OTC-26389-MS

Flow Assurance and Hydrate Prevention Methods Enabled by Medium

Voltage Electric Heating Technology
C. Molnar, and M. Riley, Chromalox

Copyright 2016, Offshore Technology Conference

This paper was prepared for presentation at the Offshore Technology Conference Asia held in Kuala Lumpur, Malaysia, 22–25 March 2016.

This paper was selected for presentation by an OTC program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material does not necessarily reflect
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Abstract
Offshore production facilities utilize a variety of process heating equipment to help start-up production
and operate efficiently. Applications include glycol reboiling, oil and gas conditioning, knock-out drum
heating, molecular sieve regeneration, sea or potable water, and fuel/lube oil maintenance. In addition, oil
producers have long investigated downhole and subsea heating solutions capable of decreasing viscosity,
preventing wax and hydrate buildup, and providing localized heating for improved productivity. The types
of heating solutions are problematic due to the large capacity and extreme environmental and process
conditions involved, especially with the downhole and subsea applications. Until recently, low voltage
(below 1000V) heating elements and low power heating cables have been the typical solutions for
downhole and subsea electric heating applications. These traditional solutions have limitations that
prevent them from significant adoption and utilization.
This paper discusses the benefits of using medium voltage technology for flow assurance and hydrate
prevention applications. The focus will be on the reduction of installation, maintenance, and operational
costs, as well as the reduction of electrical power consumption and line loss associated with using medium
voltage technology for such applications. For large heating loads, the physical size and footprint of
medium voltage electric heating systems are more compact than traditional low voltage systems. This is
especially relevant on newly designed platforms offering medium voltage power distribution.
Finally, medium voltage electric heating technology opens the door for completely new solutions in
downhole, subsea and offshore heating, as well as other process heating, in the oil and gas industry that
were not possible before. It is important to present such innovation to the marketplace so that producers
and operators are aware of new solutions to existing problems.

Introduction
Most industries use low voltage systems, typically less than 1000V, for electric heating applications.
These were practical for most application up through the 20th century. Now, however, many applications
in such heavy industries as oil and gas, petrochemical, and chemical demand much higher power output.
These applications require multi-megawatt (MW) electric heating systems. At low voltages, such require-
ments lead to challenges with power distribution, process design and costs.
2 OTC-26389-MS

A viable solution involves leveraging medium voltage power. A safe and reliable technical design for
metal-sheathed electric process heating and power controls exists for heating systems operating at medium
voltages. These medium voltage electric heating systems allow the oil and gas industry to capture all the
advantages of electric process heat while minimizing the disadvantages of low voltage, high amperage
designs. This paper discusses the benefits and cost savings associated with heating systems operating at
up to 7,200 Volts relative to traditional low voltage designs.

Description and Application of Equipment and Processes

A medium voltage electric heating element is capable of very large power output that can operate on
voltages up to 7,200 Volts. Modified dielectric material formulations are capable of ultra-high insulation
resistance and enable the element to reach withstand voltages in excess of 25,000V during safety testing.
These two properties deliver the medium voltage performance and reliability necessary for industrial
applications, even at high temperatures, up to of ~540°C. Regarding safety, typical failure modes seen
with low voltage elements (e.g. stitching and shorts to ground from Ni-Cr wire to sheath) have not been
duplicated with new MV elements technology. In addition, MV elements retain the ability to be integrated
into applications requiring welded connections or fittings to facilitate serviceability. MV elements are
capable of controlling process streams to 1°C utilizing thyristor/SCR control technology. This ensures
maximum heat production at close to 99% efficiency and minimal I2R losses over long distances.
The following section summarizes various design aspects of this new medium voltage electric heating
technology that has been researched, tested, and qualified:
Insulating Materials
One of the most important factors in the manufacture of medium voltage heating elements involves the
compound used inside of the element to provide the right combination of thermal conductivity, electrical
resistivity and dielectric strength. The dielectric and thermal properties of various granular minerals used
during manufacture determine the optimal performance characteristics of the heating element. Various
oxides have been tested under high loads and environmental conditions to produce the most optimum heat
transfer and electrical properties for use at medium voltages elements (for example, see Fig. 1). For
medium voltage elements, a blend of highly pure magnesium oxide is extruded and fired to produce ideal
compaction characteristics in a configuration that provides very high dielectric breakdown voltages. This
method of processing enables the material to be packaged and assembled in such a way to produce high
quality and consistently safe heating elements.

