Patent Abstract:
A control program for a positive displacement metering system measures the time required for the travel of a free piston in a cylinder of known volume to determine an average flow rate during a full stroke of the piston. The system may also measure and record the inlet and outlet pressures or the differential pressure between the fluid inlet and outlet. The control program positions a four-way valve which may function as an adjustable metering orifice in response to the measured average flow rate and/or changes in the inlet and outlet pressures to achieve the desired flow rate. At the end of each stroke, the four-way valve is repositioned to reverse fluid flow through the metering cylinder. The system may revise the valve position settings for both forward and reverse strokes based on the measured time required for a full stroke at a certain valve position. In this way, the system automatically and iteratively compensates for changes in fluid properties and fluid pressure. A cleaning cycle which progressively opens the valve stepwise and may culminate in full open valve travel in both fluid flow directions is provided in the event of an obstruction of the valve orifice.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a division of U.S. patent application Ser. No. 11/934,513 filed on Nov. 2, 2007. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     None 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to chemical injection systems for oil and gas wells. More particularly, it relates to autonomous control systems for injecting liquid phase chemical treatment agents into undersea wells. 
     2. Description of the Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98 
     A variety of chemical agents are injected into hydrocarbon wells for the control of corrosion, hydrates, asphaltenes, paraffins, scale and the like. These chemical agents are typically in the liquid phase and are pumped into the well at a selected rate using a chemical injection system. For undersea wells, the chemical supply and pump may be located on a production platform and are commonly connected to the wellhead via an umbilical line. If metering of the chemical agent is performed only at the surface, any leak in the umbilical or its connectors will give an erroneous indication of the quantity of chemical agent being injected into the well. Moreover, each subsea well may require its own injection system on the platform and connecting umbilical line. 
     Certain metering systems of the prior art employ a variable orifice—an adjustable orifice that allows remote control of flow at each well. Other metering systems of the prior art rely on pressure-compensated flow control—an adjustable pressure regulator and a fixed orifice can maintain a constant flow at each well. 
     Metering flow over a large range is often necessary over the life of the well. Orifice metering is limited in range and subject to filming, clogging and differing fluid properties. 
     Particulate contamination in long chemical injection lines is unavoidable and can clog the small orifices needed for metering and control. Filters on the lines are an added complication affecting system reliability, increasing capital costs and requiring periodic service (which increases operating costs). 
     U.S. Pat. No. 6,973,936 to Richard R. Watson discloses a fluid injection system that controls the distribution of fluid from a supply line to a selected well at an adjustable rate. A free piston divides a cylinder into first and second chambers. A multi-position valve comprises a first position for passing fluid from the supply line into the first chamber to displace fluid from the second chamber back through the valve to an injection point, and a second position for passing fluid from the supply line to the second chamber to displace fluid from the first chamber back through the valve to the injection point. A control system in communication with a position sensor times displacement of the free piston to selected positions, and selectively adjusts a variable valve opening to adjust flow rate, switch between the first and second positions, and periodically increase the valve opening for cleaning. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention may be embodied in a control program for a positive displacement fluid metering system that measures the time required for the travel of a free piston in a cylinder of known volume to determine an average flow rate during a full stroke of the piston. The system may also measure and record the inlet and outlet pressures or the differential pressure between the fluid inlet and outlet. The controller may take flow rate commands from a client subsea control pod and set the rate of flow by partially opening a four-way valve each time the valve is reversed. 
     The control program precisely positions a four-way valve which may function as an adjustable metering orifice in response to the measured average flow rate and/or changes in the inlet and outlet pressures to achieve the desired flow rate. At the completion of each stroke, the four-way valve is repositioned to reverse the flow of fluid through the metering cylinder. 
     The system may revise stored valve position settings for both forward and reverse strokes based on the measured time required for a full stroke at the currently stored valve position. In this way, the system iteratively compensates for any changes in fluid properties and fluid pressure. Certain embodiments of the invention additionally comprise an optional cleaning cycle which progressively opens the valve stepwise and may, if necessary, fully open the valve in both fluid flow directions in order to clear an obstruction of the valve orifice. It has been found that shear seal or gate type valve construction is the design best suited for reliable operation when high pressure fluids are contaminated with hard particulate matter. The standard operating procedure for clearing a blocked valve of this type is to move it to the fully opened and fully closed positions. This allows the accumulated particulates to pass and the seal elements to sweep away or shear any remaining obstructions. By employing this valve construction for the two-position four-way control valve and by controlling the valve actuator in response to the cylinder stroke time, precise flow control with excellent contamination resistance results. 
