Category: Chemical Injection Solutions

Date: May 2022

Client: Major Operator

Location: North Scotland

Client challenge

Our client, a major energy operator, required two Biocide Chemical Injections Pump packages for their oil and gas terminal, as elevated levels of Sulphate Reducing Bacteria had been discovered.  This bacteria caused increased corrosion rates on the main pipeline at the terminal, especially in areas with low points where water tends to accumulate. The integrity of the pipeline system was at risk due to this corrosion, necessitating biocide injection at both the pig receiver and the crude oil manifold.

Solution

Our team designed and built two bespoke chemical injection units complete with:

• Two CRP2250W600CR-BR Williams Milton Roy Air Driven W Series Plunger Chemical Metering Pumps
• One head operating to individual injection point with one complete standby pump. 

All equipment supplied was bespoke and reflected the duty parameters and chemical application specified by our client. 

The packages included the following bespoke elements:

• Two compartment containers divided by a partition wall and painted in accordance with our client’s coating specification.
• Package containerised with galvanised roller doors provided for operator access and designed to ensure safe and easy changeover of IBCs. 
• The IBC was connected by a 300mm section of flexible hose and an adapter to fit the IBC outlet connection. 
• Each side of the container was internally outfitted with ex-rated fluorescent lighting fittings, controlled by a manual switch which terminated at the package edge. 
• Package bunded with two off 1.25m³ bunded sections separated by a bulkhead wall, with flange drain valves.
• Ventilation grills were located on all three walls of the container to avoid ingress of rainwater.
• Equipped with lifting points rated for twice the weight of a fully outfitted container and holding down foot plates with slings and suitably sized and rated shackles supplied to facilitate the single point lift. The containers conform to DNV 2.7-1 lifting and structural requirements.
• Two off M12 earthing was provided and were located on diagonally opposite, external corners of the package.
• The package included safety signage.

All process tubing including, suction, discharge, and air manifolds as well as the fittings and valves were constructed from 316 stainless steel. Instruments had a permanent tag label fitted. The injection pump package was mounted in a 316 stainless steel box frame complete with all valves, instrumentation and piping for safe and proper operation.

Results & benefits

We successfully delivered the chemical injection packages within the planned schedule and under budget. Each package was specifically designed to reflect our client’s specifications, duty parameters and environmental factors.

Date: October 2021

Client: Major North Sea operator

Location: UKCS

Client challenge

Our client, a major North Sea operator, required an Automatic Processing Unit (APU) to remotely adjust injection rates. The unit had to have the following specifications:

• A stainless steel 316 box frame for attaching to a H₂S Scavenger rental unit.
• Single vs stroke speed (at 100 stroke length).

What we did

Our team provided an APU that enabled remote adjustment of chemical injection rates from a site control room. The APU received a 4-20mA signal from the control room, and based on this signal, adjusted the stroking speed of the pump proportionally. To control the pump’s stroking speed, the APU utilized a solenoid valve, which was installed locally to the pump in place of the normal Williams Controller. This solenoid valve effectively fulfilled the role of the Controller. 

The APU unit offers several advantages, including: 

• Remote adjustment of the pump flow rate allowing for quick and easy changeover, especially in a duty/standby setup. 
• Remote starting and stopping of pumps enabling remote control of pump operations, enhancing convenience and flexibility. 
• Reduction in chemical usage by remotely adjusting the chemical flow rates, the APU assists in reducing chemical consumption. 
• Compatibility with site instrumentation as the APU can receive an analog signal from the site DCS or feedback from site or package instrumentation such as flowmeters. This facilitates precise adjustment of chemical injection rates. 
• Proportional adjustment of stroke speed as the APU receives a 4-20mA signal and adjusts the pump’s stroke speed accordingly, ensuring accurate control. 

The APU controls the stroke speed of the pump by opening and closing a solenoid valve installed locally to the pump, replacing the normal Williams Controller. The solenoid valve effectively performs the role of the Controller, enabling the increase or decrease of the pump’s stroke speed. 

The table below provides an example that demonstrates the relationship between the analog signal sent to the APU and the resulting stroke speed or pump volume. It’s important to note that stroke speeds and volumes may vary depending on the specific pump models used. 

Results 

By successfully implementing the APU, our solution allowed our client to remotely adjust injection rates, control pump operations, and optimise chemical usage. The APU’s flexibility and compatibility with various instrumentation make it a valuable tool in enhancing operational efficiency and ensuring accurate control in critical processes. 

Scope 

ICR was approached by the client to replace their existing ferric sulphate injection package. The current pumps were oversized for the process requirements resulting in high pulsation and vibration due to the short stroke and fast motor frequency required to meet the flow needs. ICR conducted an engineering site survey, working closely with the client to find the best solution. 