Figure 1—Example Hipot testing based on material selection

OTC-26389-MS 3

Terminations
Dielectric breakdown and moisture intrusion at terminations is a common issue in electric heating. This
issue is exacerbated when higher voltages are applied. The inherent dielectric strength required for MV
terminations automatically eliminates moisture intrusion as a beneficial side effect. A medium voltage
termination does not yield a dielectric breakdown at the termination, even at extreme medium voltages
(~20,000V).

Failure Modes
Traditional modes of failure for low voltage heating elements (e.g. stitching and phase-to-ground shorts)
are more of a concern as voltage increases. An improved failure mode on MV elements occurs in the
non-heated region contributing to very safe dielectric properties over the element temperature ranges.
Even at extremely low insulation resistance values, these heating elements exhibit very low susceptibility
to cause catastrophic failure. The specific internal construction is such that failures commonly seen in low
voltage elements, such as stitching and phase-to-ground failures, are eliminated. Due to the high dielectric
strength of the insulation material, the element’s resistance coil will typically melt causing an open circuit
or phase-to-phase failure before a phase-to-ground trip can develop.

Processing and Element Compaction

Fill rates, vibration and compaction techniques are critical for producing the very highest in sealing and
dielectric capabilities. The fill materials are assembled into the heating element in a temperature controlled
condition avoiding many of the moisture related issues appearing with low voltage elements during
fabrication. All processing methods maintain very stringent cleanliness controls in order to produce high
quality, long lasting elements each and every time.

Pressure Boundary
Elements are able to interface effectively with a flange/tubesheet using either tubing compression fittings
to facilitate element replacement or with a traditional welded connection. Either method of attachment can
withstand up to a maximum of 240 barg. In addition, the compression fittings allow for the replaceability
of individual heating elements. While individual element replaceability is also a feature of a low voltage
system, it becomes a more critical design component of medium voltage systems. By their nature MV
systems are designed for large power output, so they will be physically larger, contain more heating
elements, and be more complex to maintain.

Dielectric Breakdown
The medium voltage heating elements exhibit high dielectric withstand voltages across a wide temperature
range, with dielectric resistance decreasing only slightly over its normal operating range as temperature
increases. A comparison of leakage current versus temperature for elements operating at medium voltage
determines their operational limits. As the sheath temperature increases the amount of leakage current
remains low until a temperature of ~590°C is reached. The leakage then begins to increase until dielectric
breakdown occurs at approximately 815°C (See Figure 2).
4 OTC-26389-MS

Figure 2—Leakage current of MV element versus temperature

Frequency, tan delta, partial discharge, and corona characteristics

Heating elements use corona resistance leadwire, that exhibit low partial discharge, in an online
configuration. Ultrasonic measurements using acoustic and ultrasonic contact probe equipment are
utilized in production tests to verify that partial discharge levels are acceptable for the heating elements
and associated bussing within the terminal housing.
Contact Resistance and Thermal Cycling
One of the most common causes of low voltage element failures in the field involve loose or compromised
terminations and electrical connections. For medium voltage elements, verification that the electrical
connections are secure and insulated is performed on every connection in order prevent excessive heat
buildup and the potential of arc related flash/blast incidents. Electrical connections to the heating element
exhibit lower contact resistance throughout thermal cycling tests when compared to low voltage elements.
Thermal Endurance
Long-term thermal endurance stress tests will determine life expectancies at various temperatures. This
allows the designer to specify the most reasonable watt densities for the selected heated medium. Medium
voltage heating elements operating in a lab environment continuously for over a year, heating both air and
water, performed as designed, even under extreme cycling conditions. Test data shows that medium
voltage heating element life expectancies are similar to low voltage heating elements under the same set
of operational conditions.
Sheath Materials
Alloy 800 and SST304 are common sheath materials currently specified and operating temperatures are
well within the design limitations of the alloys. Additionally, the sheathing wall thickness is thicker than
most common low voltage elements. Additional materials can be used based on needs within the industry.
Third Party Certification
Medium voltage heating elements are a new development for industry and therefore new standards had
to be developed. Requirements were adopted from IEEE, IEC, UL and CSA medium voltage standards
and two specifications were created – one for the heating element and one for the control system. Heating
elements can be certified under ETL File # 101361500DAL-001. The control system for medium voltage
heating systems can be certified under UL 347C. Production electrical tests consist of testing continuity/
resistance, insulation resistance and power frequency dielectric withstand voltage (hipot) verification. The
elements are dielectrically tested to nearly 3 times the nominal line voltage (up to 18,200VAC) for 60
seconds.
OTC-26389-MS 5

Certification for Hazardous Areas

Explosion testing still needs to be accomplished and certified by independent third party laboratories to
confirm that the existing terminal enclosures for low voltage duty are applicable to medium voltage
applications. It is anticipated that the enclosure will be the same, although it has not been verified yet.

