Pipe in Pipe DEH

Theory, History, Current Status

Presented by: Phil Cooper

DNVGL Pipeline Comittee, Delft, 26th April 2018.
Theory

2
Pipe in Pipe DEH principles

P.i.P 𝑃 = 𝑅𝐼 2
AC - Power Required current [ I ]
Insulation Heating power
Resistance in the conductor [Ω]
r

𝑅𝑡𝑜𝑡𝑎𝑙 = 𝑅𝑖𝑛𝑛𝑒𝑟 𝑝𝑖𝑝𝑒 + 𝑅𝑜𝑢𝑡𝑒𝑟 𝑝𝑖𝑝𝑒

Outer pipe Power source

Annulus Inner pipe

Main bore

Current End bulkhead

Useful Heat Inflow 3
System Inductance

 Magnetic nature of line pipe material

- Depending on magnetic permeability (μ) of
the material. Which determines the relation
between current and magnetism.

 Magnetic effects are:

- Causing system inductance.
- Causing the skin effect.

 Magnetic permeability
- Is a material property which cannot be
controlled during line pipe production.

- Has a significant effect on the system

parameters.

4
Pipe in Pipe DEH – System Impedance

𝐼𝑚𝑝𝑒𝑑𝑎𝑛𝑐𝑒 → 𝑍 = 𝑅𝑡𝑜𝑡𝑎𝑙 2 + 𝑋𝑡𝑜𝑡𝑎𝑙 2

𝐴𝑝𝑝𝑎𝑟𝑒𝑛𝑡 𝑃𝑜𝑤𝑒𝑟 → 𝑆 = 𝐼 2 𝑍

𝑅𝑒𝑎𝑙 𝑃𝑜𝑤𝑒𝑟 → 𝑆 = 𝐼 2 𝑅𝑡𝑜𝑡𝑎𝑙

𝑅𝑒𝑎𝑙 𝑃𝑜𝑤𝑒𝑟 (𝑃)

𝑃𝑜𝑤𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟 =
𝐴𝑝𝑝𝑎𝑟𝑒𝑛𝑡 𝑝𝑜𝑤𝑒𝑟 (𝑆)

𝑇𝑦𝑝𝑖𝑐𝑎𝑙 𝑝𝑜𝑤𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟 𝑝𝑖𝑝𝑒 𝑖𝑛 𝑝𝑖𝑝𝑒 𝐷𝐸𝐻 ≈ 0.75 5

Effective Resistance

Ϭouter ϬInner
Conducting area Outer pipe
𝐴𝑜 = 𝜋 ∙ ( 𝑟𝑜𝑖 + 𝛿 2 − 𝑟𝑜𝑖 2 )
𝑅𝑜 = 𝜌/𝐴𝑜

Conducting area inner pipe

𝑅𝑖 = 𝜌/𝐴𝑖
rio
roi 𝐴𝑖 = 𝜋 ∙ ( 𝑟𝑖𝑜 + 𝛿 2 − 𝑟𝑖𝑜 2 )

=1-3mm
Skin Depth [δ]
- Frequency [ω]
Current Density
J [A/mm2] - Material properties

- Specific resistivity [ρ]

- Temperature dependent [T]

- Magnetic permeability [μ]

- Current density dependent J (t,x)

ID Inner pipe OD ID Outer pipe OD

The current is drawn to the outer surface of the inner pipe and the inner surface of the outer pipe.
As the majority of the current travels just below the surface, the surface roughness has a 6
noticeable effect on the effective resistance.
Skin Effect – Numerical Simulation

7
Pipe in Pipe DEH - B-H Curve Hysteresis

Rop
Rip 𝐵
= 𝜇
𝐻
Hysteresis generates
additional heat

Capture the correct pipe properties for a specific installation by:

- Measuring the effective resistance and permeability per meter of inner and outer pipe.
- Measuring system impedance of completed PIP, and adjusting power supply settings if needed
8
PIP-DEH System Overview (center-fed)

Item Description
1 Umbilical riser
2 Riser Termination
3 Subsea cable
4 Subsea transformer
8 9
5 Flying lead
6 Mid Line assembly
1 7 Heated P.i.P
8 Power supply (host)
9 Power Control Module

2 4
3

5
6 7

9
History

10
History of Electrically Heated Flowlines

P.i.P:
ETH:
I.P.B:

PIP DEH:

Wet DEH:

‘98 ‘99 ‘00 ‘01 ‘02 ‘03 ‘04 ‘05 ‘06 ‘07 ‘08 ‘09 ‘10 ‘11 ‘12 ‘13 ‘14 ‘15 ‘16 ‘17

Parameters
Maximum
Systems
System Length Diameter Depth
installed [-]
[Km] [Inch] [m]

P.i.P 1 6 6 30
ETH
I.P.B 3 3 11 1350
PIP-DEH 10 (3 fields) 13 10 2100
DEH 16 43 30 1070
11
Industry Track Record in Detail (INTECSEA, 2017)

12
Water Depth and U-Value (INTECSEA, 2017)

13
Shell GoM Experience (2001-2003 installations)

 Invented late 90’s by Ron Bass, shortly after Wet DEH emerged in Norway
 End fed: Installed and operated (TRL7)

- End fed has no subsea electrical connections: power applied at electrical

isolation joint at top of SCR. Preservation only.
- Implemented on Serrano-Oregano project: 10.4km and 13km
SCR+Flowline. 6”/10” PIP, PUF, J-Lay (McDermott), 2001
- Some initial problems with EIJ contamination: solved with liner
- Worked perfectly for about 7 years
- Decommissioned after capacitor failed in power module. No issues with
pipeline itself.
 Center Fed: Qualified, installed, tested but never energized (TRL5)

