U.S. patent application number 16/077249 was filed with the patent office on 2019-02-14 for modular well pad systems and methods.
This patent application is currently assigned to Bantrel Co.. The applicant listed for this patent is Bantrel Co.. Invention is credited to Paul Hardy, Joe Overy.
Application Number | 20190048699 16/077249 |
Document ID | / |
Family ID | 59563729 |
Filed Date | 2019-02-14 |
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United States Patent
Application |
20190048699 |
Kind Code |
A1 |
Hardy; Paul ; et
al. |
February 14, 2019 |
Modular Well Pad Systems and Methods
Abstract
A modular well pad system, which includes an inlet module, a 2
well-pair module and a 3 well-pair module. The inlet module, one or
more 2 well-pair modules and one or more 3 well-pair modules may be
configured to build an interconnected well pad system for
accommodating two to twelve well-pairs wherein standardized
connections enable the 2 well-pair module and the 3 well-pair
module to be coupled together, to the inlet module, another 2
well-pair module and/or another 3 well-pair module.
Inventors: |
Hardy; Paul; (Alberta,
CA) ; Overy; Joe; (Alberta, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bantrel Co. |
Calgary |
|
CA |
|
|
Assignee: |
Bantrel Co.
Calgary
AB
|
Family ID: |
59563729 |
Appl. No.: |
16/077249 |
Filed: |
February 10, 2017 |
PCT Filed: |
February 10, 2017 |
PCT NO: |
PCT/IB2017/000188 |
371 Date: |
August 10, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62294418 |
Feb 12, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 41/00 20130101;
E21B 43/128 20130101; E21B 43/30 20130101; E21B 43/2406
20130101 |
International
Class: |
E21B 43/30 20060101
E21B043/30; E21B 43/24 20060101 E21B043/24; E21B 43/12 20060101
E21B043/12 |
Claims
1. A modular well-pad system, comprising: an inlet module
comprising a plurality of service lines, wherein one or more of the
plurality of service lines is connected at one end of the inlet
module to a central processing facility and the plurality of
service lines is connectable at another end of the inlet module to
a respective plurality of service lines connected to one end of a 2
well-pair module and a respective plurality of services lines
connected to one end of a 3 well-pair module; at least one of the 2
well-pair module and the 3 well-pair module, wherein the plurality
of service lines connected to the one end of the 2 well-pair module
and the plurality of service lines connected to the one end of the
3 well-pair module are connectable to i) a respective plurality of
service lines connected to another end of the 2 well-pair module or
a respective plurality of service lines connected to another end of
the 3 well-pair module, and ii) a respective plurality of service
lines connected to another end of another 2 well-pair module and a
respective plurality of service lines connected to another end of
another 3 well-pair module and wherein the plurality of service
lines connected to the another end of the 2 well-pair module and
the plurality of service lines connected to the another end of 3
well-pair module are connectable to a respective plurality of
service lines connected to one end of another 2 well-pair module
and a respective plurality of service lines connected to one end of
another 3 well-pair module; the 2 well-pair module connectable to
two well pairs and the 3 well-pair module connectable to three well
pairs, wherein each well pair represents an injection well and a
production well.
2. The system of claim 1, further comprising four 3 well-pair
modules.
3. The system of claim 1, further comprising two 3 well-pair
modules and three 2 well-pair modules.
4. The system of claim 1, wherein the inlet module, the 2 well-pair
module and the 3 well-pair module are transportable by truck.
5. The system of claim 1, wherein each plurality of service lines
comprises a steam or high pressure water line, a natural gas line,
an instrument control line, a production line, a casing gas line
and a start-up fluid line.
6. The system of claim 5, wherein the production line includes one
of emulsion, water, solution gas and oil.
7. The system of claim 5, wherein the instrument control line
includes one of electricity and air.
8. The system of claim 5, wherein the production line, the casing
gas line, the natural gas line and the steam or high pressure water
line are connected at the one end of the inlet module to the
central processing facility and the instrument control line and
start-up fluid lines are connected to opposite sides of the inlet
module.