     The actuation of the two-position four-way control valve may be accomplished with a conventional stepper motor which drives a ball screw to convert rotation to linear motion. This combination has been found to give very high precision to the linear position of the valve. This precision allows the valve to be partially opened thus creating a precision orifice each time the valve is shifted. 
     As the valve is shifted to admit flow to first one then the other side of the cylinder piston, flow rate is regulated by the precision orifice created by the partially opened valve. In certain embodiments, a dwell time after the cylinder piston has completed its travel and flow has stopped is included. This provides precise control of the volume of chemical injected into the oil or gas well production stream in a certain period of time. 
     A system according to the invention may be designed to accommodate all current chemicals used for the control of corrosion, hydrates, asphaltenes, paraffins, and scale in hydrocarbon wells. Viscosity or density changes of the fluid do not require recalibration of the positive displacement metering system. Verification data can be sent to the client subsea control pod. 
     Using a plurality of systems according to the invention can provide treatment chemical flow assurance for multiple subsea wells from a single umbilical. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
         FIG. 1  is a schematic diagram of a chemical injection apparatus of the prior art which may be controlled by the method of the present invention. 
         FIG. 2  is a cross-sectional view of the control valve used in the apparatus of  FIG. 1  in a first position. 
         FIG. 3  is a cross-sectional view of the control valve shown in  FIG. 2  in a second position. 
         FIG. 4  is an enlarged, cross-sectional view of a portion of the valve shown in  FIG. 2 . 
         FIG. 5  is a schematic diagram of a chemical injection system modified for use with the present invention. 
         FIG. 6A  is the first portion of a flowchart depicting the steps of a method according to one embodiment of the invention.  FIG. 6B  is the second portion of the flowchart that begins in  FIG. 6A .  FIG. 6C  is the third portion of the flowchart that begins in  FIG. 6A .  FIG. 6D  is the fourth portion of the flowchart that begins in  FIG. 6A .  FIG. 6E  is the fifth portion of the flowchart that begins in  FIG. 6A .  FIG. 6F  is the sixth portion of the flowchart that begins in  FIG. 6A . 
         FIG. 7  is a graph of the flow produced by one particular representative control valve as a function of the number of steps made by a stepper motor driving the valve&#39;s actuator. 
         FIG. 8  is a flowchart depicting the steps of a method according to a second embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  schematically illustrates details of a metering body  12  interconnected with a control system  14  and a multi-position valve  16  driven by actuator  45  in a chemical injection system  10 . The metering body  12  has a bore  20  for containing chemical fluid to be delivered to a well. An axially movable free piston  22  in bore  20  divides metering body  12  into variable-volume first and second chambers  24 ,  26 . Free piston  22  seals with metering body  12  with a sealing member such as O-ring  25 . Metering body  12  and free piston  22  conventionally comprise a cylinder and piston assembly, as shown. First and second input-output ports  28 ,  30  are provided for passing fluid into and out of first and second chambers  24 ,  26 . Supply line  33  supplies chemical fluids at high pressure through multi-position valve  16  to metering body  12 . 
     In a first valve position shown in  FIG. 1 , illustrated conceptually by alignment of parallel line segments  18  with lines  31  and  33 , fluid passes from supply line  33 , through multi-position valve  16 , line  29 , and input-output port  30 , and into chamber  26 . As fluid passes into chamber  26 , fluid pressure urges free piston  22  toward end  34  of metering body  12 , decreasing the volume of first chamber  24  and displacing the fluid out through input-output port  28 . Fluid exiting port  28  passes through line  27 , back through valve  16 , and out through line  31  to an injection point in the well. 
