Direct Chemical Injection System with Recirculation Mixing
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Solution Overview
Problem
The oil and gas industry faces challenges in accurately blending and injecting chemicals during drilling and completion operations, often relying on cumbersome and imprecise manual systems that can result in under or over dosing, leading to increased costs and potential damage to drilling systems.
Innovation Solution
An automated direct chemical injection system that includes a recirculation line, a mixing chamber with a rotating blade assembly, and a programmable logic controller (PLC) to monitor and control the injection of chemicals based on real-time flowrate measurements, ensuring precise blending and dosing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual systems are used for chemical blending and injection, then device complexity is reduced, but manufacturing precision and measurement precision deteriorate
Solution Approach 1:
The system divides the chemical injection process into separate functional modules: dedicated feed pumps for each chemical, a mixing chamber with multiple mixing zones, and separate injection points. This segmentation allows each component to be optimized independently while working together to achieve precise chemical dosing and blending.
Solution Approach 2:
The system incorporates flow meters to measure the flowrate of drilling fluid and uses this feedback information to control the feed pumps and mixing chamber, ensuring accurate chemical dosing based on real-time flow conditions. The programmable logic controller processes this feedback to adjust injection rates automatically.
2Manufacturing precision
If automated control with flow meters and PLC is implemented, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The mixing chamber serves multiple functions: it receives chemical-infused fluid from the inlet line, blends the chemical with the drilling fluid through multiple mixing zones, and outputs the blended fluid to the recirculation line. This multi-functionality reduces the need for separate components for each operation.
Solution Approach 2:
The system automatically monitors and adjusts chemical injection rates based on real-time flowrate measurements without requiring manual intervention. The programmable logic controller self-regulates the feed pumps and mixing chamber operation based on feedback from flow meters, enabling autonomous precise blending.
3Measurement precision
If dedicated feed pumps for each chemical are used, then manufacturing precision improves, but device complexity and loss of energy increase
Solution Approach 1:
The feed pumps are equipped with variable frequency drives that allow dynamic adjustment of pump speeds based on real-time flowrate measurements. This dynamic control enables the system to optimize energy consumption by adjusting pump operation to match actual chemical injection requirements, avoiding both over-pumping and under-pumping.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables consistent blending and accurate dosing of oilfield chemicals, reduces manual labor and large mix plant requirements, and minimizes chemical costs and drilling rig damage by allowing real-time monitoring and adjustment of chemical injection rates.
Implementation Method 1
a mixing chamber (110) with a mixing blade assembly (200) that rotates to blend the chemical-infused fluid
Implementation Method 2
a mainline flow meter (174) that measures the flowrate of the drilling fluid in the recirculation line
Implementation Method 3
a pump (150) that delivers the chemical from the chemical tote (145) through the injection port (160) and into the inlet line (130)
Data Source
AI summary
A system includes a recirculation line, a mainline flow meter operable to measure a flowrate of fluid flowing through the recirculation line, a mixing chamber, an inlet line coupled between the recirculation line and the mixing chamber, at least one chemical injection port coupled to the inlet line, a dedicated feed pump operably associated with each chemical injection port, and an outlet line coupled between the mixing chamber and the recirculation line. The mixing chamber includes a plurality of mixing zones, a mixing blade assembly that includes at least one blade within each mixing zone, and a motor coupled to the mixing blade assembly and operable to rotate the mixing blade assembly. Each of the dedicated feed pumps is coupled to a separate chemical supply and is operable to pump a chemical to the corresponding chemical injection port for injection into the inlet line.