Challenges

Complex sidestream unit

Benefits

Mobilised and installed within two weeks

Quick results

Scope

Chemical Injection Utilities (CIU) was approached by Roemex, an international supplier of specialist chemicals and support services to the energy sector, to design and deploy a sidestream into its client’s produced water system.

The goal of the project was to monitor how the corrosion inhibitor and any process changes were affecting the corrosion rate. Although historically installed corrosion coupons had indicated low corrosion rates, the client continued to experience corrosion issues that could not be linked to a specific cause.

Solution

A sidestream was mobilised and installed on site within two weeks, demonstrating CIU’s ability to rapidly respond to complex sidestream requests. The unit was equipped with:

An LPR probe for instantaneous detection of corrosion rate changes.

A high-sensitivity ER probe for long-term measurement of general corrosion rate.

Results

The corrosion monitoring campaign confirmed that the corrosion inhibitor was performing effectively while also revealing that certain process changes were causing short-term, severe spikes in corrosion rates.

This project provided a successful and rapid demonstration of CIU’s sidestream capabilities.

Customer Feedback

“From the initial conversations through to field deployment, CIU provided both expert insight and fantastic service provision. In working together on this project, Roemex has been able to provide new methods for long-term corrosion monitoring to our end client. The adaptability and temporary nature of using the sidestream skid has been invaluable in demonstrating the value of long-term data analysis”.

Contact Us Today

Please click here to learn more about our corrosion monitoring capabilities, or to submit an enquiry with our team.

Challenges

Serious nozzle blockages in chemical injection package

Benefits

Optimal, cost-effective equipment identified and installed within timeframe

Scope

After installing a fully automated chemical storage and injection system on a North Sea unmanned platform, CIU was asked to help resolve serious nozzle blockages affecting a separate chemical injection package. These blockages caused loss of critical injection, and because the platform is unmanned, offshore trials or remedial work were costly and impractical.

Using CIU’s unique ability to replicate offshore conditions in a controlled workshop, we conducted tests to evaluate various atomizer nozzles under representative parameters, including injection pressure, flowrate, temperatures, and spray patterns. CIU developed the detailed test procedure and rig design, enabling comprehensive data collection and identification of the appropriate equipment, prior to offshore installation.

Solution

CIU designed and built a bespoke test rig for onshore function testing of injection quills and atomiser nozzles intended for Scale and Corrosion Inhibitor injection on the platform. To account for chemical viscosity changes caused by seasonal temperature variations offshore, tests were conducted at different ambient and chemical temperatures. The following set-up was used to execute the injectivity testing:

Bespoke 6” test spool c/w Kenco Engineering sight glasses and RTJ flanged injection port.

Dual pump skid for chemical injection.

Test chemicals were stored in refrigerator to achieve various fluid temperatures.

A nitrogen supply was used to pressure the spool. Test spool pressure was adjusted to suit individual test cases, matching onsite process conditions.

Thermostatic heat blankets were fitted to test spool to adjust and maintain required test temperatures.

Insulation was installed over heat blankets.

Waste fluid container was connected to test set-up.

Results

Testing confirmed that several nozzle types and sizes were unsuitable for the designated chemicals and operating parameters, with blockages and poor spray dispersal observed –
issues that would be impossible to identify in a live system.

This allowed CIU to eliminate ineffective configurations before installation, avoiding costly offshore remedial work. Following testing, CIU produced a comprehensive Test and System Optimisation Report, enabling the customer to select the optimal equipment for their operations, while ensuring reliable long-term chemical injection performance.

Interested in learning more about our corrosion monitoring capabilities? Please click here.

Scope

A major North Sea operator engaged Chemical Injection Utilities (CIU) to carry out a comprehensive online corrosion and microbial monitoring service aboard its FPSO. The primary objective was to assess the integrity of 38 critical mechanical locations and evaluate the potential risks of microbiologically influenced corrosion (MIC). The scope of work included:

Servicing 38 mechanical locations using flush disc and multi-disc corrosion coupons
Servicing solid plugs and replacing pressure-retaining seals
Installing high-sensitivity probes equipped with data loggers

Solution

CIU quickly mobilised experienced personnel and materials to the site. To evaluate the risk of MIC and overall system integrity, the following data collection and analysis methods were employed:

Microbial swabs taken from retrieved corrosion coupons
Biostuds removed from three bio-sidestreams to measure sessile bacterial populations
Planktonic samples collected from drains and diesel tanks for further analysis

Advanced Microbial Monitoring techniques, including quantitative PCR (qPCR), Next Generation Sequencing (NGS), and Most Probable Number (MPN) analysis, were utilised. All laboratory analyses were conducted by NCIMB.

