Modular processing facility

Abstract

The various processes of a plant may be segmented into separate process blocks, which may be interconnected using fluid conduits and/or electrical connections. These process blocks may be directly connected, for example without an external piperack interconnecting process blocks. In some embodiments, each process block may be formed of one or more modules. The process-based nature of this modular approach, along with the optional lack of an external interconnecting piperack, may provide benefits over conventional modular plant design.

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.