Chemical Injection Methods "Pros and

Cons" Kilgore College 4.15.2011

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CHEMICAL INJECTION METHODS
Pros & Cons
Chemical Injection Methods "Pros and
Cons" Kilgore College 4.15.2011
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Chemical injection is an integral component of any pipeline integrity program. The petroleum,
chemical, and water treatment industries require chemical treatments to control various
undesirable contaminants and prevent asset degradation. Some of the chemicals typically
injected are corrosion, scale, and paraffin inhibitors; hydrogen sulfide, carbon dioxide and
oxygen scavengers; biocides; glycols and methanol. Careful consideration of the injection
method chosen will provide a cost effective and reliable solution.

Criteria required to select the proper chemical injection method:

1) The treatment required and chemical selected
2) Process conditions
a. Process Fluid (i.e. natural gas, crude oil, water, etc.)
b. Pressure (min-normal-max)
c. Temperature (min-normal-max)
d. Flow rate (min-normal-max)
e. Process density
3) Chemical density relative to water
4) Injection site specifics
a. Pipeline diameter or vessel size
b. Injection port size and type
c. Utilities to power pump





Chemical Injection Methods "Pros and
Cons" Kilgore College 4.15.2011
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A typical chemical injection system:

1) Chemical bulk tank constructed of materials compatible with the chemical
and sized adequately to minimize refilling
2) Spill containment reservoir sized to hold 1.5 2 times the storage tank contents
3) Chemical strainer/filter (80 mesh) for larger particulate removal
4) Gauge to set the pump discharge rate
5) A positive displacement pump capable of pumping pressures well above
maximum process pressure; *materials of construction compatible with the chemical
A. Diaphragm or piston actuated pneumatic
a. Natural gas instrument supply requires instrument supply regulator, filter
dryer, and lubricator.
b. Instrument air supply
B. Electric motor actuated
a. 240 VAC or 120 VAC supply must consider electrical area classification
b. 12 VDC solar and battery sized for winter temperatures and lack of sunshine
6) Pump discharge pulsation dampener constructed of materials compatible with chemical
7) Nipple, quill, or atomizer with 50 micron inlet filter, check valve, pressure gauge, and
isolation valve

*An adjustable relief should be plumbed from the pump discharge to the pump suction for over pressure protection.

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Chemical Injection Methods "Pros and
Cons" Kilgore College 4.15.2011



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Chemical Injection Methods "Pros and
Cons" Kilgore College 4.15.2011


Characteristics of Various Chemical Treatments:
1) H2S, O2, and CO2 scavengers*
A. Densities similar to water and must be dispersed and distributed thoroughly within the
process media for maximum contact time.
B. Requires continuous direct injection distributed via an atomizer.
4) Corrosion inhibitors *
A. Density similar or slightly heavier than water and is applied to the interior wall of the
pipeline or vessel.
B. Requires continuous or batch injection distributed via a nipple with check valve.
5) Paraffin inhibitors in crude oil
A. Densities slightly lighter than water and must be dispersed and distributed thoroughly
within the process media for maximum contact time.
B. Requires continuous or batch injection distributed via a quill with check valve. Static
mixers may be considered if pressure drop can be tolerated.
4) Glycols
A. Density slightly heavier than water and is applied to the interior wall of the pipeline or
vessel.
B. Requires continuous or batch injection distributed via a quill with check valve.
5) Methanols
A. Densities slightly less than water and must be dispersed and distributed thoroughly within
the process media for maximum contact time.
B. Requires continuous direct injection distributed via an atomizer.
* Injection quills should be used when distributing chemical in a liquid media.
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Chemical Injection Methods "Pros and
Cons" Kilgore College 4.15.2011
There are numerous pump styles available, but they all have common components.


1) Actuation Motor
A. Pneumatic
a. Natural Gas
b. Instrument air
B. Electric
a. 240 VAC or 120 VAC (Area Class)
b. 24 VDC Batteries with Solar Panel
2) Pump
a. Piston
b. Plunger
d. Diaphragm
e. Bellows
3) Packing/Seals compatible with chemical
4) Air Bleeders
5) Inlet and Outlet Check Valves
6) Rate Adjustment
a. Stroke Length
b. Timer



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Chemical Injection Methods "Pros and
Cons" Kilgore College 4.15.2011
Information required to choose the correct pump:

1) Size the pump for the full range of injection rates required.