Presentation of Data and Results

The following section of the paper presents the generalized impacts of medium voltage heating technology
along with a specific case study analysis of those benefits.

Installation Savings
Medium voltage technology permits operation of process heat equipment directly from of an existing
distribution system up to 7,200V, potentially eliminating the installation of dedicated step-down trans-
formers for low voltage duty. When operating multi-megawatt systems, this cost avoidance has shown to
be approximately $25,000 or more per MW installed as determined in the following case study.
Additionally, using medium voltage heating elements instead of low voltage elements for electric
process heating reduces the amperage draw for the same heat output. For example, operating process
heating equipment at an industry standard 4160V or 6600V reduces amperage by a factor of nine to ten
as compared to the typical low voltage supply (400-480V or 600-690V). This allows the end user to
reduce both the wire diameter and number of wires necessary for installation when compared to a low
voltage source. Even considering the higher cost of MV wire compared to low voltage wire, at higher
voltages, the material savings on wire alone can equal $1.50 per amp per foot of run. A multi-megawatt
system operating at 4160V installed several hundred feet from the main distribution bus can save the end
user close to $200,000.
Finally, the higher voltage reduces the labor cost necessary for installation. Using fewer wires of
smaller diameter reduces the time and effort for installation. At higher voltages, the estimated labor cost
savings on wire installation is approximately $0.15 per amp per foot of run. In addition, electrical
installation time drops by a factor of 10, decreasing wire and conduit labor time from weeks to only days.

Operating Savings
Operating at medium voltages increases the efficiency of power distribution and consumption. Electric
process heat and control solutions have much higher efficiencies than fuel-fired systems, especially at
reduced duty cycles. However, they are not 100% energy efficient. Energy losses occur in the form of heat
generation often designated as I2R losses. A typical low voltage system will operate at about 96%
efficiency, with 4% energy loss coming from heat generated by current transmission across wire, bussing,
connections and instrumentation.
However, the lower amperage associated with medium voltage technology minimizes power loss.
Electric power transmission lines operating at hundreds of thousands of volts exhibit the same benefit—
high transmission efficiency and reduced line loss. For example, a purely resistive load multi-megawatt
electric heating solution operating at 4160V will run at almost 99% power efficiency. That 3% improve-
ment in efficiency over low voltage translates into operating cost savings for the life of the system. For
example, assuming a cost of $0.05/kWh from your utility, an end user will save tens of thousands of
dollars every year of operation. For a 2.5MW heater drawing 350A at 4160V with a 50% duty cycle, that
adds up to a $410,000 saving over With a life expectancy of a 20 years life.
In addition, there is a tremendous reduction in the amount of I2R heat generated by an MV system,
which reduces air conditioning costs for indoor equipment. When comparing the same power system
operating at 4,160V versus 480V (for example), the heat generated by the low voltage system is 80 times
greater than the medium voltage system.
6 OTC-26389-MS

