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by Tristian McCallion on Thu, May 27, 2021 @ 13:05 PM
Steam-assisted gravity drainage is an enhanced oil recovery (EOR) technique that is widely used in northern Alberta to recover heavy crude oil and bitumen through steam injection. SAGD is a less invasive technique compared to conventional open-pit oil sands operations and can result in lower environmental impact. It also boasts an 80% recovery rate and makes use of treated brackish water, instead of freshwater, to generate the steam required to heat bitumen.
A number of oil and gas and SAGD operations have struggled with delays and productivity issues over the past decade, slowing down improvements to the process. However, there have been substantial improvements in refining and improving the efficiency of the extraction process. The current challenge facing SAGD operations is procuring proper materials and equipment that can tolerate the harsh nature of SAGD applications. The high-temperature applications combined with chemical compatibility issues pose a serious challenge for safe and efficient operations. It is critical to have local access to fluid systems experts who can assess a process to provide equipment with proper materials of construction to hold up under the unforgiving SAGD applications. Fluid systems experts can also be of great benefit when critical equipment is not functioning properly and must be troubleshot quickly to minimize downtime and reduce project delays.
SAGD Challenges to be Met Through Improved Communication
Communication during the project phase is one critical SAGD challenge that has proven difficult to alleviate—especially considering the size and number of people involved in a single SAGD operation. The inability to communicate quickly and effectively with fluid systems experts when faced with seal flush and sampling system issues can impact the success of a SAGD operation. Thus, finding local access to highly experienced fluid systems experts is imperative to procuring equipment suited for the harsh applications associated with SAGD.
Communication During Procurement Throughout Project Phase
Procuring all necessary equipment to arrive on time for critical SAGD applications depends on accounting for lead times through effective communication. This means maintaining communication between and amongst engineering, procurement, and project teams as well as communication with vendors on the status of components and equipment. While there are typically project management tools in place to ensure clear and effective communication between and within in-house teams, this is not always the case with outside vendors. This becomes problematic when custom-configured panels and equipment are involved, as mistakes can be made due to lack of communication or miscommunication.
Another factor to consider is that vendors who designed and built equipment for SAGD operations, such as seal flush systems and sampling systems, are not typically the ones installing the equipment. This can lead to the equipment being installed incorrectly or installed in a location that is not easily accessible. Incorrect installation of equipment may cause the equipment to not function properly or may shorten its life cycle. Installation that results in the equipment not being easily accessible can also make maintenance difficult and can lead to operator error in the future.
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To help alleviate any missteps in communication, Edmonton Valve & Fitting can provide walk-through demonstrations and testing of panels and equipment throughout the building process to project completion with our augmented reality (AR) capabilities in our Custom Solutions department. We can also use our AR capabilities to provide guidance during equipment installation and implementation. |
Lack of Resources to Quickly Troubleshoot Problems and Optimize Operations
Lack of equipment, such as seal flush and sampling systems, that can hold up under the inherently harsh applications involved in SAGD can result in mechanical seal failure or an inability to make informed decisions to optimize SAGD operations. When an issue arises during SAGD operations in remote or otherwise restricted locations, assessment to determine a solution within a timely manner can become difficult. This can lead to unplanned downtime and a delay in project completion.
Seal flush systems for pumping equipment and sampling systems play an important role in SAGD operations. A wide range of pumping equipment from emulsion well pad and boiler feed pumps to water treatment and export pumps are heavily depended on throughout the course of a SAGD project. When a seal fails or a seal flush system isn’t performing properly, operations are halted to assess the cause. When onsite engineers are unable to identify the source of the problem or find an adequate solution, unplanned downtime becomes another issue.
To verify water treatment efficacy, quantify steam-oil and water-oil ratios, and ensure product quality, safe and reliable grab samples must be obtained. However, liquid samples at SAGD sites have been known to be taken in plastic bottles or even coffee cups. This not only creates a very dangerous situation for operators but can also lead to obtaining a misrepresentative sample. Without a representative sample, it is impossible to make well-informed decisions regarding the process and can result in a level of uncertainty in product quality.
Addressing SAGD Challenges Through Superior Communication with Local Experts
Typically, entire field advisory teams from local fluid systems vendors can perform onsite visits to assess issues concerning seal flush systems and sampling systems. However, when a location is remote or there are other access restrictions in place, onsite visits can be challenging. Coordinating an entire team of field advisors to visit a site requires each individual to receive safety clearance. This can be time-consuming and isn’t ideal for issues requiring immediate attention.
Edmonton Valve & Fitting offers virtual evaluation onsite service using their AR collaboration headset. This technology allows one Edmonton Valve & Fitting Field Advisor to visit a site wearing a headset that projects visuals back to a remote team in real-time, allowing them to provide expertise from other locations. This eliminates the difficulties of taking an entire team through a safety orientation as well as the challenges of having to fit an entire field advisory team in tight spaces, such as an analyzer shelter. This technology opens up the ability to provide faster deployment of resources to get fluid system problems solved quicker and allows Edmonton’s Field Advisors to have more brain power ‘onsite’ while matching the right experts with the right problems.
Swagelok’s AR collaboration headset also opens the door to:
- Assist with time-sensitive seal flush and grab sampling challenges quicker with a simplified process with access to the right experts for the specific problem
- Perform virtual commissioning of fluid systems
- Advise during the construction and testing of analytical equipment by providing oversight during crucial stages of the fluid systems implementation process, helping customers prevent errors and integrate long-lasting assemblies
- Provide virtual witnessing of key procurement processes, such as manufacturing and shipping practices
About Tristian McCallion, Custom Solutions Manager, Edmonton Valve
Edmonton Valve has relied on McCallion for 26 years. His current title is Custom Solutions Manager. Earlier, he supervised our sales team. Before that, he managed sales throughout Edmonton and northeastern Alberta. For 12 years he also worked with Swagelok Energy Advisors across North America, training customers on steam fundamentals (TAP), testing steam traps, and conducting steam system audits.