     In a second position (not shown), which may be visualized conceptually by sliding the crossed flow lines  15  in valve  16  to the left to align with lines  31  and  33 , fluid passes from supply line  33 , through multi-position valve  16 , line  27 , input-output port  28 , and into chamber  24 . As fluid passes into chamber  24 , fluid pressure urges free piston  26  toward end  36  of metering body  12 , decreasing the volume of chamber  26  and displacing the fluid out through input-output port  30 . Fluid exiting port  30  passes through line  29 , back through valve  16 , and out through line  31  to the same injection point in the well. Thus, by repeatedly reversing the direction of multi-function valve  16  after free piston  22  has reached a selected position, the fluid may be continually passed from line  33  to line  31  to the injection point in the well. 
     Position sensors  38  and  40  are included for sensing the position of free piston  22 . Position sensors  38 ,  40  are in communication with control system  14  as represented by dashed lines  39 ,  41  through conventional means, such as by wire, optical fiber or wireless signal. When free piston  22  reaches selected positions, position sensors  38 ,  40  signal control system  14 , in response to which control system  14  may selectively reverse the position of multi-position valve  16  to reverse the direction of travel of free piston  22 . 
     Because the selected positions are known, relative displacement of free piston  22  is also known, corresponding to a known volumetric displacement of fluid from metering body  12 , computed as the product of displacement of free piston  22  and cross-sectional area of bore  20 . The control system  14  includes an internal timer for timing displacement of free piston  22  between the selected positions, as signaled by position sensors  38 ,  40 . A volumetric flow rate is therefore also known, which may be computed as the volumetric displacement divided by displacement time. The multi-position valve  16  includes a variable valve opening discussed below in conjunction with  FIGS. 2-4 , for controlling flow between supply line  33  and metering body  12 . The control system  14  selectively adjusts the variable valve opening in response to displacement time of free piston  22 . If the displacement time is too long, indicating a flow rate less than a desired flow rate, control system  14  may increase the variable valve opening to increase the flow rate. Conversely, if the displacement time is too short, indicating a flow rate more than the desired flow rate, control system  14  may selectively decrease the valve opening to reduce the flow rate. The flow rate of the fluid delivery to the well is thereby controlled. 
     As shown in  FIG. 1 , the selected positions of free piston  22  are preferably the positions of free piston  22  having reached either end  34 ,  36  of metering body  12 . The selected positions of free piston  22  could alternatively be anywhere along the range of travel of free piston  22 , and need not be at ends  34 ,  36  of metering body  12 . In typical embodiments, as illustrated, position sensors  38 ,  40  are at substantially the same axial position as the selected positions. Conventional position sensors such as spring-loaded pins or magnetic or infrared proximity sensors may be used. In other embodiments, the position sensors conceivably may not need to be axially aligned with the selected positions. A position sensor may further comprise an optional pressure transducer  49  or a flow transducer  42 . These types of position sensors may sense position implicitly, such as when there is a sudden drop of pressure in line  31  as the free piston reaches ends  34 ,  36  of metering body  12 . Optional port valves such as might comprise sealing members  43 ,  44  on free piston  22  may be included for sealing input-output ports  28 ,  30  when free piston reaches ends  34 ,  36 . This may more dramatically decrease pressure in line  31 , and thereby provide a more distinct indication that free piston  22  has reached the end of its travel. Such an indication may provide a backup to confirm or substitute for position sensors  38  and  40 . 
     The terms “first position” and “second position” in connection with valve  16  refer generally to the resulting direction of flow, rather than a fixed position of components of valve  16 , because there is generally a degree of adjustability in each of the two positions, such as to adjust flow rate.  FIG. 2  shows a detailed view of the preferred embodiment of the multi-position valve  16  in the first valve position, partially open to limit flow through the valve.  FIG. 3  shows a detailed view of preferred valve  16  in the second valve position, also partially open.  FIG. 4  shows in closer detail a portion of gate-type valve  16  in the first valve position of  FIG. 2 . 