Maintenance Savings
One key advantage of electric process heat in general is the low cost of maintenance. With no moving
parts and a robust design, electric process heaters will often operate for decades with minimal maintenance
relative to fuel-fired equipment. And although the major parts of an electric process heater do not require
regular adjustments, routine inspections of electrical connections help to ensure safety and minimize
inefficiency from losses. The fact that medium voltage technology requires less current, less kA and fewer
wires and connections reduces electrical stresses on the system.
Life-Cycle Savings
Often electric heaters in heavy industry operate in process-critical situations where downtime can cost
hundreds of thousands, if not millions of dollars, a day. Heating element failure can be a major cost factor.
Regardless of cause, the impact to a user’s operation can be catastrophic. End users must make decisions
regarding their source of replacement heating bundles: whether sourced as needed or stocked for
emergencies.
For critical process situations, the end user may choose to purchase a spare heating bundle along with
the original equipment. This can add as much as 50% to 60% to the entire system cost. The alternative
is to source a heating bundle as needed, which can result in a significant lead time and/or cost for
expediting. These alternatives can be costly, time consuming, and unpredictable.
The system is designed to incorporate individually replaceable medium voltage elements to reduce
both time and cost in repair situations. The end user can remove a failed element, and the controller will
make the necessary compensations allowing the heater to continue in service. Alternatively spare elements
from on-site storage can be used, rather than having to obtain a full heating unit from a manufacture.
Should an emergency arise, the production downtime involved with replacing failed elements is greatly
reduced. For a typical multi-megawatt system, the cost savings associated with replaceable elements can
reach $100,000 per incident. Downtime may drop to a matter of days as opposed to many weeks for a
sourced replacement bundle.
Weight Savings
One of the more important aspects of medium voltage heating equipment as compared to a traditional low
voltage system is weight savings. Heat output is a function of ohm’s law such that for a given power (heat)
output, the amperage and voltage are in a one-to-one inverse relationship. This, when amperage is cut by
a factor of 8 to 10, the voltage must be increased by the same factor. For the electric heater itself, this has
only a slight impact on size and weight of the equipment. However, for the electric control panel and
switch gear, there is a significant reduction of volume and weight when utilizing medium voltage power
over low voltage. It holds true that for medium voltage systems, the weight and volume space savings can
be as high as 35%. In the case of oil and gas electric heating applications, especially on offshore platforms,
this could equate to anywhere between 5 to 15 tons of weight reduction and 100 to 300 cubic feet of
volumetric space savings.
However, it is important to note that the above accounts for direct weight savings of the heating
equipment itself. It does not factor into account the reduction in structural support that accompanies the
equipment weight savings. Generally, the structure-to-equipment ration is 4:1, meaning that for every
pound of reduction topside, one can eliminate four pounds of structure steel needed to support the
equipment.
Design and Safety Impacts
A common assumption when comparing LV to MV equipment is that LV equipment is safer and less
dangerous due to the lower voltage. However, depending on the switchgear and devices installed, that may
not actually be true. An analysis by CCG Facilities Integration evaluated the arc flash incident energy and
PPE requirements needed when managing a 750MVA load through 600amp 4160V switchgear compared
to 4000amp 480V switchboard (Mosman, 2009). Under the worst case scenario, the 480V switchboard
OTC-26389-MS 7

was classified as PPE Category ⬙Dangerous,⬙ not to be worked on live, while the 4160V switchgear had
a PPE Category 1. Also, when performing IEEE 1584 calculation on arc flash, the maximum incident
energy for a low voltage fault was more than an order of magnitude greater than the medium voltage fault.
In addition, the relative arc flash boundary distance was 297 inches (24.8 ft) for 480V, but only 128 inches
(10.6 ft) for 4160V, and as these clearances extend all around the equipment so it can be seen that MV
can result in major real estate cost savings.
Even if the MVA level in the above example is reduced enough to allow personnel to carry our
calibration and diagnostic work on the equipment, the PPE required to prevent critical burns makes such
work extremely hard and is extremely limiting on the time that work can be done before personnel suffer
excess heat effects. The ability to carry out such work on MV panels wearing suitable cotton clothing has
an incalculable benefit.
The electro-magnetic forces produced by such a short circuit are proportional to I2 and inversely
proportional to the the conductor spacing. A typical LV heater would draw 9 times the current at 480V
than at 4160V. The resulting short circuit currents in the event of a fault would be proportionately higher.
The clearance needed between insulated conductors doubles for MV conductors, but because the
conductor size is so much smaller the actual conductor spacing may be much the same. The electro-
magnetic forces on the conductors will therefore be as much as 80 times higher between LV conductors
compared with MV conductors resulting in a significant increase in cable support costs and consequential
damage if the support system fails.

Offshore Applications
As mentioned above, typical heating applications on offshore platforms and production facilities include
glycol reboiling, oil and gas conditioning, knock-out drum heating, molecular sieve regeneration, sea or
potable water, and fuel/lube oil maintenance. Medium voltage heating technology is ideally suited for
such high capacity heating applications. However, there is the potential to install high pressure medium
voltage heating elements for downhole and subsea heating applications.
Medium voltage element heating technology has advantages over low voltage heating solutions
because of the minimal I2R losses that come from operating at thousands of volts over long distances. In
addition, it has advantage over heating cable solutions because those cables are limited to minimal heat
output per linear foot requiring the entire well/pipe length to be heated. By utilizing MV heating elements,
high powered heating systems can be integrated into a clamshell assembly capable of delivering large
amounts of heat to much smaller underwater heating zones as a downhole and subsea tool. Further, a
complete centralized hot water/oil subsea heating system can be used for the distribution and control of
heat across a subsea field.

