Fluid Metering System with Closed-Loop Feedback for Precise Chemical Dosing

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Solution Overview

Problem

Conventional fluid metering pumps in the oil drilling industry are inaccurate, prone to air locks, and fail to adjust to changing flow rates, leading to excessive chemical usage and potential equipment damage due to salt accumulation and corrosion.

Innovation Solution

A closed-loop feedback system with a measuring tube and pressure sensor that calculates the volume of chemical added to water, adjusting the chemical input based on measured flow rates and volumes to ensure precise mixing ratios, eliminating the need for conventional metering pumps and preventing air locks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional metering pumps are used to dose chemicals into water, then chemical dosing is achieved, but measurement precision and manufacturing precision deteriorate due to inherent pump inaccuracies

Engineering Contradiction:

Improvechemical dosing accuracyVSAvoidchemical to water mixing ratio

Core Design Contradiction:

Measurement precisionVSManufacturing precision

Solution Approach 1:

The patent replaces the mechanical metering pump system with a non-mechanical dosing system that uses a reservoir, flow control valve, and electronic control unit. This substitution eliminates the inherent mechanical inaccuracies of pump-based metering while maintaining precise chemical dosing through electronic feedback control based on actual flow measurements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system implements a feedback mechanism where flow meters measure the actual flow rates of both water and chemical, the control unit receives these measurements, and automatically adjusts the chemical dosing accordingly. This closed-loop feedback ensures precise mixing ratios despite variations in flow conditions, resolving the precision contradiction.

Inventive Principle:

Principle #23Feedback

2Reliability

If conventional metering pumps operate continuously, then chemical dosing is maintained, but reliability deteriorates due to air lock problems

Engineering Contradiction:

Improvecontinuous dosing capabilityVSAvoidair lock formation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent extracts and eliminates the problematic metering pump component that causes air lock issues. By removing the pump entirely and using a gravity-fed or pressure-driven reservoir system with flow control, the system maintains continuous dosing capability without the air lock vulnerability inherent in pump-based systems.

Inventive Principle:

Principle #2Taking out (Extraction)

3Adaptability or versatility

If conventional metering pumps are used, then chemical dosing is achieved, but adaptability deteriorates as they cannot adjust to changing flow rates

Engineering Contradiction:

Improveadjustment to flow rate changesVSAvoidchemical dosing efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system implements dynamic adaptability through electronic control that continuously monitors actual flow rates via flow meters and automatically adjusts chemical dosing in real-time. This dynamic response to changing flow conditions replaces the static, fixed-ratio dosing of conventional pumps, maintaining both adaptability and productivity.

Inventive Principle:

Principle #15Dynamics

4Reliability

If operators set metering pumps to exceed desired chemical ratios, then adequate chemical coverage is ensured, but loss of substance increases due to chemical waste

Engineering Contradiction:

Improvechemical coverage adequacyVSAvoidchemical waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The feedback-controlled system measures actual water and chemical flow rates and automatically adjusts dosing to match the precise desired ratio. This eliminates the need to over-dose chemicals to ensure adequate coverage, thereby preventing chemical waste while maintaining reliable coverage adequacy.

Inventive Principle:

Principle #23Feedback

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

This system ensures accurate and consistent mixing of fluids, reducing chemical waste, minimizing environmental impact, and preventing equipment damage by maintaining optimal chemical concentrations and flow rates.

Implementation Method 1

a pressure sensor measures the pressure of the chemical in the measuring tube thereby allowing a control unit to calculate the total volume of chemical in the measuring tube

Methodology Applied

Scientific EffectPressure measurement:

Data Source

PatentUS10144653B2Fluid metering system

Publication Date: 2018.12.04 FLOWCORE SYST

AI summary

A fluid metering system for accurately and consistently mixing two or more fluids together. The fluid metering system generally includes a closed loop feedback system that monitors the flow rate of the water and the volume of liquid chemical added to the water over a period of time. Based on the measured amount of chemical added to the water over a period of time, the system calculates whether or not an adjustment is required for the next addition of chemical to the water. The present invention utilizes a measuring tube that is filled with a chemical wherein a pressure sensor measures the pressure of the chemical in the measuring tube when filled and after being emptied to calculate the total volume of chemical added to the water.