Once-through steam generator for use at oilfield operation site, and method

Abstract

A once-through steam generator for use at an oilfield operation site includes: a control module having an enclosure including controls for operating the steam generator, a radiant module including a radiant chamber, and a convective module including an economizer heat exchanger. The enclosure is erected prior to transportation to the operation site.

1 . A once-through steam generator for use at an oilfield operation site, the steam generator comprising:
 a control module supported by a first steel frame and having an enclosure comprising controls for operating the steam generator, the enclosure being erected prior to transportation to the operation site;   a radiant module supported by a second steel frame and comprising a radiant chamber having a burner installed at an end thereof, the burner being configured to provide a heat transfer of between about 80 million Btu/h and about 200 million Btu/h;   a convective module comprising an economizer heat exchanger, and   
       wherein the radiant module supported by the second steel frame is transportable separately from the control module supported by the first steel frame. 
     
     
         2 . (canceled) 
     
     
         3 . The steam generator of  claim 2 , wherein the enclosure is configured to accommodate the burner. 
     
     
         4 . (canceled) 
     
     
         5 . The steam generator of  claim 1 , wherein the radiant module further comprises at least one water conduit and at least one steam conduit, said conduits being external to the radiant chamber. 
     
     
         6 . The steam generator of  claim 5 , wherein one or more of the conduits comprise:
 an electrical heating element disposed thereon, and   a thermal insulation layer covering the conduit and the electrical heating element.   
     
     
         7 . (canceled) 
     
     
         8 . The steam generator of  claim 1 , wherein each steel frame is configured to be installed on a plurality of steel piles. 
     
     
         9 . The steam generator of  claim 1 , wherein each of the control module and the radiant module is installed on the respective steel frame prior to delivery to the operation site. 
     
     
         10 . The steam generator of  claim 1 , wherein the enclosure has an insulated interior sized to accommodate at least one worker. 
     
     
         11 . A method of installing a once-through steam generator at an oilfield operation site, the method comprising:
 providing each of:
 a control module supported by a first steel frame and having an enclosure comprising controls for operating the steam generator, the enclosure being erected prior to transportation to the operation site, 
 a radiant module supported by a second steel frame and comprising a radiant chamber having a burner installed at an end thereof, the burner being configured to provide a heat transfer of between about 80 million Btu/h and about 200 million Btu/h, 
 a convective module comprising an economizer heat exchanger, 
   
       wherein the radiant module supported by the second steel frame is transportable separately from the control module supported by the first frame; and
 installing the control module, the radiant module and the convective module at the operation site. 
 
     
     
         12 . The method of  claim 11 , wherein said providing further comprises:
 transporting each of the control module, the radiant module and the convective module to the operation site.   
     
     
         13 . The method of  claim 12 , further comprising, prior to said transporting:
 testing said controls for operating the steam generator.   
     
     
         14 . The method of  claim 11 , further comprising, prior to said installing:
 forming a foundation in ground at the operation site.   
     
     
         15 . The method of  claim 14 , wherein the foundation comprises an array of steel piles.