9. The system of claim 5, wherein the 2 well-pair module and the 3
well-pair module each comprise another production line and another
casing gas line connected at a production side of each respective 2
well-pair module and 3 well-pair module to each respective
production well.
10. The system of claim 9, wherein the 2 well-pair module and the 3
well-pair module each comprise another natural gas line and another
steam or high pressure water line connected at an injection side
and the production side of each respective 2 well-pair module and 3
well-pair module to each respective injection well and each
respective production well.
11. The system of claim 10, wherein the 2 well-pair module and the
3 well-pair module each comprise another start-up fluid line
connected at the injection side of each respective 2 well-pair
module and 3 well-pair module to each respective injection
well.
12. The system of claim 6, further comprising an electric
submersible pump positioned below each production well.
13. The system of claim 12, wherein the emulsion, water, solution
gas and oil are each a single phase liquid product.
14. The system of claim 1, wherein each connection is standardized.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The priority of U.S. Provisional Patent Application No.
62/294,418, filed Feb. 12, 2016, is hereby claimed and the
specification thereof is incorporated herein by reference.
FIELD OF THE DISCLOSURE
[0002] The present disclosure generally relates to modular well pad
systems and methods. More particularly, the present disclosure
relates to a modular well pad system, which includes an inlet
module, a 2 well-pair module and a 3 well-pair module. The inlet
module, one or more 2 well-pair modules and one or more 3 well-pair
modules may be configured to build an interconnected well pad
system for accommodating two to twelve well-pairs wherein
standardized connections enable the 2 well-pair module and the 3
well-pair module to be coupled together, to the inlet module,
another 2 well-pair module and/or another 3 well-pair module.
BACKGROUND
[0003] Steam Assisted Gravity Drainage (SAGD) is a methodology of
oil extraction where steam is injected into the underground oil
reservoir through an injection well and bituminous product is
collected though a production well. The steam is injected downhole
to melt bitumen trapped within a sand layer, typically anywhere
from 200 to 500 meters below grade. The resultant mixture of
bitumen and water (hereinafter referred to as a production
emulsion) flows up through the production well, potentially with
some free gas, where a well pad and surface facilities handle the
transfer of the production emulsion to a central processing
facility (CPF). Because the production emulsion is a multiphase
product, the liquid and gases are separated and sent to the CPF.
Conventional SAGD well pads thus, require the use of separator
vessels.
[0004] Conventional SAGD well-pads are often constructed in a way
that allows for much of the construction and fabrication work to be
performed offsite, in a more controlled environment, and then
assembled on-site. Each well pad thus, may include multiple modules
that can be shipped by highway on a flatbed trailer of a transport
truck and then lowered or lifted into place for assembly on-site.
Such modules, however, still lack the requisite standardization
necessary to permit simple interconnectivity between the modules
regardless of the module type, well pad location and design
parameters. Moreover, the lack of simple interconnectivity also
renders such modules significantly inflexible for expansion. As a
result, conventional SAGD well pads remain highly customized and
therefore, costly to construct.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The present disclosure is described with reference to the
accompanying drawings, in which like elements are referenced with
like reference numbers, and in which:
[0006] FIG. 1 is a site plan illustrating one embodiment of a
modular well-pad system comprising an inlet module, a 2 well-pair
module and a 3 well-pair module for accommodating 5 well-pairs.
[0007] FIG. 2 is a schematic sectional view of the inlet module in
FIG. 1 illustrating standardized connections to the inlet
module.
[0008] FIG. 3 is a schematic sectional view of the 2 well-pair
module in FIG. 1 illustrating standardized connections to the 2
well-pair module.