     Referring particularly to  FIG. 2 , the schematic of  FIG. 1 , and the closer view of  FIG. 4 , the multi-position valve is indicated generally at  16 , having a body  17 . A gate  50  is positioned within a cavity  52  in body  17 . The gate  50  has a bore  54 , which in the position shown is in communication with an entrance port  32  and with a first flow passage  56  extending through body  17  to a first exchange port  57 . Thus, in this position, chemical fluid supplied by supply line  33  discussed above flows into body  17  through entrance port  32 , through gate bore  54 , and through first flow passage  56 , exiting through first exchange port  57  to line  29 . As described above, fluid passes through line  29  into metering body  12 , and other fluid passes from metering body  12  through line  27  back to valve  16 . Flow then passes back into body  17  through second exchange port  59 , into a second flow passage  58 , passes around gate  50 , into an exit passage  53 , and out through an exit port  55 . Flow out through exit port  55  finally passes through line  31  to the injection point in the well, as described above. 
     In  FIG. 3 , gate bore  54  is instead positioned in communication with entrance port  32  and with second flow passage  58 . Thus, flow from line  33  passes through entrance port  32  into entrance passage  51 , through gate bore  54 , and through second flow passage  58 , exiting through second exchange port  59  to line  27 . As described above, fluid passes through line  27  into metering body  12 , and other fluid passes from metering body  12  through line  29  back to valve  16 . Flow then passes back into body  17  through first exchange port  57 , into first flow passage  56 , into exit passage  53 , and out through exit port  55 . Flow out through exit port  55  finally passes through line  31  to the injection point in the well. Thus, as described in connection with  FIG. 1 , flow between valve  16  and metering body  12  may be reversed by moving the valve between the first and second valve positions shown respectively in  FIG. 2  and  FIG. 3 , but in each case the net flow is from line  33  to line  31  to the injection point in the well. 
     In the embodiment shown in  FIGS. 2-4 , stepper motor  45  drives a ball screw  48  to axially move gate  50  within cavity  52 , adjusting the size of the flow path defined between gate bore  54  and first flow passage  56 , thereby adjusting flow to a desired flow rate. The gate  50  can be moved axially to change between the first valve position of  FIG. 2  and the second valve position of  FIG. 3 . Those skilled in the art will recognize alternative means for moving the gate, other than stepper motor  45 . 
     Hall effect devices used in motion sensing and motion limit switches can offer enhanced reliability in extreme environments. As there are no moving parts involved within the sensor or magnet, typical life expectancy is improved compared to traditional electromechanical switches. Additionally, the sensor and magnet may be encapsulated in an appropriate protective material. Hall effect devices when appropriately packaged are immune to dust, dirt, mud, and water. These characteristics make Hall effect devices particularly preferred in a system according to the present invention for piston position sensing compared to alternative means such as optical and electromechanical sensing. 
     Controlling flow to a few gallons per day at pressure drop of several hundred pounds per square inch requires a very small orifice of just a few thousandths of an inch. The valve used in one particular preferred embodiment of the invention is a gate type shearing seal valve with a 2880:1 turndown ratio. This valve provides the required small orifice and reverses flow for each positive displacement charge so that clogging is avoided. 
     Certain systems of the prior art have used filters to avoid particulate clogging of small flow-control orifices but these filters typically need to be serviced subsea which is highly costly. Devices of the prior art have also used capillary orifices which are larger in area for a given restriction to flow and these can be made to adjust their bore diameter by means of a tapered mating screw thread so flow rates can be changed and a temporary larger opening can be used to provide cleaning of contamination. With each of these solutions, metering over a wide range of flow rates is a separate necessary task that requires expensive flow instrumentation; flow cannot be accurately measured by the pressure loss across an orifice of unknown restriction as is the situation with partial particulate clogging. The present invention may include means for creating the small metering orifice with a 4-way gate type valve that is constantly shifted to avoid clogging and may also be opened fully to allow particulate to pass. In addition, the system provides very accurate metering of the flow that is immune to partial clogging or change in fluid properties or filming of the orifice—all conditions which are present and can defeat conventional meters that rely on a pressure drop across an orifice. 
     The pressure transducers  49  and  49 ′ can provide the controller more information with which to establish the degree of valve opening, but they cannot measure or verify the flow rate. Measurement and verification of the flow rate is provided by the timing circuits and position sensors on the positive displacement cylinder. 
     If the displacement cylinder fails to stroke in the expected time, a condition that indicates clogging, the controller can drive the 4-way valve to the full open position to allow debris to pass. 
