Pipeline Corrosion Inhibitor Dosing With Risk-Based Feedback Control
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Solution Overview
Problem
Determining the optimal dosage of corrosion inhibitors for pipelines is challenging, as under-dosing reduces effectiveness while over-dosing leads to chemical waste and increased costs, without a reliable method to accurately calculate the required amount.
Innovation Solution
A corrosion inhibitor optimizer system that computes a failure probability and consequence, generates a risk matrix to identify the necessary inhibitor concentration, and adjusts the dosage based on this data to minimize under-dosing and over-dosing, using sensors and user data to inform the injection rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If corrosion inhibitor dosage is increased, then pipeline corrosion protection is improved, but chemical waste and operational costs increase
Solution Approach 1:
The system dynamically adjusts the inhibitor dosage concentration parameter based on real-time pipeline conditions (fluid composition, flow rate, temperature, existing corrosion level) to achieve optimal protection while minimizing chemical waste. This resolves the contradiction by making the dosage adaptive rather than fixed.
Solution Approach 2:
The system implements a feedback loop where corrosion monitoring sensors continuously measure pipeline corrosion levels and feed this data back to the dosage calculation module, which then adjusts the inhibitor injection rate accordingly. This ensures adequate protection without excessive chemical application.
2Loss of substance
If corrosion inhibitor dosage is decreased, then chemical waste and costs are reduced, but corrosion protection effectiveness deteriorates
Solution Approach 1:
The system dynamically adjusts the inhibitor dosage concentration parameter based on real-time pipeline conditions to achieve optimal protection while minimizing chemical waste.
Solution Approach 2:
The system implements a feedback loop where corrosion monitoring sensors continuously measure pipeline corrosion levels and feed this data back to the dosage calculation module, which then adjusts the inhibitor injection rate accordingly.
3Reliability
If corrosion inhibitor dosage is increased, then corrosion protection is improved, but operational costs increase
Solution Approach 1:
The system dynamically adjusts the inhibitor dosage concentration parameter based on real-time pipeline conditions to achieve optimal protection while minimizing chemical waste.
Solution Approach 2:
The system implements a feedback loop where corrosion monitoring sensors continuously measure pipeline corrosion levels and feed this data back to the dosage calculation module, which then adjusts the inhibitor injection rate accordingly.
4Loss of substance
If precise dosage calculation is implemented, then chemical waste is minimized, but system complexity increases
Solution Approach 1:
The system uses a multi-functional integrated platform that combines corrosion monitoring, data analysis, dosage calculation, and injection control in one system. This reduces overall complexity despite the sophisticated algorithms employed, as all functions share common hardware and software infrastructure.
Solution Approach 2:
The system introduces an intermediary dosage calculation module that processes sensor data and translates it into optimized injection parameters. This intermediary layer simplifies the control architecture by centralizing the complex calculations in a dedicated component rather than distributing complexity across multiple subsystems.
Data Source
AI summary
The present disclosure relates to pipeline corrosion inhibitor optimization and control. In an example, a failure probability representative of a likelihood of a pipeline corrosion failure and a consequence level representative of a consequence from the pipeline corrosion failure can be computed. A risk matrix can be generated and used to identify an inhibitor concentration based on the failure probability and consequence. A dosage of a corrosion inhibitor for mitigating corrosion of a pipeline can be computed based on the inhibitor concentration. In some examples, the dosage of the corrosion inhibitor can be adjusted based on a modification factor computed at least based on a corrosion rate measured for the pipeline.