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KEY WORDS
ABSTRACT
Electrical heating, cable design, screen voltage, semi-conductive cable
The direct electrical heating system (DEHS) has been developed and sheath, hydrate and wax prevention.
qualified for heating of flowlines and is the only system for heating that
has been installed on subsea flowlines in the North Sea. Especially for
deep-water fields electrical heating of pipelines is attractive for INTRODUCTION
achieving reliable operation of transport flowlines.
Experiences on installed systems have proven easy operation and have When transporting untreated well stream in ordinary pipelines, the
also shown to imply high reliability for flow assurance. temperature of oil, gas and produced water will drop rapidly due to
At present DEH has been applied to pipelines of chromium (13Cr) up cooling from the surrounding seawater. The low temperature results in
to 16 km length. Projects are now coming up in the North Sea where undesired fluid properties. At high pressures hydrates start to
application of DEH for pipelines of carbon steel with lengths up to 50 precipitate already at temperatures in the range of 20-25oC. Large
km are considered. A qualification project was initiated in 2003 to amounts of hydrate, which is similar to ice crystals, can precipitate on
expand the technology base for DEH to include these new installation the pipe wall and cause blocking of well stream transport.
parameters.
An important issue has been to obtain the electrical and magnetic For some fields wax formation in the flowing crude may also cause
characteristics of carbon steel pipes. The difference in magnetic operational problems due to increased pressure loss in the pipeline.
characteristics of individual carbon pipes results in variation of the The viscosity of waxy oil can be of such magnitude, that full “shut in
heated pipe temperature. Carbon Steel materials are more sensitive than wellhead pressure” will not be sufficient for getting the cold fluid on
13Cr for thermal and mechanical stresses on the outer surface in regard stream again after long shut downs.
to DEH properties.
For long pipelines a new cable design is essential to avoid high screen The use of chemicals to remove hydrates will in practice mean to use
voltages caused by capacitive and inductive currents. In order to solve methanol or glycol. These chemicals move the hydrate equilibrium to
this problem a semi-conductive outer sheath has been developed for higher pressure and lower temperature, and thus work in the same way
continuous transfer of the capacitive current to surrounding ground as non-freeze solution in an automobile radiator. The disadvantage with
potential (seawater/seabed). use of chemicals is that large amounts are often needed and implies a
The results from the study is promising and have given basis of rating risk to the environment if leakage should occur.
of DEH to maintain or raise the thermally insulated steel pipe
temperature above the critical value for hydrate (typically 15 - 25 oC) or An obvious way to remove hydrates is to supply heat to the flow. On a
wax formation (typically 20 - 40oC). Furthermore the single-phase platform or on shore this can be done by injecting hot water or steam
power supply to the heating system is normally available from the into the pipe, but subsea this mostly has to be done by using electrical
general topside (platform) power system. Topside equipment for power heating. The direct electrical heating system (DEHS) has been
factor compensation and load symmetry is based on commercial developed and qualified for heating of flowlines and is the only system
components. Experiences from installed systems prove that the load that has been installed on subsea flowlines in the North Sea. Electric
current can be quite easily adjusted to give the required heating for the heating of pipelines implies reduced investments of depressurizing
different operation modes. systems and recovery plants for chemical residual products. Especially
for deep-water fields electrical heating of pipelines is attractive for
achieving reliable operation of transport flowlines.
Transfer Stationary part Transfer In order to avoid high screen voltages due to capacitive currents and
zone zone induced inductive currents it is possible to use a semi-conductive outer
sheath with sufficient electrical and mechanical properties as indicated
Fig. 1. DEHS schematically shown with the XLPE insulated single in Fig. 2. However, the HV cable can be subjected to high temperatures
core cable strapped to (piggybacked) and connected to the in buried seabed sections combined with seawater. In order to reveal if
end of the heated flowline. 50 - 70% of the return current will a cable design with a semi-conductive outer sheath can be used in high
flow in the seawater. The generated heat in the pipeline is temperature seawater conditions for several decades, an accelerated
approx. 70% of the total heat generation. The voltage of the ageing program was started (S. Hvidsten, 2005).
piggyback cable increases linearly with length.
b) Fig. 4. Per length circuit equivalent for 50/60 Hz DEHS for the case
with a) Insulating outer sheath and a metallic screen of
Copper conductor Conductor screen Stainless Steel. b) Semi-conducting outer sheath and no
metallic screens. Zc : Cable impedance, Zs : Sheath
XLPE insulation impedance, Zg : Ground impedance, Cd: Cable insulation
capacitance, Cs: Sheath capacitance.
