Alberta SAGD Projects Need This in Their Back Pocket

Heavy oil and bitumen production has been on the rise in Alberta, with data showing over 11.6% increase in 2021. Among the different methods of recovery, Alberta SAGD projects have seen the most significant increment. Interest in these projects is likely to increase further, thanks to the cost and energy efficiency of the process. 

SAGD is an in-situ process that deals with high-temperature and high-pressure to recover bitumen and crude oil. These production conditions are inherently the biggest challenges of the projects. There have been many instances in the past when the project has encountered failures, especially due to limited subsurface data, mechanical errors, and lack of communication and troubleshooting resources. 

While the industry has seen significant improvements in some areas, getting the right components that can handle extreme operating conditions is still a challenge. It is advantageous for a project to consult a local fluid systems expert that can inspect the issues in the field and supply you with the right equipment for your project.

Mechanical Errors in the Production Phase

Steam-assisted gravity drainage (SAGD) is inherently a very complex process. It involves installing wells deep into the sub-surface and injecting the high-pressure super-heated steam from the boiler down to the injection well to recover the bitumen from the oil sands. The injected steam usually has a temperature range between 300°C - 340°C and a pressure of around 1100 psi. This is one of the primary factors of mechanical failure in a SAGD project.

Smaller components, such as the mechanical seals, valves, and fittings are prone to wear and leakage at high temperature and high-pressure conditions. The harsh winter conditions in Alberta and the thermal stresses can affect the performance of the pipelines and fittings to cause system failure. Additionally, the mixing of highly viscous fluid (buffer and process fluid) can clog the mechanical seals and block the recovery path, causing seal leakage and failure. Another reason for seal leakage can be the constant vibration of the pumps. 

Because SAGD is a relatively new EOR process, there is a lack of data to properly analyze the causes of error. So, it is advantageous for the SAGD process to have high-quality components that can counter the aforementioned failures and provide better resistance against corrosion and extreme temperatures.

Small Components Make Big Difference

The process interface valves, seal support system, and flush system from Edmonton Valve & Fitting, are ideal solutions for your SAGD projects. The valve and fitting system can handle superheated steam efficiently, irrespective of the harsh Canadian winter. The VB 03/04/05 series DBB valves and ZSML fittings from Swagelok are specially designed to do so. The double block and bleed valves (DBB) offer:

• Minimal installation time
• Reduced fugitive emission (API 641/ API 624 certified)
• Improved vibration resistance
• Minimal potential points for leakage or failure
• Pressure ratings of flanges as per the ASME B16.5

The ZSML fittings, on the other hand, offer:

• High-temperature resistance with the use of high-temperature carbon steel (up to 427 degrees C)
• 1035 carbon steel and molybdenum disulfide (MoS2) coating for improved wear resistance

Similarly, the seal support system designed in accordance with API 682 keeps the operation running by flushing the contaminants and preventing blockage and abrasion in the seal. 

By keeping the temperature requirement, wear and corrosion resistance, and flow path in check with the right system and components from the local fluid system consultant, Alberta SAGD projects can gain the productivity and efficiency they desire.

Improve Alberta SAGD Project Performance with Edmonton Valve & Fitting

If your SAGD project is facing the constant issue of seal leakage, valve failure, or gauge failure, it may be time for you to examine the quality and reliability of the components in use. The right fluid system components used in SAGD are made up of ideal materials and have desirable mechanical properties. 

Components for improved SAGD performance should be:  

• Erosion- and corrosion-resistant to handle chemically reactive gases, condensates, solid particles, and high-velocity fluids
• Winterized to resist cold temperatures such as in Alberta SAGD projects
• Able to handle the various degrees of vibration from the pumping equipment

The right systems and components are low maintenance and keep your operation running smoothly with reduced chances of failure. At Edmonton Valve & Fitting, we aim to provide high-quality components that are able to withstand common SAGD challenges. 

Edmonton Valve & Fitting has experience with seal flush systems and sampling systems for SAGD applications in Alberta and a deep understanding of the local challenges. We place focus on helping you achieve the greatest level of efficiency for all of your projects through high-quality components, seal flush systems, and sampling systems. Our Field Advisors can perform an onsite analysis of your process and equipment to ensure you are set up for project success.