Chemical Injection Control Using Real-Time Flow and Ion Sensing
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Solution Overview
Problem
Existing chemical injection systems for resource extraction systems adjust chemical injection rates infrequently, leading to over-injection or under-injection, which increases costs and reduces efficiency due to corrosion and solid deposition on equipment.
Innovation Solution
A chemical injection system that adjusts chemical injection rates in real-time based on real-time sensing and analysis of fluid flowrates and ion concentrations, using pressure sensors and ion sensors to determine operational events and adjust injection rates accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If chemical injection rates are adjusted infrequently based on remote laboratory testing, then device complexity is reduced, but manufacturing precision deteriorates due to over-injection or under-injection
Solution Approach 1:
The system continuously monitors produced fluid characteristics (ion concentrations, flow rates) and uses this feedback to automatically adjust chemical injection rates in real-time, resolving the contradiction by implementing intelligent control that maintains precision without requiring complex manual intervention systems
Solution Approach 2:
The injection system performs self-adjustment based on sensor data and processed fluid analysis, automatically modifying injection rates without external intervention, thereby maintaining high precision while keeping the control system relatively simple through autonomous operation
2Manufacturing precision
If chemical injection rates are adjusted frequently based on real-time monitoring, then manufacturing precision is improved, but device complexity increases due to additional sensors and control systems
Solution Approach 1:
The system uses multi-functional sensors and controllers that perform multiple tasks (monitoring flow rate, analyzing ion concentrations, adjusting injection rates) simultaneously, reducing overall device complexity while enabling frequent real-time adjustments for high precision chemical injection
Solution Approach 2:
The system combines fluid monitoring, analysis, and injection control functions into an integrated system where sensors, processors, and injection mechanisms work as a unified whole, achieving high precision adjustments without proportionally increasing device complexity through consolidation
3Device complexity
If remote laboratory testing is used to monitor produced fluid, then device complexity is reduced, but loss of time increases due to infrequent monitoring every 3-6 months
Solution Approach 1:
The system replaces periodic manual laboratory testing with continuous automated electronic sensing and analysis of produced fluid characteristics, eliminating time delays while keeping the monitoring system simple through electronic rather than mechanical/laboratory-based methods
Solution Approach 2:
The system introduces intermediate on-site sensors and analysis devices that bridge the gap between simple monitoring and complex laboratory testing, enabling continuous real-time fluid characterization without requiring full laboratory analysis, thus reducing time loss while maintaining system simplicity
Data Source
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AI summary
A chemical injection system for a resource extraction system includes a controller having a memory and a processor. The memory stores instructions that cause the processor to receive a first pressure from a first pressure sensor of the resource extraction system, receive a second pressure from a second pressure sensor of the resource extraction system, determine a flowrate of a produced fluid of the resource extraction system based on the first pressure and the second pressure, determine an ion concentration of the produced fluid, and adjust an injection rate of a chemical into the resource extraction system based on the flowrate of the produced fluid, the ion concentration of the produced fluid, or both.