Insulation screen
As an example, by DEH on a 10” Carbon steel pipeline of 16 km with a
U-value of 5 W/m2K, about 1,5 kA is required to keep the pipe content
Semi-conducting above hydrate formation temperature of 25oC at a seawater temperature
outer sheath of 5oC. Fig. 5 shows the results from calculations of the screen voltages
referred to ground and shows that maximum is about 1 kV and appears
at about 6 km from the power input. This voltage level is considered to
Fig. 3. Schematic illustration of two DEHS cable designs: a) Cable
be acceptable considering the material properties of the outer cable
equipped with a stainless steel screen and an insulating outer
sheath. Hence the cable design with metallic screen is feasible for a
sheath. b) Cable equipped with a semi-conductive outer
DEH heating length of 16 km.
sheath.
1
10
The relation between the cable length (with a metallic screen) and the
maximum screen voltage is shown in Fig. 6. Below 10 km pipeline
Max. screen voltage [kV] 1,2
length the screen voltage is relative small, but from approx. 10 km the
screen voltage increases more rapidly and is almost linear with length. 1
For a 50 km pipeline the screen voltage is approx. 9 kV, which is far
0,8
above acceptable level. As indicated in Fig. 5 the location of the
maximum screen voltage occurs not on the geometric midpoint for the 0,6
pipeline. This location depends on the electrical parameters of the
system. For the 50 km long pipeline the graph for the screen 0,4
voltage is shown in Fig. 7, indicating the maximum value at
approx. 12 km from the near end of the heated length. 0,2
0
Max. screen voltage [kV]
10
0 10 20 30 40 50
8
Distance along the pipeline [km]
6
4
Fig. 8. Values for the screen voltage along the 50 km pipeline.
2
0 The graph in Fig. 8 indicates that with an intermediate earthing system
0 10 20 30 40 50 for the cable screen every 5 km along the pipeline, the screen voltage is
sufficiently reduced. From an installation point of view it may be
Pipeline length [km] required to introduce splices at a similar interval. Earthing of the screen
may be performed during the splicing operation of the cable. As seen
from the graph the screen voltage decreases along the pipeline, and
Fig. 6. Relation between pipe length and screen voltage for the DEH hence the distance between the earthing points can be increased. At the
piggyback cable with metallic screen. last section with an earthing distance of 15 km, the screen voltage will
be kept below 1 kV.
For the “transient case”, 90oC was exceeded for three of the cases with
Max. rock clay coverage of 0,5 and 1 m, with temperatures ranging from 94 to
coverage 104oC. However, when the pipe was covered by clay to the middle and
rock dumped the temperature was slightly below 90oC.
Max. clay
coverage ELECTRICAL AND MAGNETIC PROPERTIES OF PIPES
Thermal
insulated Electrical and magnetic characteristics of steel pipes are important for
the heat generation and efficiency of the heating system. These data are
pipeline
normally not available from the steel mill (pipe manufacturer).
Measurements in the verification work on the concept indicate that the
Piggyback cable designation of type (“13Cr”, “Carbon” and “Clad steel”) does not
inside identify the material characteristics properly. Experiences prove that
protection profile these data should be specified within an uncertainty of ±10%. Until
there is obtained a data bank for these material properties,
b)
measurements are necessary to provide data for rating of the heating
system in detail engineering work. Such measurements have been made
Fig. 9. a) Pipeline and DEH cable surrounded by seawater.
on steel pipes for projects in the North Sea.
