Analysis of Output Flow Rate Nonconformity in the Chemical Injection Package

Abstract

The Chemical Injection Package (CIP) is widely used in the oil and gas industry to inject corrosion inhibitors at controlled flow rates to maintain equipment reliability. During commissioning, twelve dosing pumps exhibited significant flow rate discrepancies despite operating under identical parameters, including stroke length, stroke frequency (SPM), pneumatic supply pressure, and discharge pressure. This study aims to analyze the causes of this output flow rate nonconformity and identify the dominant factors affecting pump performance. A Fishbone Diagram combined with empirical field verification was employed to investigate potential root causes. The validation results indicate that the flow rate deficiencies were primarily caused by pneumatic supply instability. The dominant contributing factors were an undersized ½-inch air supply hose, which caused pressure loss, and fluctuating compressed air pressure resulting from a shared workshop compressor network. These conditions reduced the effective pneumatic pressure supplied to the dosing pumps, leading to output flow rates below the design values. To address these nonconformities, this study recommends upgrading the air supply hose to 1 inch and providing a dedicated compressed air supply during commissioning to ensure stable pneumatic pressure and improve dosing pump performance.