     An orifice cannot be used as a reliable, subsea, flow-measuring device because it is subject to clogging and filming (coating) by the chemicals which pass through it. The chemicals which are metered in a chemical injection system for a hydrocarbon well may have filming characteristics as a desired trait. Common flow-measuring devices of the prior art use a measurement of pressure loss across an orifice to indicate flow. If an inexpensive pressure drop metering system cannot be used, the conventional alternatives are expensive. Additionally, no other metering device such as turbine, ultrasonic, vortex, or mass thermal type can match the range of a displacement cylinder according to the present invention; they all are limited to 100:1 to 200:1 total range. That means they can accurately measure 1 gallon per day (GPD) up to about 200 GPD. A system according to the present invention can measure 1 GPD up to over 3000 GPD. Also, many well treatment chemicals are non-Newtonian fluids—i.e., their viscosity changes with pressure in a nonlinear fashion, a characteristic that makes accurate flow measurement more challenging for most measurement technology of the prior art but has no effect on a system that employs a positive displacement cylinder. 
     Referring now to  FIG. 6 , one particular preferred embodiment of the invention is disclosed in the form of a flowchart which represents certain steps in a method for controlling a valve in a chemical injection system. The chemical injection system may comprise a processor and the method may be implemented as instructions for the processor which may be stored in a storage medium. 
     As depicted in  FIG. 6A , the process may begin at manual input  100  with an operator inputting the desired flow rate of the chemical to be injected. The flow rate may have the dimensions of unit volume per unit time. The flow rates for chemical injection systems used in connection with oil and gas wells in the domestic energy industry are often expressed in gallons per day (GPD). In certain embodiments, inputting the desired flow rate may be accomplished by an operator situated on an offshore production platform and the command may be transmitted to the controller on or near the subsea wellhead via an umbilical cable. The command may also be transmitted via a telemetry system from an onshore facility or another offshore unit. 
     In one particular preferred embodiment, system initialization includes driving the valve actuator to a mechanical limit by commanding a stepper motor driving the actuator to step a number of steps in one direction that exceeds the number of steps previously determined to correspond to full travel of the actuator. One or more reversals of the actuator followed by attempted “forward” travel in excess of the reverse travel may be used to ensure that the actuator is hard against the mechanical limit. Thus, although the initial position of the valve may be unknown upon system startup, an initialization routine can be used to move the valve to a known position. At block  105 , the system may determine initial valve settings (number of steps) for both forward and reverse valve positions from the desired flow rate input at  100 , a stored flow curve  115  and valve cracking position data  120 —i.e., the number of steps from the valve closed position to the point at which the valve orifice begins to open in a certain direction. In one particular preferred embodiment, initialization includes moving the valve actuator from the mechanical limit position to a “center” closed position defined to be the midpoint between the “forward” valve cracking position and the “reverse” valve cracking position. By way of example, using the flow curve of  FIG. 7 , if the desired flow rate is 40 GPD and the forward valve cracking position is 33 steps from the “center” closed position, then the initial forward valve setting would be 171 steps from center (138+33). It has been found that the valve cracking position is valve-dependent and may vary from valve to valve and/or change following maintenance on the valve or valve actuator. The initial forward and reverse valve settings may be loaded in registers designated for that function. 
     Flow curve data  115  may be in the form of a digitized flow curve such as the curve depicted in  FIG. 7 . In one particular preferred embodiment, flow data is tabulated for each step of a stepper motor-actuated valve. In other embodiments, the flow curve data may be in the form of a mathematical representation—e.g., slope and intercept values for a substantially linear flow curve. In the case of embodiments using digitized curves, the system may comprise means for interpolating between data points using conventional curve fitting techniques. 
     In certain embodiments (not shown), the initial system inputs may include the selection of a particular flow curve which may be associated with a particular chemical or chemical mixture to be injected or with a certain property of the fluid to be injected—for example, the specific gravity of the fluid, the viscosity of the fluid, the concentration of an active ingredient(s) in a solvent, or the like. In yet other embodiments, the initial input may include a correction factor which the system may use to modify a previously-stored, general-purpose flow curve for use with a specific chemical or chemical property—i.e., the stored flow curve may be for dilute aqueous solutions and a supplied correction factor allows the system to adapt the curve for a fluid having substantially different rheological properties. It will be appreciated, however, that a system according to the present invention will automatically compensate for fluids having different properties and tailoring the flow curve to a specific fluid provides an advantage only in the initial settings of the valve position and the first few computations of valve setting corrections. 
