e.g. at the one or more
location different (remote/away) from the ultimate site of the
processing facility (for example, a fab or mod yard)) integral E+I
distribution for each of the at least 3 process blocks (e.g. to
eliminate home run interconnecting cabling). In a twenty-first
embodiment, wherein each of the process blocks comprises its own
integral E+I Distribution. In a twenty-second embodiment, the
method of embodiments 15-21, wherein arranging a plurality of
process blocks (e.g. at least 3 process blocks) with respect to one
another comprises positioning each process block so that it abuts
any of the other process blocks to which it is connected. In a
twenty-third embodiment, the method of embodiments 15-22 wherein
each of the plurality of (e.g. at least 3) process blocks is
configured to allow for independent pre-commissioning, check-out,
or commissioning of a corresponding process system (for example,
with each such process block being configured with multiple types
of equipment in order to allow for the corresponding process system
to run independently of the other process blocks (e.g. without
interacting with other, outside equipment in the midst of
performing the process) to perform its process, for example using
only feeds into the process (e.g. process block) for the process
block to perform its corresponding process system (e.g. with no
interaction with equipment or process blocks outside the process
block to perform any portion of the process (e.g. within the
internal system flow of the process--so that the only external
interaction is for feeds to the entire process of the process
block, and from there the process of the process block is
self-contained))). In a twenty-fourth embodiment, the method of
embodiments 15-23 further comprising beginning partial operation of
the facility before all of the process blocks for the full facility
are provided at the ultimate facility site and/or are
interconnected (for example, operating a first process block
independently while awaiting installation of a second process
block; or operating a first and second (interconnected) process
block while awaiting installation of a third process block; or
operating a first, second, and third (interconnected) process block
while awaiting installation of a fourth process block; etc.).
[0083] 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, utilized, or combined with
other elements, components, or steps that are not expressly
referenced. Where the specification claims refer 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.
[0084] Accordingly, the scope of protection is not limited by the
description set out above, but is defined by the claims which
follow, that scope including all equivalents of the subject matter
of the claims. In the claims, any designation of a claim as
depending from a range of claims (for example #-##) would indicate
that the claim is a multiple dependent claim based on any claim in
the range (e.g. dependent on claim # or claim ## or any claim
therebetween). Each and every claim is incorporated as further
disclosure into the specification, and the claims are embodiment(s)
of the present invention(s). Furthermore, any advantages and
features described above may relate to specific embodiments, but
shall not limit the application of such issued claims to processes
and structures accomplishing any or all of the above advantages or
having any or all of the above features.
[0085] Additionally, the section headings used herein are provided
for consistency with the suggestions under 37 C.F.R. 1.77 or to
otherwise provide organizational cues. These headings shall not
limit or characterize the invention(s) set out in any claims that
may issue from this disclosure. Specifically and by way of example,
although the headings might refer to a "Field," the claims should
not be limited by the language chosen under this heading to
describe the so-called field. Further, a description of a
technology in the "Background" is not to be construed as an
admission that certain technology is prior art to any invention(s)
in this disclosure. Neither is the "Summary" to be considered as a
limiting characterization of the invention(s) set forth in issued
claims. Furthermore, any reference in this disclosure to
"invention" in the singular should not be used to argue that there
is only a single point of novelty in this disclosure. Multiple
inventions may be set forth according to the limitations of the
multiple claims issuing from this disclosure, and such claims
accordingly define the invention(s), and their equivalents, that
are protected thereby. In all instances, the scope of the claims
shall be considered on their own merits in light of this
disclosure, but should not be constrained by the headings set forth
herein.
[0086] Use of broader terms such as "comprises", "includes", and
"having" should be understood to provide support for narrower terms
such as "consisting of", "consisting essentially of", and
"comprised substantially of". Use of the terms "optionally," "may,"
"might," "possibly," and the like with respect to any element of an
embodiment means that the element is not required, or
alternatively, the element is required, both alternatives being
within the scope of the embodiment(s). Also, references to examples
are merely provided for illustrative purposes, and are not intended
to be exclusive.
[0087] Also, techniques, systems, subsystems, and methods described
and illustrated in the various embodiments as discrete or separate
may be combined or integrated with other systems, modules,
techniques, or methods without departing from the scope of the
present disclosure. Other items shown or discussed as directly
coupled or communicating with each other may be indirectly coupled
or communicating through some interface, device, or intermediate
component, whether electrically, mechanically, or otherwise. Other
examples of changes, substitutions, and alterations are
ascertainable by one skilled in the art and could be made without
departing from the spirit and scope disclosed herein.
* * * * *