[0009] FIG. 4 is a schematic sectional view of the 3 well-pair
module in FIG. 1 illustrating standardized connections to the 3
well-pair module.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0010] The subject matter of the present disclosure is described
with specificity, however, the description itself is not intended
to limit the scope of the disclosure. The subject matter thus,
might also be embodied in other ways, to include different
structures, steps and/or combinations similar to and/or fewer than
those described herein, in conjunction with other present or future
technologies. Moreover, although the term "step" may be used herein
to describe different elements of methods employed, the term should
not be interpreted as implying any particular order among or
between various steps herein disclosed unless otherwise expressly
limited by the description to a particular order. Other features
and advantages of the disclosed embodiments will be or will become
apparent to one of ordinary skill in the art upon examination of
the following figures and detailed description. It is intended that
all such additional features and advantages be included within the
scope of the disclosed embodiments. Further, the illustrated
figures are only exemplary and are not intended to assert or imply
any limitation with regard to the environment, architecture,
design, or process in which different embodiments may be
implemented.
[0011] The pressure profile for a well-pad cannot be standardized
because the location of each well pad in relation to the CPF is
unique to each project. Similarly, the topography along the right
of way is also unique to each project. Due to these factors, the
selection of some well-pad design parameters (e.g. single phase
pipelines vs multi-phase pipelines; separation on or off the well
pad; pipeline size (internal diameter); and pumping
configuration--pumps in series, multi-phase pumps), based on costs,
cannot be easily made using a standardized design. As used herein,
the terms "pipeline" and "pipelines" may also be referred to as
piping, line or lines.
[0012] Other parameters of the well pad design and its production
(engineering, procurement, fabrication, installation and
construction), however, may be standardized to achieve substantial
production savings. The modular well pad described herein employs
carefully controlled reservoir pressure and temperature conditions
along with the use of submersible downhole pumps that produce a
product with a single liquid phase, thereby eliminating the
requirement for separator vessels and a costly gas pipeline back to
the CPF. The modular well pad and its production may thus, be
standardized by (i) removing separators (group and test) from the
design by raising the product pressure to above the bubble point
using electric submersible pumps (ESPs); (ii) providing an option
to connect to a multi-phase pump to boost the pressure further if
need be to remain a single phase (liquid) for the product; and iii)
providing an option to connect to a separation building if required
to enable two single phase pipelines (1 gas, 1 liquid emulsion) for
the product.
[0013] Because the modular well-pad connections between modules are
standardized, the modular well-pad allows for increased flexibility
and repeatability without any additional engineering. Moreover,
production costs for the modular well-pad are lowered because the
modular well-pad is based on a design that: i) reduces the scope of
a well-pad to the maximum possible extent without sacrificing life
cycle cost; ii) reduces the scope of on-site field production using
modularization; iii) reduces materials; and iv) provides options to
enable the design to be customized.
[0014] The modular well-pad thus, overcomes one or more of the
prior art disadvantages with an inlet module. a 2 well-pair module
and a 3 well-pair module. The inlet module, one or more 2 well-pair
modules and one or more 3 well-pair modules may be configured to
build an interconnected well pad system for accommodating two to
twelve well-pairs wherein standardized connections enable the 2
well-pair module and the 3 well-pair module to be coupled together,
to the inlet module, another 2 well-pair module and/or another 3
well-pair module.
[0015] In one embodiment the present disclosure includes a modular
well-pad system, comprising an inlet module comprising a plurality
of service lines, wherein one or more of the plurality of service
lines is connected at one end of the inlet module to a central
processing facility and the plurality of service lines is
connectable at another end of the inlet module to a respective
plurality of service lines connected to one end of a 2 well-pair
module and a respective plurality of services lines connected to
one end of a 3 well-pair module; at least one of the 2 well-pair
module and the 3 well-pair module, wherein the plurality of service
lines connected to the one end of the 2 well-pair module and the
plurality of service lines connected to the one end of the 3
well-pair module are connectable to i) a respective plurality of
service lines connected to another end of the 2 well-pair module or
a respective plurality of service lines connected to another end of
the 3 well-pair module, and ii) a respective plurality of service
lines connected to another end of another 2 well-pair module and a
respective plurality of service lines connected to another end of
another 3 well-pair module and wherein the plurality of service
lines connected to the another end of the 2 well-pair module and
the plurality of service lines connected to the another end of 3
well-pair module are connectable to a respective plurality of
service lines connected to one end of another 2 well-pair module
and a respective plurality of service lines connected to one end of
another 3 well-pair module; the 2 well-pair module connectable to
two well pairs and the 3 well-pair module connectable to three well
pairs, wherein each well pair represents an injection well and a
production well.