     Upon system startup, the position of free piston  22  within bore  20  may be unknown. Accordingly, upon initialization the system may configure the valve to drive the piston to a known location. At decision diamond  125  the system may first test for actuation of the forward limit switch (indicating that piston  22  is at the end of forward stroke travel). If switch actuation is detected, the process may proceed at block  130  to the reverse stroke sequence. If the forward limit switch is not actuated (N branch at diamond  125 ) the system proceeds at block  140  with a forward stroke sequence (see  FIG. 6B ). 
     Following system initialization, the normal flow process of alternating forward and reverse strokes may begin. A representative forward stroke sequence is illustrated in the flowchart of  FIG. 6B  and a corresponding reverse stroke sequence is depicted in  FIG. 6C . 
     Referring now to  FIG. 6B , the forward stroke sequence begins at block  200  with the current forward stroke valve setting (which may be in steps from the actuator limit, the center (closed) position, or from the most recent valve position) being loaded from register  202 . At block  204 , the control valve is driven by the stepper motor to the most current forward valve setting and a timer is started (block  205 ). In this condition, the system is now metering fluid through the control valve  16  from supply line  33  to chamber  26  via line  29 . As fluid is pumped into chamber  26 , piston  22  moves (to the left in  FIG. 5 ) displacing fluid in chamber  24  which flows via line  27 , valve  16  and line  31  to the injection point of the well. Fluid pressure in injection line  31  may be measured by pressure transducer  49  while that in supply line  33  is measured by pressure transducer  49 ′. 
     The program may include one or more routines that test for piston movement. For example, a forward stroke sequence ( FIG. 6B ) is usually entered from the completion of a reverse stroke sequence as signaled by actuation of the reverse limit switch  40 . Movement of piston  22  away from the reverse stroke limit should deactivate reverse limit switch  40 . This condition may be tested for at diamond  208 . If the switch remains activated (i.e., the piston is still within the actuation range of the limit switch) the system may wait for a selected time interval before taking remedial action. In the illustrated embodiment, the system waits (at diamond  210 ) for an interval equal to 50% of the expected stroke time (cylinder displacement volume divided by selected flow rate) and if the reverse limit switch remains activated, the valve may be opened  20  additional steps (at block  212 ). In similar fashion, the system may now wait (at diamond  216 ) an additional time interval which, in the illustrated embodiment, is equal to the expected stroke time (now, cumulatively, 150% of the expected stroke time) for the reverse limit switch to deactivate (diamond  214 ). As before, if the piston does not move sufficiently to deactivate the reverse limit switch, the valve is opened an additional 20 steps (at block  218 ). In the illustrated embodiment, the progressive opening of the valve in the event of no piston movement may be repeated at diamonds  220  and  222  with additional valve opening at block  224 . If the reverse limit switch remains activated (N branch at diamond  226 ) and the cumulative time since valve opening reaches 350% of the expected stroke time (Y branch at diamond  228 ), a flush cycle (as described more fully, below) may be initiated (at block  230 ). If, however, the reverse limit switch deactivates (Y branches of diamonds  208 ,  214 ,  220  or  226 ), the system proceeds to a normal forward stroke sequence block  232 . 
     While fluid is flowing, the outputs of pressure transducers  49  and  49 ′ may be periodically sampled and a differential pressure (ΔP) stored by controller  14 . In one particular preferred embodiment, a running average ΔP is stored by controller  14  along with the three most recent ΔP values in a FIFO stack. Additional filtering algorithms may be applied to eliminate or reduce the influence of pressure spikes which may be encountered during a stroke. This process may be implemented as shown in  FIG. 6B  at block  232  which subroutine is run at a pre-selected interval measured at diamond  238 . 
