Location: North Sea (Norway)
Application: Scale Inhibitor
Stable injection rate
FluidCom is quite innovative technology for Chemical injection systems which was developed by a Norwegian company in 2015, then Yokogawa Electric Corporation have acquired them as Yokogawa Techinvent AS since 2017.
Fluidcom combines Valve, Flowmeter, Actuator and Control Software functions to make an all in one full-automatic flow controller which can achieve long term chemical injection stability.
Also, Fluidcom has a self-cleaning function which can flush the particles adhered to the slit of valves and hence it does not require any maintenance.
In addition, Fluidcom's performance is independent of ambient changes i.g. Pressure, Temperature, viscosity and specific gravity of the chemical.
To prove our concept, we conducted 2 types of Field test with Norwegian company at their offshore Platform in 2015, then we got a great result and confidence as follows.
A: Scale Inhibitor
Temperature variations: ± 10 °C
Pressure variations: upstream 210 bar, downstream -0.6 to 180 bar (U-tube effect)
Test duration: 5 months
*No maintenance and adjustment were required during the test period.
Temperature variations: ± 8 °C
Pressure variations: upstream 210 bar, downstream 1.5 bar
Test duration: 3 months
*Any maintenance and adjustment were not required.
Acceptance Criteria for this Field Test
± 5 % system stability to flow set point.
A: In refer to the below chart, we can see FluidCom achieved ± 5 % stability in flow rate to the set flow rate. In addition, it showed approximately 1 % stability in flow rate compared to the indicated flow rate of referenced flowmeter even ambient temperature was fluctuating.
B: This result is the proof of our self-cleaning function.
Once particles cause plugging the valves, flowrate was going down, however Fluidcom detected it, then opened the valves to remove the particles, then the flowrate automatically set back to normal.
From the above test results, we have proved that our technology can not only solves the well-known challenges for of conventional chemical injection with conventional system but also brings plenty of additional values such as OPEX reduction, CAPEX reduction, Production increase and so on.
Feedbacks from our customers indicate that overdosing in the range of at least 10 to 20 % from set flowrate are very common.
Here, we would like to show an example of calculation on how much you can reduce the chemical cost if you have been overdosing due to difficulties to keep stable injection rate with conventional system.
As we mentioned that total accuracy for FluidCom system is up to ± 5 % regardless of ambient condition changes.
It means that FluidCom can reduce chemical cost by 5 % to 15 % if your current system have been intended to 10 % to 20 % of overdosing.
Assumptions: Ideal flow rate 15 L/h, Chemical Cost 5 USD/L
Suppose your chemical injection system is overdoing chemicals 20 % more than set flow rate
Set point: [FluidCom] 15 × 1.05 (+ 5 % accuracy) = 15.75 L/h, [Conventional] 15 × 1.2 (+ 20 % accuracy) = 18 L
Chemical Cost reduction: ( 18 - 15.75 ) × 24 × 365 × 5 USD = 98,550 USD per injection point
* It depends on the process condition.
* This is only for 1 injection point. Ex: 10 injection points = 985,500 USD
* Also, customer can reduce labour costs associated with flow rate adjustment and maintenance because of fully Fluidcom's self–cleaning function.
Chemical plants rely on continuous and batch production processes, each posing different requirements for a control system. A continuous process calls for a robust and stable control system that will not fail and cause the shutdown of a production line, whereas the emphasis with a batch process is on having a control system that allows great flexibility in making adjustments to formulas, procedures, and the like. Both kinds of systems need to be managed in available quality history of product, and to be able to execute non-routine operations. With its extensive product portfolio, experienced systems engineers, and global sales and service network, Yokogawa has a solution for every plant process.
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The oil & gas downstream industry has been facing an increasing number of challenges in recent years. These include the changing characteristics of the feedstock to be processed, aging of process facilities and equipment, rising cost of energy, lack of skilled plant operators who can run a refinery safely and efficiently, and the ever-changing requirements from both the market and the customer.
Over the years, Yokogawa has partnered with many downstream companies to provide industrial solutions focused on solving these challenges and problems. Yokogawa's VigilantPlant solutions have helped plant owners to achieve maximum profitability and sustainable safety within their plants.
Flow assurance in the oil and gas industry is all about the effective chemical injection process.
FluidCom ensures optimal performance with its autonomous valve control.
An OPEX saving device, it maintains accurate and stable flow rates while ensuring HSE.
Contact a Yokogawa Expert to learn how we can help you solve your challenges.