This case determines the heat requirement.
b) Maximum coverage of the pipeline represents the “worst
The results from measurements performed on a large number of
case” in respect to the thermal condition for the cable.
pipejoints display significant variation indicating that material
characteristics are not properly covered by the production quality
An example of thermal rating for DEH for an 18” pipeline with a U-
programme. Table 2 shows typical measured values for different steel
value of 4 W/m2K is chosen to give basis for thermal rating of the
pipes.
piggyback cable. The calculations were performed both for the steady
state condition with no production, and for the “transient case” with
A considerable random variation of effective relative permeability for
immediately turning on DEH after shutdown of the production with a
individual pipes within a pipeline has great influence on the variation in
well stream temperature of 116oC. The required supply current was
pipe temperatures.
1320A to keep the pipe content above 25oC determined by the case
with the pipe surrounded by seawater. The calculations were performed
with a copper conductor cross section of 1200 mm2.
Subsequent to delivery from the steel mill, the pipe joints are exposed As the electrical resistivity can be dependent upon water content in the
to heat treatment and grit blasting during the thermal insulation process clay samples, also the water content was measured both prior and after
and later to excessive strain during pipe laying (especially reel vessel). the resistivity measurements by using the weight method.
These stresses may influence the electrical and magnetic properties.
Fig. 10 shows results from measurements of the resistivity of the clay
Measurements indicate that the effect of stresses was different on taken from two different locations in the North Sea. It was seen that the
Carbon steel and 13Cr pipes. In general Carbon steel pipes were more resistivity decreases with temperature. At about 4oC the resistivity is
affected by the stresses than 13Cr pipes. Measurements show that the approximately 1,3 ȍm, decreasing to about 0,3 ȍm at 70oC which is
generated heat in the pipe may be reduced by approx. 20 % for Carbon close to that typically measured for seawater (0,2 ȍm). No change in
steel pipe after grit blasting. For 13Cr steel pipes the grit blasting has resistivity was observed when the samples were measured again at
insignificant influence. 20oC after the measurements at elevated temperatures.
The reason why the electrical and magnetic properties for Carbon steel As see from the results the electrical resistivity of the clay (seabed) was
materials are more affected by external stresses can explained by the sufficiently low. This indicates that the capacitive currents can easily be
depth of penetration or skin depth, G , given by Eq. 1. The skin depth is
transferred to seabed (seawater) avoiding voltage buildup at the sheath.
approx. 1 mm for Carbon steel materials and 9 mm for 13Cr at 50 Hz,
see Table 3. 2
A1
Hence the outer surface of the steel pipe will be active in a DEHS in a A2
depth of twice the skin depth. Typical wall thickness for pipes is from 1,6
10 – 20 mm. For a Carbon steel pipe the main current passes through B1
m]
the outer 1 – 2 mm of the pipe cross section, while for a 13Cr pipe B2
almost the whole pipe cross section is an active conductor. It is 1,2
Resistivity [
therefore reasonable that Carbon Steel materials are more sensitive than
13Cr for stresses (thermal and mechanical) on the outer surface in
regard to DEH properties. 0,8
U 0,4
G (1)
S
P0
Pr
f
0
0 10 20 30 40 50 60 70
G - skin depth T emperat ure [°C]
U - electrical resistivity
P0 - permeability of air Fig. 10. Results from measurements of resistivity of four different
Pr - relative permeability sample of clay taken from two different locations (A and B)
f - frequency in the North Sea.
Table 3. Skin depth for different steel for frequency of 50 Hz. CONCLUSIONS
Skin depth Numerical calculations of screen voltages for the cable design with
Steel insulating sheath show that the voltage can become several kV for long
[mm]
Carbon steel 1 pipelines. Such high voltages can not be accepted. The screen voltages
Clad steel 1 can be reduced by earthing the screen at some locations along the
13Cr 9 pipeline.
The new cable design with a semi conducting outer sheath requires no
ELECTRICAL RESISTIVITY OF CLAY metallic screen. This design requires sufficient electrical conductivity
of surrounding seabed.
The alternative cable design by use of a semi-conductive sheath and no
metallic outer screen for long pipelines, requires sufficient conductivity Measurements show that the electrical resistivity of the surrounding
of surrounding seabed to avoid high voltage at the sheath. In general seabed of clay was less than required for the semi-conductive outer
sheaths of the cable. This indicates that the capacitive currents can