     In the normal course of events, fluid flow continues until piston  22  reaches the end of its forward stroke (left wall of cavity  24  in  FIG. 5 ) which activates limit switch  38  which activation is detected at diamond  234 . As shown in  FIG. 6C , the timer is stopped at block  270  and the accumulated time in the timer counter is the total time taken for piston  22  to move a full stroke. Since a full stroke displaces a known volume of fluid (as determined by the physical dimensions of cylinder  12  and piston  22 ), that volume divided by the accumulated time yields the average flow rate of fluid during that particular forward stroke. At block  272 , the measured average flow rate for the stroke is compared to the desired flow rate which was input by the operator at  100 . 
     Corrections (if any) to the forward stroke valve setting are computed at block  274 . In one particular preferred embodiment, the difference between the measured flow rate and the desired flow rate is equated to a certain number of steps from the flow curve stored at  115 . The correction may be taken directly from the curve or computed from the first derivative of the curve. As discussed above, in certain embodiments, the system may interpolate between data points in order to determine the correction. 
     As shown at block  276 , the valve setting correction may further be refined by a factor relating to a change in the average ΔP from the previous forward stroke. In certain embodiments, the ΔP correction factor may be a function (in whole or in part) of selected ΔP values, e.g., the three most recent ΔP values stored in the FIFO stack of the illustrated embodiment. Especially at relatively slow flow rates, a change in ΔP immediately prior to the end of the stroke may be more indicative of the ΔP likely to be encountered during the next forward stroke. 
     The ΔP correction may be derived from empirically determined values of flow rate at various differential pressures. In other embodiments, the ΔP correction may be calculated from a function which relates flow (or steps of the valve actuator motor  45 ) to ΔP. 
     It should be appreciated that the process of the present invention will function without ΔP data—i.e., the absence or failure of a pressure sensor  49  will not disable the system. The corrections computed at block  274  will compensate for changes in ΔP. The use of ΔP information (at block  276 ) enables the system to make better predictions of the valve setting needed to produce the desired flow rate. However, the iterative process will “zero in” on the correct setting even without this data. 
     At block  278 , the revised valve setting to be used on the next forward stroke is stored in the register (or other storage device) designated for that purpose and the process proceeds to the reverse stroke sequence, as shown at block  282  (and in  FIGS. 6D and 6E ). Optionally, at block  280 , data concerning the just-completed stroke sequence may be logged before proceeding to the reverse stroke sequence. Examples of log data include actual stroke time, the time and number of additional valve openings (e.g., blocks  212 ,  218 ,  224 ,  240  and/or  246 ) and whether a flush cycle (blocks  230  or  256 ) was required. Any other parameters sensed by the system may also be recorded at this step in the process. 
     Since the full travel of free piston  22  displaces a known volume of fluid, the time which should be required for a full stroke of piston  22  at the desired flow rate may be calculated to produce an expected stroke time. As shown at block  236 , the elapsed stroke time may be compared to the expected stroke time and, if the elapsed stroke time exceeds the expected stroke time by a selected margin (100% in the illustrated example), the system may initiate corrective action—progressive opening of the valve in 20-step increments at 200% of the expected stroke time (diamond  236 ) and again at 300% of the expected stroke time (diamond  244 ). If the time exceeds 400% of the expected stroke time (Y branch at diamond  254 ), a flush cycle (block  256 ) is initiated in the illustrated embodiment. In each of these routines, ΔP readings may be taken and stored (blocks  250  and  260 ) at a selected, repetitive time interval (diamonds  248  and  258 ). 
     The control of a “reverse” stroke cycle—i.e., a stroke wherein the control valve is positioned such that flow path  15  is active and fluid flows into chamber  24  via line  27  and is expelled from chamber  26  and into line  29  as piston  22  moves from left to right in  FIG. 5 —is illustrated in  FIGS. 6D and 6E . The process is analogous to that illustrated for a “forward” stroke in  FIGS. 6B and 6C  and discussed above. Reference numbers for corresponding elements in  FIGS. 6B and 6C  differ by a value of 100 from those in  FIGS. 6D and 6E . The current reverse stroke valve setting may be stored in register  302  and loaded into the controller at block  300 . Corrections computed for the reverse valve setting at block  374  and (optionally) block  376  may be stored in register  305  at block  378  and used for the next reverse stroke. At the completion of a “reverse” stroke, the process returns to the forward stroke sequence (at block  382 ). In this way, the system continuously iterates forward and reverse valve settings to provide the requested fluid flow rate. 
