Scalable modular solutions provide a competitive advantage

By DistributionNOW on 8/16/2016
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Image: DistributionNOW.

Traditional well-site fabrication is assembled and integrated on location. This approach has been the standard of oil and gas production for decades. At Power Service, a DistributionNOW company, we offer a better solution. Our modular production units provide quick installation times, a reduced footprint, greater flexibility and are scalable. By allowing the producer to quickly integrate additional production units as pads are completed, we can dramatically reduce installation time and overall cost.

Our production manifolds handle a wide range of production rates and are seamless to integrate and decommission. The modularized equipment is easily removed and can be redeployed to new locations. Our vessels are designed, sized and optimized for specific fields, addressing process concerns such as surging, foaming, emulsions and solids handling, while eliminating cost concerns from oversized vessels. Measurement for allocation or well dynamics are easily integrated due to our optimized design and provide accurate figures for all three phases of production. Taking it a step further, the data collection, control and automation of the equipment can be added to provide a true, turnkey solution. Platform options are unlimited and can be wireless or hardwired. Integration into existing SCADA platforms or remote communications is effortless.

In the animation above, you will see the design features that make this possible. The incoming production stream is plumbed to the inlet of the separator. As the production mix is separated into its constituents, internal design features, such as wave baffling and vane packs, ensure adequate retention time by forcing the liquids through the entire length of the vessel. Further fine-tuning is achieved by an external real-time interface-level adjustment. Changes to the oil and water levels in the vessel for fluctuations in incoming oil and water ratios can be made without the need to take the unit offline. The separated production streams are metered and plumbed to the integrated production manifold. All necessary data is captured and relayed through a customized control platform. You will also see the ease at which additional units can be brought online, lowering installation costs, improving separation quality and providing highly accurate measurement.

High levels of quality assurance and control (QA/QC) are maintained since a large bulk of the fabrication is done in a climate controlled indoor facility. Units are fully tested and required non-destructive testing (NDT) is performed, documented and provided for each package. The controlled environment creates efficiency gains in the fabrication process, realizing dramatic savings compared to the traditional method of field welding, assembly and testing. Each unit is shipped with all required documentation, operation and maintenance (O&M) manuals and complete bill of materials (BOM) for all components.

Building on the modular separation platform, Power Service can design and integrate a majority of the required well pad components. After production fluid has exited the separation phase, we can engineer, specify and fabricate: Modular Pipe Racks, Vapor Recover Towers (VRT), Vapor Recovery Units (VRU), water transfer skids, Lease Automatic Custody Transfer Units (LACT), recycle equipment, control valves and piping. Components can be staged and delivered just-in-time (JIT) as pads are completed, coordinated and delivered, providing flexibility and eliminating the need for costly excess inventory and yard storage facilities.

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Image: DistributionNOW.

According to Power Service’s North American Business Development and Engineering Manager Jeremy Olson:

Our goal has been to create a One-Stop Solution for our customers, eliminating some of the unnecessary downtime between the well hookup and getting oil to market. We found that offering the ability to fabricate modular solutions that provided installation flexibility was one of the best ways to increase efficiencies for our customers.

The final step in providing a true turnkey solution is the design and inclusion of the control, data acquisition and monitoring. We handle all aspects of the facility, from development of the control narrative and programming for each component, to HMI design. Optimizing the control platform and eliminating the cumbersome task of integrating multiple PLC’s dramatically reduce automation costs. The facility design will include a central control and acquisitions PLC, and remote IO on each component. The remote IO can be connected wirelessly, or through traditional means, and allows control and monitoring of any piece of equipment from any other piece of equipment. The control is configurable and expandable to allow easy additions as new production is brought online.

Decommissioning of equipment is seamless and simple with the modular concept. As shown in the previous animation, a unit can be pulled from production with minimal disruption to the other wells. Because the mechanical and electrical platforms are uniform and configurable, the decommissioned piece can be easily refurbished and redeployed at a new location.

With our vast network of field service and support locations, Power Service can provide start up support, troubleshooting and training for operations, engineering and construction personnel. Furthermore, because the operation interfaces are uniform, regardless of component sizing, training for operators is simplified and provides a smooth transition for personnel who move or deal with multiple asset locations.

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