MODULAR PROCESSING FACILITY

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.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

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

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

TECHNICAL FIELD

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

Building large-scale processing facilities can be extraordinarily challenging in remote locations, or under adverse conditions. One particular geography that is both remote and suffers from severe adverse conditions includes the land comprising the western provinces of Canada, where several companies are now trying to establish processing plants for removing oil from oil sands.

Given the difficulties of building a facility entirely on-site, there has been considerable interest in what we shall call 2nd Generation Modular Construction. In that technology, a facility is logically segmented into truckable modules, the modules are constructed in an established industrial area, trucked or airlifted to the plant site, and then coupled together at the plant site. Typically such 2nd Generation (“2nd Gen”) modules are not process based, but rather are equipment based, meaning that each of the modules in a 2nd Gen Construction typically relate to a specific equipment type (e.g., pumps, compressors, heat exchangers, cooling towers, etc.). Several 2nd 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.

2nd 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 2nd Gen Modular facility is described in US20080127662 to Stanfield.

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.

There have been very significant cost savings in using 2nd 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 2nd Gen Modular, there are still problems. Possibly the most serious problems arise from the ways in which the various modules are interconnected. In 2nd 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 2nd 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 2nd 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 2nd 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 2nd 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).

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 (“3rd Gen”) Modular Construction or as 3rd Gen processing facilities.

SUMMARY

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.

Typically, embodiments of a 3rd 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 3rd Gen techniques might be used for some off-shore modular construction, more often 3rd Gen modules and construction techniques would be used to construct on-shore processing facilities.

Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints, and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.

As used herein the term “process block” means a part of a processing facility that has several process systems within a distinct geographical boundary. 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 2nd 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 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, 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 3rd Gen, it is typically true of 3rd 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.

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.

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.

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.

One very significant advantage of 3rd 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 (N2), oxygen (O2), water (H2O), 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).

Process blocks can be assembled in any suitable manner. For example, in some embodiments 3rd 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 2nd Gen modular design for example). Instead, in these embodiments the 3rd Gen process blocks typically are directly interconnected with one another in accordance with a 3rd 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 3rd 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 3rd 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).

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.

In some contemplated embodiments, 3rd 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 3rd Gen Modular facility would collectively include at least one of a vessel, a compressor, a heat exchanger, a pump, and/or a filter.

Although a 3rd 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.

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

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.

FIG. 1 is a flowchart showing some of the steps involved in a 3rd Gen Construction process.

FIG. 2 is an example of a 3rd Gen Construction process block showing a first level grid and equipment arrangement.

FIG. 3 is a simple 3rd Gen Construction “block” layout.

FIG. 4 is a schematic of three exemplary process blocks (#1, #2 and #3) in an oil separation facility designed for the oil sands region of western Canada.

FIG. 5 is a schematic of a process block module layout elevation view, in which modules C, B and A are on one level, most likely ground level, with a fourth module D disposed atop module C.

FIG. 6 is a schematic of an alternative embodiment of a portion of an oil separation facility in which there are again three process blocks (#1, #2 and #3).

FIG. 7 is a schematic of the oil treating process block #1 of FIG. 3, showing the three modules described above, plus two additional modules disposed in a second story.

FIG. 8 is a schematic of a 3rd Gen Modular facility having four process blocks, each of which has five modules.

FIG. 9 is a schematic of another 3rd Generation Modular facility having a total of six interconnected process blocks.

 DETAILED DESCRIPTION

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.

The following brief definition of terms shall apply throughout the application:

The term “comprising” means including but not limited to, and should be interpreted in the manner it is typically used in the patent context;

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);

If the specification describes something as “exemplary” or an “example,” it should be understood that refers to a non-exclusive example;

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

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.

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.

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).

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.

Methods of laying out a 2nd Gen Modular facility are different in many respects from those used for laying out a 3rd 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 2nd 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 2nd Gen Modular Construction can prefab about 50-60% of the work of a complex, multi-process facility, 3rd Gen Modular Construction can prefab up to about 90-95% of the work. 3rd 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 3rd 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.

Also, in at least some embodiments, each process block in a 3rd 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 3rd 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 2nd 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 2nd 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 3rd Gen).

Additional information for designing 3rd Gen Modular Construction facilities is included in the 3rd 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.

FIG. 1 is a flow chart 100 showing steps in production of a 3rd Generation Construction process facility. In general there are three steps, as discussed below.

Step 101 is to identify the 3rd 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.

Step 102 is to allocate a plot space for each 3rd Gen Construction process block. The plot space allocation requires the piping layout specialist to distribute the relevant equipment within each 3rd 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 3rd 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:

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.

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.