     As shown at blocks  230  and  256  ( FIG. 6B ) and blocks  330  and  356  ( FIG. 6D ), the system may initiate a flush cycle in the event that the elapsed stroke time exceeds the expected stroke time by a selected margin. One possible cause of less-than-expected fluid flow rate is debris obstructing or partially obstructing an orifice in control valve  16 . The system may act to flush debris from the control valve (or an associated fluid conduit). A flush cycle according to one preferred embodiment of the invention is illustrated in the flowchart of  FIG. 6F . In this cycle, the control valve is first driven to its full open position in one direction (block  460 ) and then to its full open position in the opposite direction (block  465 ). It has been found in practice that this cycle is almost always successful in flushing obstructive debris from the chemical injection system. Following a flush cycle, the system may perform an initialization sequence (block  470 ). 
       FIG. 8  is a flowchart that illustrates an alternative embodiment of the invention wherein a fixed, known volume of chemical is injected in a predetermined time interval. This embodiment has particular advantage in those applications where controlling the total volume of chemical injected in a certain period of time is more important than injecting the chemical at a constant rate. 
     The process may begin at manual input  500  with the operator&#39;s selection of an average flow rate. Since a full stroke of piston  22  displaces a known volume of chemical, at block  510  the system may compute the time required to displace the volume of chemical injected during a full stroke at the selected flow rate. At block  520 , the system may be initialized as described previously in order to position piston  22  at the beginning of a stroke. Using the stored flow curve, the valve setting which should produce the selected flow rate is determined at block  530  from the flow curve stored at  535 . At block  540 , the valve is opened to provide a somewhat larger orifice than that required to achieve the selected flow rate. The absolute value of the overage may be a selected percentage increase in the selected flow rate (e.g., X+10% GPD), a selected incremental increase in flow rate (e.g., X+5 GPD) or a pre-selected number of additional steps of the stepper motor which positions the valve (e.g., computed position from the flow curve+15 steps). 
     A timer may be started at block  545  and the system may then test for piston movement (at diamond  550 ) by sensing deactivation of the previously activated limit switch. If piston movement is not detected (N branch at  550 ) in the illustrated embodiment, the valve is opened an additional 20 steps. This process may be repeated (A branch at diamond  557 ) at selected time intervals and, if no piston movement is detected after a selected cumulative time (B branch at  557 ) a flush cycle may be initiated at block  559  to clear any obstruction in the valve orifice. 
     Once piston movement has been detected (Y branch at  550 ), the system may wait (at  560 ) for the limit switch to signal that the piston has reached the end of a stroke and the known volume of a full stroke has been injected into the well. The valve position set at  540  should result in a full stroke being completed before the time interval computed at  510  has elapsed—i.e., the system should need to wait for a “dwell time” to elapse before initiating another stroke. At diamond  565 , the system tests for the end of the computed time interval before actuation of the limit switch. If true (Y branch at  565 ), an error condition exists (block  570 ) and the system may take remedial action by correcting the valve setting used at block  530 . If the limit switch is still not activated after a selected interval (diamond  572 ), the remedial action may include a flush cycle (block  573 ), as described previously in connection with  FIG. 6F , and/or an upward adjustment of the store valve position. 
     However, in the normal course of events, the piston will reach the end of a stroke (thereby actuating the limit switch) prior to the end of the time interval computed at  510  (Y branch at  560 ). The system may store the time of limit switch actuation at  575  and then wait (at  580 ) for the end of the time period at diamond  580 . 
     The time taken by the piston to make a full stroke (recorded at  575 ) may be used to compute and store a revised valve setting at block  585 . This revised setting may then be used by the system for the next stroke in the same direction. In this way, the system continuously refines the valve setting to compensate for any changes in parameters which may affect flow rate—e.g., supply pressure, viscosity, density, etc. 
     At block  590 , the system sequences to a corresponding process for a stroke in the opposite direction (which may begin at block  530 ) and the system alternates between “forward” and “reverse” strokes while iterating the required valve settings. 
     Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of the invention as described and defined in the following claims.

Technology Classification (CPC): 8