[0016] Referring now to FIG. 1, a site plan 100 illustrates one
embodiment of a modular well-pad system comprising an inlet module
102, a 2 well-pair module 104 and a 3 well-pair module 106 for
accommodating five well-pairs 108-116. Each well pair represents
one production well (p) and one steam injection well (i). The
modular well-pad system may also include various support
structures. A natural gas heater 118 is used for heating the
natural gas from the CPF in order to avoid the formation of
condensation in the natural gas entering the inlet module 102. An
instrument air package (consisting of compressor, dryer and
receiver) 120 is used for providing the instrument air entering the
inlet module 102 that controls the valves in each module. An
optional start-up package 122 may be used for providing start-up
fluid entering the inlet module 102 that supports the formation of
a steam chamber below each injection well as part of the SAGD
process. An electrical building 124 is used for transmitting power
to i) each ESP below each production well; ii) each electrical heat
tracing (EHT) panel for freeze protection on the piping in each
module; and iii) general utilities (e.g. lighting) in each module.
A stick built cable tray and pipe (not shown) connects the
electrical building 124 to the inlet module 102. The electric
building 124 also includes a pre-fabricated access platform and
stairs (not shown). A pre-fabricated access platform and stairs may
also be provided for each EHT panel. An ATCO transformer 126 is
used for supplying power to the electrical building 124 and
variable frequency drive (VFD) skids 128 are used for controlling
the power to each ESP. A stock pile may be used for storing excess
soil and a storm water pond may be used for collecting excess water
runoff from the well-pad system.
[0017] The modular well-pad system is based on receiving a
pre-drilled well-pad to rough grade with an installed power
transformer 126. Each module is sized for highway transport and
designed to be lowered onto piles from the bed of a transport
vehicle so that the on-site use of cranes is no longer required.
Because the modular well-pad system and its production is largely
standardized, it is expandable from two well-pairs up to a maximum
of twelve well-pairs within a well-pad boundary 134 using 2 and 3
well-pair modules that can be assembled in any configuration
necessary to achieve the required count. Because module operating
platforms are designed to mate closely field platforms or handrail
construction is not required. Field installed stairways. however,
can be provided on any module based on local construction and
safety requirements.
[0018] Referring now to FIG. 2, a schematic sectional view of the
inlet module 102 in FIG. 1 illustrates standardized connections to
the inlet module 102. The inlet module 102 functions as the
interface between the interconnecting pipelines to and from the CPF
and interconnecting pipelines from other support structures. An
emulsion line and a casing gas line are connected to each end of
the inlet module 102. Emulsion and casing gas produced by each
production well (p) in the well-pairs 108-116 (FIG. 1) enter the
inlet module 102 from the 2 well-pair module 104 or the 3 well-pair
module 106 and exit the inlet module 102 to the CPF. A steam line
and a natural gas line are also connected to each end of the inlet
module 102. Steam and natural gas enter the inlet module 102 from
the CPF and exit the inlet module 102 to the 2 well-pair module 104
or the 3 well-pair module 106. An instrument air-line and a
start-up fluid line are connected on opposite sides of the inlet
module 102 and at one end of the inlet module 102 that is connected
to the 2 well-pair module 104 or the 3 well-pair module 106.