Please see the video below for an overview of the scope delivered!

Results

The service was completed efficiently and within schedule and budget. CIU provided the client with a comprehensive assessment of mechanical integrity and a clear understanding of MIC-related risks.

Regular and continuous monitoring of corrosion, pitting rates, and microbial activity across process systems enables the client to promptly detect and mitigate any emerging issues, helping to ensure ongoing asset integrity and operational reliability.

For more on our Integrity Monitoring solutions, please click here, or get in touch directly with our Business Development Manager, Craig Wilkinson (craig.wilkinson@ciu.ltd).

Challenges

Limited space

Benefits

Fully bespoke packages

Delivered on time and within budget

Scope

ICR was contracted to supply a one off Scale & Corrosion Inhibitor Injection package for a major oil and gas production facility in the North Sea. The project scope consisted of an integrated Chemical Injection Package, including two off duplex (dual headed) Electric Drive API-675 injection pumps, and all necessary process equipment and instrumentation required to meet client specification.

The client requirements included:

Injection package fully compliant with all applicable client, site, national, international and hazardous area specifications.

One off electric drive, skid-mounted, integrated Scale & Corrosion Inhibitor Chemical Injection Package complete with all necessary process equipment and instrumentation, suitable for installation offshore.

Solution

The facility’s space constraints meant that the allocated area for equipment was extremely small. ICR conducted an optimisation study to identify pumps that were suitable for the given process parameters, while minimising required footprint. Through detailed design, ICR configured the package to fit within the allocated area, all while maintaining optimal package operability and ergonomics.

ICR designed and manufactured the package in accordance with all relevant client and end user specifications.

The Scale & Corrosion Injection Package included the following equipment:

One off painted and load tested Carbon Steel skid c/w integral drip tray, and certified lifting gear.
Two off Milton Roy Primeroyal PH Duplex API-675 injection pumps (in duty / standby configuration) c/w 1.1kW electric motors, capable of injection rate up to 8.34 l/hr at an operating pressure of 320 barg. Pump diaphragm rupture detection via Endress & Hauser pressure transmitters.
Two off local start / e-stop stations.
Four off Kenco Engineering pump setting gauges (1 off per pump head).
Four off Coorstek pulsation dampers (1 off per pump head).
Four off API-520 Pressure Relief Valves (supplied loose).
Four off Endress & Hauser pressure transmitters c/w double block and bleed manifolds.
Discharge non-return valves (NRV’s).
Double block and bleed isolation on package suction and discharge.
All required package process piping, fittings and equipment in 316 SS.
All package instrumentation terminated into skid edge junction boxes (1 off DCS & 1 off ESD) for client hook-up on site.

Result

Fully assembled and tested package completed and delivered within planned cost and schedule.

Bespoke packages designed to meet client specifications and process parameters, and fit into small laydown area.

Duplex pumps allow for two chemical duties via a single pump / motor.

To learn more about our chemical injection solutions, or to enquire with our team, please click here.

Challenges

Multiple packages

Benefits

Completed within timeframe and budget

ICR supplied all bespoke equipment and personnel

Scope

A trusted supplier of tubular goods, surface and subsea equipment, our customer requested ICR’s experts to supply two permanent air-driven Williams chemical injection packages for its end user in the Middle East.

The project required ICR’s team to design and deliver a WI Biocide system, intended to kill bacteria and mitigate damage, as well as a Truescale system to prevent scale build-up.

Solution

At the beginning of the project, ICR conducted an optimisation study of the pumps supplied by a third party. Following a thorough assessment, ICR identified several improvements to the pump selection that would make the project more cost-effective. Reducing the variety of pumps used would also help streamline future maintenance and improve operational efficiency.

Thereafter, ICR designed and manufactured the topside packages as per the client’s specifications, while aligning these to industry standards. Both the Bioside and Truescale Injection packages included a Williams Milton Roy CLD400-316-TFE air-driven chemical injection pump with a duty / standby configuration, which was mounted in a robust 316-grade stainless steel box frame. The packages were complete with all necessary valves, instruments, and piping to ensure the system operates safely and efficiently.

All Williams pumps were designed and built in compliance with API1675 and have been assessed to be compliant with ATEX directive 2014/34/EU.

Result

ICR supplied all the required equipment to complete both the offline and online packages. The fully assembled, bespoke packages were completed by ICR’s experienced technicians as per the customer’s specifications and unique process parameters, and were delivered to the client’s site within budget and the required timeframe.

Both packages were a standardised size, ensuring a seamless installation in the client’s laydown area with only minor site infrastructure modification being required, leading to minimal disruption.

