Real-Time CO2 Corrosion Modeling With Inhibitor Injection Control
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Solution Overview
Problem
Existing CO2 corrosion models in oil and gas facilities are primarily excel-based and rely on offline data, failing to provide real-time predictive capabilities, which are crucial for managing corrosion inhibition and design integrity due to the dynamic nature of oil and gas operations.
Innovation Solution
A system and method for real-time predictive CO2 corrosion rate modeling using a semi-empirical model that incorporates dynamic process input data, including CO2 inhibitor residuals, to control inhibitor injection rates and optimize asset integrity by minimizing corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If excel-based offline corrosion models are used, then the system is simple and easy to operate, but real-time predictive capabilities are lost
Solution Approach 1:
The patent transforms static excel-based corrosion models into dynamic real-time predictive systems by continuously updating corrosion rate predictions based on live process data from sensors and historians. The system adapts to changing operating conditions by recalculating corrosion rates as new data becomes available, enabling real-time predictions while maintaining manageable complexity through automated data processing.
Solution Approach 2:
The patent replaces manual excel-based calculations with an automated computer-implemented system that retrieves process data from historians, applies corrosion models algorithmically, and generates predictions automatically. This substitution of manual mechanical processes with automated computational systems enables real-time operation without proportionally increasing system complexity.
2Measurement precision
If real-time dynamic process data is incorporated, then corrosion prediction accuracy improves, but data processing complexity increases
Solution Approach 1:
The patent creates a multi-functional system that simultaneously performs data retrieval from multiple sources (process historians, sensors), data validation, corrosion rate calculation using established models, prediction generation, and output to multiple destinations. This universal platform handles diverse data types and processing requirements through a unified architecture, improving prediction accuracy while managing complexity through consolidation rather than separate specialized systems.
Solution Approach 2:
The system automatically retrieves required process data from historians and sensors, applies appropriate corrosion models based on operating conditions, and generates predictions without manual intervention. The automated data processing pipeline selects and applies the correct corrosion calculation methodology based on real-time parameter values, enabling high accuracy predictions while reducing the operational complexity burden on users.
3Reliability
If continuous inhibitor injection control is implemented, then corrosion protection reliability improves, but operational complexity and cost increase
Solution Approach 1:
The patent implements a closed-loop control system where real-time corrosion rate predictions feed back to automatically adjust inhibitor injection rates. The system continuously monitors process conditions, calculates predicted corrosion rates, and modifies injection settings to maintain corrosion rates below acceptable thresholds. This automated feedback mechanism improves protection reliability while simplifying operation by eliminating the need for manual monitoring and adjustment of inhibitor dosing.
Solution Approach 2:
The system dynamically adjusts inhibitor injection parameters (flow rate, dosage) based on real-time predicted corrosion rates and changing process conditions. By automatically modifying injection parameters in response to varying corrosion risks, the system maintains optimal corrosion protection across different operating scenarios while simplifying operator tasks through automated parameter management rather than fixed manual settings.
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
Enables real-time prediction and control of CO2 corrosion rates, enhancing the remaining life of facility components and preventing loss of containment by automating inhibitor injection based on real-time data and advanced inspection techniques.
Implementation Method 1
the CO2 reacts with the aqueous phase to form carbonic acid, which is highly corrosive to the CS material
Data Source
AI summary
A system and method for providing real-time predictive carbon dioxide (CO2) corrosion rate modelling for an oil and gas operation facility includes a modeling system configured to receive dynamic process input data of the oil and gas operation facility, including data relating to CO2 inhibitor residuals of the oil and gas operation facility. The modeling system implements a semi-empirical real-time corrosion rate model and an injection control module operable to control an injection rate of CO2 inhibitor into a component of the oil and gas operation facility based on the semi-empirical real-time corrosion rate model.