Instrument air and start -up fluid enter the inlet module 102 from
the instrument air package 120 and the start-up package 122,
respectively, and exit the inlet module 102 to the 2 well-pair
module 104 or the 3 well-pair module 106. The instrument air
entering the inlet module 102 controls any valves in the inlet
module 102 such as the emergency shutdown valves for the critical
steam, emulsion, natural gas, casing gas, and start-up fluid lines
at the well pad limits. The inlet module 102 also includes the
required metering for process measurement of steam, emulsion,
natural gas, casing gas, instrument air and start-up fluid lines
(hereinafter collectively referred to as service lines) and
regulatory purposes. A pre-fabricated metering system piping spool
and steam pressure safety valve (PSV) piping spool (not shown) are
connected to one side of the inlet module 102 on site. The inlet
module 102 minimizes the spacing required for piping, mechanical
and electrical connections. Standardized connections allow for
mating-up between the service lines connected to the inlet module
102 and the respective service lines connected to the 2 well pair
module 104 or the 3 well pair module 106. The standardized
connections thus, allow for predictable connectivity in any
conceivable well pad design. In any combination of the well-pad
system modules, only one inlet module 102 is required.
[0019] Referring now to FIG. 3, a schematic sectional view of the 2
well-pair module 104 in FIG. 1 illustrates standardized connections
to the 2 well-pair module 104. An emulsion line and a casing gas
line are connected to each end of the 2 well-pair module 104.
Alternatively, an emulsion line and a casing gas line may be
connected to only one end of the 2 well-pair module 104 when it is
the last module on the end of a modular well-pad system. Emulsion
and casing gas produced by each production well (p) in the
well-pairs 108-116 (FIG. 1) enter the 2 well-pair module 104 from
another 2 well-pair module 104, the 3 well-pair module 106 and/or
another emulsion line and casing gas line connected to the
production side of the 2 well-pair module 104 from each production
well. The emulsion and casing gas exit the 2 well-pair module 104
to the inlet module 102, another 2 well-pair module 104 or the 3
well-pair module 106. A steam line, a natural gas line, an
instrument-air line and a start-up fluid line are also connected to
each end of the 2 well-pair module 104. Alternatively, a steam
line, a natural gas line, an instrument-air line and a start-up
fluid line may be connected to only one end of the 2 well-pair
module 104 when it is the last module on the end of a modular
well-pad system. Steam, natural gas, instrument air and start-up
fluid enter the 2 well-pair module 104 from the inlet module 102,
another 2 well-pair module 104 or the 3 well-pair module 106. The
instrument air entering the 2 well-pair module 104 controls any
valves in the 2 well-pair module 104 and exits the 2 well-pair
module 104 to another 2 well-pair module 104 or the 3 well-pair
module 106. Steam and natural gas exit the 2 well-pair module 104
to another 2 well-pair module 104, the 3 well-pair module 106
and/or another steam line and natural gas line connected to the
injection side and the production side of the 2 well-pair module
104 from each respective injection well and production well. Steam
is used to form a steam chamber below each injection well and each
production well as part of the SAGD process. Natural gas is used as
blanket gas for each injection well and each production well.
Start-up fluid also exits the 2 well-pair module 104 to another 2
well-pair module 104, the 3 well-pair module 106 and/or another
start-up fluid line connected to the injection side of the 2
well-pair module 104 from each respective injection well. The
start-up fluid may be used to support the formation of a steam
chamber below each injection well as part of the SAGD process. The
2 well-pair module 104 contains the process piping and controls
necessary to supply steam to each injection well and receive
emulsion from each production well. Each injection well and
production well are connected to the 2 well-pair module 104 by a
respective pre-fabricated piping spool (not shown), which includes
swivel joints. The 2 well-pair module 104 minimizes the spacing
required for piping, mechanical and electrical connections.
Standardized connections allow for mating-up between the service
lines connected to the 2 well-pair module 104 and the respective
service lines connected to the inlet module 102, another 2
well-pair module 104 and/or the 3 well-pair module 106. The
standardized connections allow for predictable connectivity in any
conceivable well pad design. The 2 well pair module 104 may thus.
be combined with the inlet module and the 3 well-par module 106 in
any quantity or combination to achieve a modular well-pad system
that can accommodate two to twelve well-pairs on a well pad. For
example, seven well-pairs will contain a 3 well-pair module 106 and
two 2 well-pair modules 104.
[0020] Referring now to FIG. 4, a schematic sectional view of the 3
well-pair module 106 in FIG. 1 illustrates standardized connections
to the 3 well-pair module 106. An emulsion line and a casing gas
line are connected to each end of the 3 well-pair module 106.