2) Size the pump for discharge pressures well above process pressures plus any
restrictions within the chemical injection system.

Example: Process pressure of 800 psi and spring loaded nozzle cracking pressure of 425 psi.
The pump must be capable of pumping pressure s above 1225 psi.

3) Method of pump actuation
a. Clean dry instrument supply gas
a. Natural Gas (consider emissions, poor gas quality)
b. 240/120 VAC Electric (subject to power outages)
c. 24 VDC solar and battery (consider lack of sunshine, battery disposal)

4) Durability
a. Materials of construction must be compatible with the chemical.
b. Undersized pumps must be stroked at their maximum range.



Chemical Injection Methods "Pros and
Cons" Kilgore College 4.15.2011
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Pulsation dampeners are a valuable
addition to any well-designed
chemical injection system.

Pulsation dampeners are used
to decrease pressure spikes in
the pump discharge as well as
becoming a secondary pump. The
pulsation dampener contains
compressed stored energy which
discharges with the back stroke
of the pump. Ultimately, the pump
stroke time can be slowed down
reducing valuable wear and tear.

The bladder style pulsation
dampener is better suited to the
challenges of a continuous
pipeline injection system.



Chemical Injection Methods "Pros and
Cons" Kilgore College 4.15.2011
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Choosing the appropriate chemical distribution method.

1) Is the process fluid a gas or liquid?
A. Gas
a. Requires an insertable atomizer for most chemicals.*
b. Quill can be used if velocity is greater than 15 ft/second.
c. Nipple with check valve should be used for corrosion inhibitors.
B. Liquid
a. Requires an injection quill for most chemicals.*
2) Does the chemical require distribution and dispersion for maximum contact
throughout the process fluid?
a. Requires an insertable atomizer.*
3) Is the chemical required to coat the pipeline or vessel walls?
a. Requires a nipple and check valve.
4) Is the chemical required to target a specific undesirable with a specific
location within the pipeline of vessel (i.e. water in crude oil)?
a. Requires a quill to the bottom of the pipe or a bottom injection
with a nipple and check valve.*

*Insertable probes within a liquid process and a gas process with excessive velocity
are susceptible to bending and frequency oscillations which may cause stress failures.
Probe stress calculations are suggested when in doubt.



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Chemical Injection Methods "Pros and
Cons" Kilgore College 4.15.2011
1) What are the design and operating pressures and
temperatures?
A. Can a hand insertable atomizer or quill be used?
B. Is a mechanically insertable atomizer or quill required?
2) What is the process fluid velocity and density?
Is a probe stress calculation required?
Need process velocity, density, and temperature .
3) What is the pipeline diameter or vessel size?
What is the insertion length required to injection zone?
4) What is the access port size and type?
A. If insertable atomizer or quill is desired a full port
process isolation ball valve is required.
Ball valve size and type connection (i.e. 1/2 -2
NPT or flanged)
B. If fixed quill is desired.
Size and type of port (i.e. 1/2-2 NPT or flanged)

Choosing the appropriate chemical distribution method (part 2).
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Chemical Injection Methods "Pros and
Cons" Kilgore College 4.15.2011
Chemical Injection Methods "Pros and
Cons" Kilgore College 4.15.2011
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The nozzle is the key component
of an injection atomizer. Sizing and
selection is based on several factors.

1) Injection rates (min-max)
2) Density of chemical
3) Pump discharge pressure capability
4) Process pressures (minmax)


A 50 micron filter, check valve,
and pressure gauge is a must when
using an atomization nozzle.
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Chemical Injection Methods "Pros and
Cons" Kilgore College 4.15.2011
Conclusion

Chemical injection is not merely
an after thought. Rather, it takes
considerable planning for a safe,
reliable, and efficient system!