Pressure-Based Dosing Tank Control for Precise Chemical Injection
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Solution Overview
Problem
Existing methods for determining chemical discharge in wellbores are inaccurate due to variables in pump strokes, expensive flow meters, and non-standard tank shapes, leading to inefficiencies in chemical delivery.
Innovation Solution
A system with a dosing tank of known geometry and a fluid level detector, such as a pressure sensor, calculates fluid volume and adjusts the injection pump's speed/duty cycle to achieve precise chemical dosing by correlating fluid level changes with volume changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If pump strokes are used to measure chemical discharge, then the measurement system is simple, but the measurement precision is poor due to variables in pump strokes
Solution Approach 1:
The patent replaces the mechanical pump stroke counting system with a pressure-based measurement system. A pressure sensor monitors pressure changes in the dosing tank, and a controller calculates fluid volume based on pressure differential and tank geometry, eliminating the need to mechanically track pump strokes while achieving accurate measurement.
Solution Approach 2:
The patent introduces a pressure sensor as an intermediary element between the dosing tank and the measurement system. The pressure sensor converts fluid level information into electrical signals that the controller can process, enabling accurate volume calculation without direct mechanical measurement of pump strokes.
2Measurement precision
If flow meters are used to measure fluid discharge, then the measurement precision is high, but the device complexity and cost increase significantly
Solution Approach 1:
The patent extracts the measurement function from the complex flow meter system and implements it using simpler components: a pressure sensor and a controller that calculates volume based on pressure changes and known tank geometry. This removes the need for expensive, complex flow meters while maintaining measurement capability.
Solution Approach 2:
The patent uses inexpensive pressure sensors instead of expensive flow meters. The pressure sensor is a low-cost component that can be easily replaced if needed, providing accurate measurement functionality without the high cost and complexity of traditional flow metering equipment.
3Adaptability or versatility
If non-standard shaped tanks are used for chemical storage, then the tank design is flexible, but the measurement precision of fluid volume is poor due to difficulty in mathematical conversion
Solution Approach 1:
The patent changes the measurement parameter from direct volume calculation (which requires complex geometry) to pressure measurement. By monitoring pressure changes in the tank and using the known tank geometry, the system calculates volume changes without needing to perform complex mathematical conversions for non-standard tank shapes.
Solution Approach 2:
The patent replaces complex geometric calculations with a pressure-based measurement approach. The controller uses pressure sensor data combined with stored tank geometry information to calculate fluid volume, eliminating the need for real-time mathematical conversion of non-standard shapes.
4Reliability
If batch treatment with treater trucks is used to ensure chemical lasts, then the chemical delivery is reliable, but the productivity decreases due to difficulty of accessing remote locations
Solution Approach 1:
The patent implements a precision dosing system that accurately measures and controls chemical delivery in real-time. This allows the system to reliably deliver the exact amount of chemical needed without requiring frequent truck visits to monitor or adjust dosing, improving productivity while maintaining delivery reliability.
Solution Approach 2:
The patent uses a feedback mechanism where the controller continuously monitors pressure changes in the dosing tank and adjusts the pump operation accordingly. This closed-loop control ensures reliable chemical delivery with precise dosing, eliminating the need for batch treatment approaches that require frequent truck interventions.
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 provides highly accurate and precise chemical dosing, eliminating the need for expensive flow meters and improving accuracy by directly measuring fluid volume, ensuring consistent chemical delivery.
Implementation Method 1
The fluid level detector measures the pressure of the dosing tank to determine a fluid level
Data Source
AI summary
A method and system to precision dose a fluid system with an injection fluid having chemicals is provided. The method and system includes providing a buffered dosing tank of a known geometry between a source tank and an injection pump. The fluid level detector measures the pressure of the dosing tank to determine a fluid level. The fluid level together with the known geometry allow for a controller to calculate a fluid volume in the dosing tank and a change of volume over time. Using the change of volume over time, the controller can calculate an actual dose rate and adjust a speed or duty cycle of the injection pump such that the actual dose rate is approximately the target dose rate.