ICR delivered a fully automated, containerised ferric sulphate injection package consisting of 6 electric drive, VFD controlled injection pumps (4 duty and 2 standby). 

Solution 

Ferric Sulphate Injection Package consisting of the following: 

• Fully automated ferric sulphate injection package, with required hardware to allow remote monitoring, control and operation via onsite control system 
• Package integrated into modified 20-foot shipping container, housing all chemical injection, electrical, and ancillary equipment. 
• Container internals lined out with 12mm thick “Aqua-panels”, chemical resistant non-slip floor and integral stainless-steel bund 
• 3 Polypropylene injection pump cabinets (2 duty and 1 standby) c/w Perspex sliding doors 
• Each cabinet contains 2 Milton Roy MAXROY, VFD controlled, electrically driven pumps with each pump being capable of injecting 407.5 litres per hour 
• Package control panel with integral HMI touch screen and local VFD touch pads 
• Emergency eye bath station 

Results & Benefits 

• Fully assembled package delivered to site, minimising hook-up and onsite work requirements 
• Bespoke package designed to meet client specifications and process parameters 
• Fully automated to be integrated into on-site control systems 

Scope 

To supply an electric drive Pour Point Depressant injection package. Injection Rate: 0-1800 litres per hour Duty Process Pressure: 13.8 barg Fluid Viscosity: Up to 600 cP Ambient Temperature: -15 to +30 °C Skid ATEX Classification: Zone 2 IIA T3 Power Requirement: 440V 3ph 50hz Chemical reservoir: Tanker (by others) 

Required Injection Rate: 0-1800 litres per hour 

Duty Process Pressure: 13.8 barg 

Fluid Viscosity: Up to 600 cP 

Ambient Temperature: -15°C to 30°C 

Skid ATEX Classification: Zone 2 IIA T3 

Power Requirement: 440V 3ph 50hz 

Chemical reservoir: Tanker (by others) 

Solution 

• ICR proposed SPX Flow Internal Gear Pumps in a duty/standby arrangement c/w variable speed electric motors 
• Motor speed was locally controlled by a skid-mounted Ex d control panel 
• Coriolis Flowmeter power supplied via the control panel 
• On-skid equipment earthing provided along with On-skid cable support system 
• Package was installed on a painted carbon-steel base frame c/w integral sloping drop tray with drain valve, certified lifting points, sling set and spreader lift beam 
• Tubing, fittings, valves and components supplied in 316 stainless steel 
• Discharge manifold fitted with dissimilar check valves for increased reliability 

Results & Benefits 

• Pumps capable of pumping viscous fluids at the required flowrate 
• Bespoke control system configured to accept incoming power from client distribution board Overpressure safety built into design with discharge pressure relief valves 
• Stable discharge flow and pressure through use of pulsation dampeners 
• Real time flow rates and cumulative flow displayed locally on Coriolis flowmeter 

Scope 

ICR was approached by a major North Sea operator to design and manufacture a bespoke, permanent Injection Pump Package for dosing of Sodium Hypochlorite to four seawater lift pump caissons on a UKCS Platform. 

Solution 

ICR supplied a package with 4‐off air driven, API-675 dosing pumps for Sodium Hypochlorite dosing to respective seawater lift pump caissons. Each pump was served by a dedicated Solenoid Valve (SOV) to start / stop pump on signal from platform Integrated Control and Safety System (ICSS). 

The package included a back‐pressure control valve on each pump discharge line to prevent syphoning of the sodium hypochlorite solution from existing hypochlorite storage tank. 

The package comprised of the following: 

• 1 of painted carbon steel base frame c/w titanium drip tray 
• 4 off (4 off duty) Williams Milton Roy CRLD200-TI-TFE air driven hydraulic actuated diaphragm chemical injection pumps 
• Process tubing, fittings, and wetted metallic parts supplied in Grade 2 Titanium. 
• Suction manifold incorporating all valves, suction filter for each pump and common calibration pot 
• Discharge lines for each pump incorporating a pressure relief valve (PRV) routed to pump suction, pressure indicator, back pressure control valve and isolation valve 
• Air manifold incorporating isolation valves, filters, and regulator 
• Pneumatic installation on the package incorporating 4‐off SOVs (each supplied with manual override) on each pump supply (for individual pump start/stop control) 
• Instrument junction box, located at skid edge to facilitate connection of client cabling 

Results & Benefits 

• Fully assembled package delivered to site, minimising hook-up, and onsite work requirements 
• Bespoke package designed, built and fully tested to meet client specifications and process parameters.