Step 102C is to allocate space for the electrical and control distribution panels on the first level. FIG. 2 is an example of a 3rd 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 3rd Gen primary process block module. Refer to E+I installation details for 3rd Gen module designs.

Step 102D is to group the equipment and instruments by primary systems using the process block process flow diagrams (PFDs).

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.

The use of Fluor's Optimeyes™ is an effective tool at this stage of the project to assist with process block layouts.

Step 103 is to prepare a detailed equipment layout within process blocks to produce an integrated 3rd 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 3rd Gen “block” layout is illustrated in FIG. 3.

Step 104 is to develop a 3rd 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 3rd Gen module configuration table is developed using the above data. Templates can be used, and for example, a 3rd Gen power and control distribution plan can advantageously be prepared using the 3rd Gen power and control distribution architectural template.

Step 105 is to develop a 3rd 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 3rd Gen Modular Execution plan, which can be used for setting the baseline to proceed to the next phase. It is contemplated that a 3rd Gen Modular Execution will require a different schedule than traditionally executed modular projects.

Many of the differences between the traditional 1st Generation and 2nd Gen Modular Construction and the 3rd Gen Modular Construction are set forth in Table 1 below, with references to the 3rd 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 1 Activities Traditional Truckable Modular Execution 3rd 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 3rd 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 3rd Gen Process Block. piperack/sleeperways and misc. supports Detailed equipment layout within Process Blocks using 3rd 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 3rd 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

A typical 3rd 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, 3rd Gen modular construction may be quite different from typical 2nd Gen construction approaches, since the 3rd Gen facility typically would not simply be multiple, substantially identical modules, for example in parallel (as may be typical of 2nd Gen modular construction, for example).

Typically, the at least 3 process blocks of an exemplary 3rd 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). 3rd Gen modular facilities typically employ a different layout (of modular elements) than conventional 2nd Gen facilities. For example, typically the at least 3 process blocks of an exemplary 3rd 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 3rd Gen facility (for at least the process blocks associated with the primary process fluid flow through the production facility). Instead, the 3rd 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 3rd 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 3rd 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 3rd 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).

Typically, each of the at least 3 process blocks of a 3rd 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 2nd Gen approaches, which may typically use an equipment-based approach (such that typical 2nd Gen modules may be required to interact with equipment from several modules being needed to perform a specific process). In other words, 3rd Gen process block embodiments may not have an equipment-based approach or layout.

In at least some embodiments of a 3rd 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 3rd Gen modular processing facility.

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.

In a typical exemplary 3rd 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 3rd 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 2nd 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 3rd 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 2nd 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 3rd Gen production facility may be greatly shortened from that typically experienced in a 2nd Gen production facility.

The arrangement/layout of process blocks in exemplary 3rd 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 3rd 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 3rd 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).

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, N2, O2, 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.

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.

Such 3rd Gen modular process facilities may be constructed uniquely, due to the 3rd Gen nature of the process blocks and/or modules and/or the process-based approach. For example, a typical exemplary 3rd 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 3rd 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 2nd Gen (e.g., equipment only modules).

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 3rd Gen production facility) would typically flow between adjacent and directly interconnected process blocks. Stated another way, the process blocks in a 3rd 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 3rd Gen facility that are not adjacent and/or interconnected with one or more other process blocks with which it interacts, in a 3rd 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.

In addition, in some embodiments, one or more of the fluid lines interconnecting the inputs and outputs of the 3rd 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, N2, O2, 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.

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.

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).

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.

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).

FIG. 7 is a schematic of the oil treating process block #1 of FIG. 3, showing the three modules described above, plus two additional modules disposed in a second story.

FIG. 8 is a schematic of a 3rd Generation Modular facility having four process blocks, each of which has five modules. Although dimensions are not shown, each of the modules should be interpreted as having (a) a length of at least 15 meters, (b) a height greater than 4 meters, (c) a width greater than 4 meters, and (d) having open sides and/or ends where the modules within a given process block are positioned adjacent 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.

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.

FIG. 9 is a schematic of a 3rd 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 3rd 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 3rd 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.

Having described above various system/facility and method embodiments, various additional embodiments may include, but are not limited to the following:

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).

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.).

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.

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.

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.

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.

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.

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.

Patent History
Publication number: 20170159305
Type: Application
Filed: Feb 23, 2017
Publication Date: Jun 8, 2017
Inventors: Fred Haney (Calgary), Gary Donovan (Canmore), Todd Roth (Calgary), Alan Lowrie (Calgary), George Morlidge (Okotoks), Simon Lucchini (Calgary), Sean Halvorsen (Calgary)
Application Number: 15/440,812
Classifications
International Classification: E04H 1/00 (20060101); E04H 5/02 (20060101);