Optimising chemical injection dosage and concentration

Replacing estimates with robust calculations based on real-time data

Problem: Production chemicals make up a significant and increasing share of operating costs as the field matures. A lack of instrumentation to record chemical stock levels and chemical injection rates can leave many operators over-reliant on spreadsheet-based estimates and snapshot data.

As a consequence, many operators over-inject for fear of under-dosing, wasting substantial opex.

One Norwegian oil and gas operator approached Eigen to build a digital window into its chemical management system.

Solution: Building off a number of similar previous chemical management projects with other operators, Eigen built a new chemicals dashboard using Ingenuity version 7, with its dramatically improved interface and functionality.

Now the operator can see more than a dozen different chemical injection and concentration rates per well, as well as stock levels. Complex calculations to derive virtual flow rates and tank levels using the Eigen Analytics Platform are performed pulling data from multiple different sources.

The dashboard shows injection rates over time, rather than the snapshots available before – and crucially, a recommended range, so engineers can determine if a well is being over-dosed (and therefore wasting opex) or under-dosed (and introducing integrity risks, low production and downtime).

Indicators for each chemical chart on the dashboard signal whether each chemical is being injected in line with the recommended range, enabling engineers to see at a quick glance how the field is operating.

Ingenuity 7 has been built integrating Node-RED, a low-code workflow editor that enables engineers to adjust recommended limits by themselves, giving them more control and reducing reliance on the software vendor for updates.

Impact: Estimates of dosing levels and concentrations are now a thing of the past for the operator, thanks to the new Ingenuity 7-based chemicals management dashboard.

Complex calculations linked to source data provide robust assurance of stock and dosage and concentration levels without requiring manual intervention from operational staff, meaning the latest data is available 24/7.

The engineering team can quickly identify whether the field is optimised for risk and opex, as well as monitoring longer-term changes through trends over time.

The user configurability of the new dashboard enables engineers to make changes independent of Eigen or any other service provider, giving them improved autonomy and flexibility.

The operations team now has an intuitive, beautifully designed dashboard, shareable with senior management and other functions, visualising the latest data to assure safe, reliable and economic production.

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