- Power applied subsea, at center of PIP segment, continuous heat OK

- Nakika: 6 segments, 1.6-13.2km long. 10”/16” PIP. 1kV/1100 A. J-Lay
(Technip) 2003, PUF. See OTC Paper
- Habanero: 2 segments, ~13km, 6”/10” PIP. J-Lay (McDermott) 2003

14
Nakika Schematic (OTC15145, 2003)

15
BP Tests – Bayou, Louisianna. c2010

 Performance tests on short length of 10”/14.5” PIP

 Custom power supply – high current, low volts, highly controllable

 Published at DOT, 2012

 Approximately 150 W/m confirmed with 800A current

 Considered TRL5 by BP

16
BP Tests: Heat Input, Step-out, Current

Heated Segment Length per 1 kV (50 Hz, 10in Flowline)

Preservation Remediation Active Heating
20
(U-value) (duration) (Flow rate, DT)

18

16
400 [A]
14
400 [A]

12
Distance [Km]

500 [A]
10
500 [A]
8 600 [A]

600 [A] 800 [A]

6 700 [A]
700 [A] 800 [A]
4

0
0 50 100 150 200
[W/m] Effective Heat Input
HMC, Calibrated Paper BP Trials DOT 2012

17
ExxonMobil Annulus Improvements
 Assisted by Ron Bass, after he retired from Shell
 Objective:

- Increase annulus electrical insulation capability to allow high voltage and

hence longer lengths (Arctic developments, 22” flowline)
- Improved robustness against annulus contamination (moisture, debris)
 Testing at SINTEF – no published results

 Considered qualified by ExxonMobil

 Arrangements described in 2015 patent:

- Up to 3kV with simple corrosion coating under insulation

- Up to 6kV with additional features

18
Qualification Status

19
Power Supply and Umbilical: TRL7

 Topside equipment [TRL 7]

- Similar to Open-DEH
- Significantly smaller power factor correction
required (capacitor bank)
- Possible suppliers are:
- ABB
- Wartsilla
- Siemens

 Power umbilical [TRL 7]

- (Typically 2 x 150 mm 2 @ 15 KV)
Nakika Topside
- High voltage cables are used on a range of projects
- Ormen Lange (146 KV)
- Tyrihans Open DEH (52 kV @ 1600 A)
- Jack St Malo & Julia MPP
- Voltage rating in the range for Open DEH
- NaKika: 11kV/180A, 2.5in OD, 2x50mm2
- Small conductor sizes allows for integration in SPS
Umbilical?
- Multiple suppliers

Possible coaxial cable arrangement

20
Subsea Transformer: TRL 5-7

 15 Subsea transformers installed

- 1 Single phase for NaKika (6.6t)
- Up to 145 kV, 1600 [A], 3000m

 ABB is market leader.

 Siemens: qualification completed, (6.3

MVA, 3000m WD)

 Minimal change to conventional oil-filled

onshore transformer internals; no
moving parts  High reliability

 Specific single-phase unit does not

require full re-qualification

 Modest cost
21
Wet–Mate Connectors [TRL 4-7]

 Wet mate connector current capacity 50

45
is limiting factor in system 40

- Solved by “Big Subsea Power” JIPs 35

Volts [KV]
30

 Multiple qualified suppliers 25

20
- BHGE MECON (up to 1600 A) 15
10
- Siemens SpecTRON (up to 1500 A) 5
- TE Connectivity DEUTSCH (up to 1800 A) 0
0 500 1000 1500 2000
 Current (hence heating power) can Current [A]

be doubled with 2x connectors in Siemens TE Connectivity BHGE

parallel
 Hard-wired connection also possible
- Integrate transformer with MLA
- Wet-mate HV primary

22
Pipe in Pipe DEH – Flowline Components

Annulus cross section design

Mid – Line Assembly Non - conducting bulkhead

Fibre-reinforced grout, epoxy, polymer

3LPP/3LPE under Aerogel

(see ExxonMobil patent) 23
Mid-Line Assembly: TRL4

 First MLA was developed and installed on NAKIKA. (1 kV, 2000m

WD)
 Improved MLA was designed and patented by ExxonMobil,
considering a voltage of 6kV
 Pressure containing housing with:
- Wet-mate connectors (or penetrators with pig-tails)
- Electrical connection to the Inner pipe
- Electrical connection to the Outer pipe
 Positioned in the center of the flowline
 Installed as an in-line structure
 Electrical insulation, round corners and clearance to avoid short
circuit or arcing

24
Conclusions
 PIP-DEH is a field-proven method for electrical heating of deepwater flowlines
- Basic method is TRL7 (seven years operation)
- Simple, robust and relatively high efficiency
 Suitable for installation by reeling, J-Lay or S-Lay

- Larger diameters possible

 Minimal changes to conventional carbon steel PIP cross section design

- No delicate components in annulus

- No special equipment or procedures needed
 Electrical components are all external to pipeline

- Extensive range of qualified equipment

- Multiple suppliers
 No major technology gaps

- Mostly verification, not qualification

 Low and High heat inputs, continuous or intermittent

- Preservation, Remediation and Active Heating (200 W/m) all OK

 Long heated lengths possible

- >30km per segment @ 3kV and 50 W/m

- ExxonMobil annulus design doubles this length 25