Alternatively, an emulsion line and a casing gas line may be
connected to only one end of the 3 well-pair module 106 when it is
the last module on the end of a modular well-pad system. Emulsion
and casing gas produced by each production well (p) in the
well-pairs 108-116 (FIG. 1) enter the 3 well-pair module 106 from
the 2 well-pair module 104, another 3 well-pair module 106 and/or
another emulsion line and casing gas line connected to the
production side of the 3 well-pair module 106 from each production
well. The emulsion and casing gas exit the 3 well-pair module 106
to the inlet module 102, the 2 well-pair module 104 or another 3
well-pair module 106. A steam line, a natural gas line, an
instrument-air line and a start-up fluid line are also connected to
each end of the 3 well-pair module 106. Alternatively, a steam
line, a natural gas line, an instrument-air line and a start-up
fluid line may be connected to only one end of the 3 well-pair
module 106 when it is the last module on the end of a modular
well-pad system. Steam, natural gas, instrument air and start-up
fluid enter the 3 well-pair module 106 from the inlet module 102,
the 2 well-pair module 104 or another 3 well-pair module 106. The
instrument air entering the 3 well-pair module 106 controls any
valves in the 3 well-pair module 106 and exits the 3 well-pair
module 106 to the 2 well-pair module 104 or another 3 well-pair
module 106. Steam and natural gas exit the 3 well-pair module 106
to the 2 well-pair module 104, another 3 well-pair module 106
and/or another steam line and natural gas line connected to the
injection side and the production side of the 3 well-pair module
106 from each respective injection well and production well. Steam
is used to form a steam chamber below each injection well and each
production well as part of the SAGD process. Natural gas is used as
blanket gas for each injection well and each production well.
Start-up fluid also exits the 3 well-pair module 106 to the 2
well-pair module 104, another 3 well-pair module 106 and/or another
start-up fluid line connected to the injection side of the 3
well-pair module 106 from each respective injection well. The
start-up fluid may be used to support the formation of a steam
chamber below each injection well as part of the SAGD process. The
3 well-pair module 106 contains the process piping and controls
necessary to supply steam to each injection well and receive
emulsion from each production well. Each injection well and
production well are connected to the 3 well-pair module 106 by a
respective pre-fabricated piping spool (not shown), which includes
swivel joints. The 3 well-pair module 106 minimizes the spacing
required for piping, mechanical and electrical connections.
Standardized connections allow for mating-up between the service
lines connected to the 3 well-pair module 106 and the respective
service lines connected to the inlet module 102, the 2 well-pair
module 104 and/or another 3 well-pair module 106. The standardized
connections allow for predictable connectivity in any conceivable
well pad design. The 3 well pair module 106 may thus, be combined
with the inlet module and the 2 well-par module 104 in any quantity
or combination to achieve a modular well-pad system that can
accommodate two to twelve well-pairs on a well pad. For example,
seven well-pairs will contain a 3 well-pair module 106 and two 2
well-pair modules 104.
[0021] Those skilled in the art will appreciate that the inlet
module 102, the 2 well-pair module 104 and the 3 well-pair module
106 may include many possible different internal configurations of
piping, mechanical and electrical components. If, for example,
these modules needed to support a water flood reservoir support
design (high pressure water injection downhole), then each steam
line would be replaced with high pressure water line (with suitable
controls) and each emulsion line would be replaced with another
reservoir production fluid line such as a water, solution gas or
oil line. Suitable controls for these new lines may require
electrical actuation in which the instrument-air line may be
replaced with an electrical line. In these cases the piping may
vary at the Christmas tree accordingly.
[0022] While the present disclosure has been described in
connection with presently preferred embodiments, it will be
understood by those skilled in the art that it is not intended to
limit the disclosure to those embodiments. It is therefore,
contemplated that various alternative embodiments and modifications
may be made to the disclosed embodiments without departing from the
spirit and scope of the disclosure defined by the appended claims
and equivalents thereof.
* * * * *