Furthermore, ICR quickly identified positive changes that could be made to the pump models. Standardising the pumps across both packages made the project more cost-effective and efficient, and minimised the amount of spare stock that needed to be held on site.

To discover more about ICR’s chemical injection solutions, and to see more case studies like this, please click here.

Client challenge

Our client, based in Equatorial Guinea, required three pumps to service two separate methanol injection points on their production platform. Two pumps were needed to inject 64.35l/h at 22.4barg process pressure in a duty/standby arrangement, while one pump was required to inject 60.56l/h at 165.5barg process pressure. Limited deck space mandated that the skid footprint could not exceed 1.65m x 0.6m.

What we did

To address our client’s needs, we designed and built a package consisting of three Milton Roy electric drive pumps, each compliant with Atex Zone II. This included two MRoy XB simplex dosing pumps for 22.4barg injection and one Primeroyal K injection pump for 165.5barg injection. A common package suction system was created to feed all three pumps.
Two separate discharge manifolds were designed to independently supply each injection point.
The limited deck space challenge was mitigated by the absence of height restrictions in the designated area. This allowed for a package design which incorporated the pumps and instrumentation within a crash frame, 2 metres in height. The carbon steel frame incorporated earthing points and lifting eyes. Each pump was equipped with an individual discharge pressure transmitter, terminated in a skid-edge junction box. The 22.4barg injection line featured a flow transmitter terminated to the client’s DCS. Individual pump start/stop stations were installed at the skid edge and also terminated to the client’s DCS.

Results

The bespoke package was delivered to the client’s exact specification and within the agreed timeframe. The successful delivery prompted an immediate request for an additional package from the client, again requiring a bespoke design.

Date: March 2023

Client: Chemical Supplier

Location: Wales

Client challenge

Our client required a Super Drag Reducer Injection Package to handle a chemical with high viscosity which had the potential to impact pump performance. Due to varying process parameters, a solution was needed to automatically adjust injection rates and maintain constant concentration, regardless of flow and pressure variations in the pipeline. The goal was to provide a fully automated system that allowed remote control of pump operations with minimal input required.

The high viscosity (100,000 cP) of the chemical posed a significant challenge in maintaining consistent injection rates as the varying process parameters further complicated the task of ensuring a constant concentration. Our team was asked to design a chemical injection skid with an innovative solution that would automatically adjust the pump stroke length via an Actuator Capacity Controller (ACC). This approach aimed to achieve reliable and automated control of injection rates, enabling automatic pump control remote pump control and ensuring efficient chemical injection.

What we did

To address these specific requirements, our team developed a comprehensive solution encompassing the following key elements:

Automated injection rate adjustment: The design of the chemical injection skid incorporated an Actuator Capacity Controller (ACC) that was capable of automatically adjusting the pump stroke length. This innovative feature allowed for precise control of injection rates, ensuring a constant concentration, regardless of variations in flow and pressure within the pipeline.

Integration of on-skid flow meter and control panel: The ACC was seamlessly tied into an on-skid flow meter and control panel, providing real-time monitoring of flow conditions. This integration facilitated automatic adjustment of injection rates based on the measured flow, ensuring accurate and consistent chemical injection.

Remote pump control: The automated solution enabled remote start and stop functionality for the pumps, allowing the client to control operations remotely without the need for additional input. This feature provided convenience and flexibility in managing the injection process.

Results

The successful implementation of the Super Drag Reducer Injection Package effectively met the challenging requirements posed by the high viscosity of the chemical, enabling efficient and reliable chemical injection. The automated system also allowed for the automatic adjustment of injection rates based on flow conditions, ensuring a constant concentration, regardless of variations in flow and pressure within the pipeline. This provided consistent chemical treatment and optimised performance.

Our client expressed satisfaction with our solution, highlighting its effectiveness, reliability and first-class service and support provided by our team throughout the project.

The Super Drag Reducer Injection Package exemplified our team’s expertise in designing and delivering automated solutions for challenging chemical injection requirements. By incorporating the Actuator Capacity Controller (ACC) and integrating it with on-skid flow monitoring and control systems, we achieved precise and adaptive injection rates, enabling remote pump control and consistent chemical treatment. Our client benefitted from a reliable and efficient solution that not only met their specific needs – but also led to a 60% reduction in power usage (which will increase in the winter) – and received exceptional service and support throughout the project lifecycle.

Client quote:

“To sum up, amazing! We have seen a 30% increase in flow through pipeline at 50 ppm, they do not have to use booster pumps now, and pressure drops across the pipe is reduced. They actually have to gag the flow at the terminals at points because there’s too much! All looking very positive, and the skid pump has been used regularly with no problem. It will be in continuous use today, and tomorrow.”

Client: Major North Sea Operator

Location: UKCS