Case Study
The following presentation outlines an actual case study evaluating the medium voltage impact of a 2.6
MW inline heating system for oil and produced gas coming from a subsea tieback project in the Gulf of
Mexico:

Installation Savings
The platform had a 250-foot span between the main power distribution system and the heating system. The
following table compares the installation components and labor costs of a 4160V system versus a
traditional low voltage installation:
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Low Voltage

480V Construction - 24 Circuits

2,600kW Heater $ 495,000

Power Control Panel $ 145,000
Start-Up Service $ 25,000
Product Sub-Total $ 665,000

Transformer $ 130,000
50 ft. Wire to Panel $ 31,400
250 ft. Wire to Heater $ 156,700
180 Labor Hours $ 12,750
Install Sub-Total $ 330,850

Total Cost $ 995,850

Medium voltage

4160V Construction - 2 Circuits

2,600kW Heater $ 665,000

Power Control Panel $ 340,300
Start-Up Service $ 25,000
Product Sub-Total $ 1,030,000

Transformer $0
50 ft. Wire to Panel $ 3,050
250 ft. Wire to Heater $ 15,250
30 Labor Hours $ 1,700
Install Sub-Total $ 20,000

Total Cost $ 1,050,000

Installation savings were not realized in this particular design due to the smaller power requirements
per heater and the cost of ancillary equipment. Typically significant savings are seen for larger power
systems.
Operating Savings
The reduced amperage of the medium voltage system minimizes I2R losses in the wires, heater bussing,
and panel heat losses. For the platform, these factors can contribute to a significant cost savings for the
new 2.6 MW application. The operation runs 24 hours per day with electric utility costs of $0.05 per kWh.
The following table shows their annual energy savings by switching away from the traditional low voltage
design.

System Low Voltage Medium voltage

480V 4160V
I2R Losses (Watts) 83,713 12,031
Efficiency Rating 96.8% 99.5%
I2R Operating Cost $ 35,160 $ 5,050

An annual operating savings of $30,110 realized using 4160V electrical supply.

OTC-26389-MS 9

Maintenance Savings
The smaller number of 4160V circuits allows inspection time to be reduced proportionally. The following
table compares medium voltage and low voltage systems assuming a monthly inspection program with
annualized costs

System Low Voltage Medium voltage

480V 4160V
Number of Circuits 24 2
Monthly Inspection 3 hours 0.5 hours
Maintenance Cost $ 3,060 $ 510

An annual operating savings of $2,550 can be realized using 4160V electrical supply.

Life-Cycle Savings
Process heating equipment installed on a platform, with a proper maintenance program, should have a life
expectancy of 20 years. However, it’s likely that at least one element bundle replacement will be required
over the life of the heating system. For this platform, a traditional low voltage system would include a
large heating bundle using 480V welded-in elements.
By taking advantage of the 4160V system with individual replaceable heating elements, the platform
can cut downtime and save expensive repair costs. The following table shows the platform’s anticipated
failed element replacement cost savings by avoiding a traditional low voltage design.

System Low Voltage Medium voltage

480V 4160V
Replace Contactors / Thyristor $ 25,500 $ 15,000
Replace Expired Elements $ 82,000 $ 62,100
Labor $ 27,200 $ 9,660
Maintenance Cost $ 134,700 $ 86,760
Downtime 14-21 days <5 days

A life cycle savings of $47,940 can be realized using 4160V electrical supply.
Note: that the above savings does not include the potential cost of lost production avoided from the
minimized downtime of less than a week versus much longer for a traditional solution.

Weight Savings
For this particular case study, the reduction in weight for the medium voltage system as compared to the
low voltage system was 25,600 pounds and 420 cubic feet of space savings. This weight savings came
from the reduction is control panel and cabling sizes, as well as the elimination of the MV to LV
transformer. As a general rule of thumb, the structural weight reduction as a result is roughly 100,000
pounds with a cost reduction associated with that of approximately $500,000.
10 OTC-26389-MS

Case Study Summary

The table below summarizes the costs expected by the platform as a result of this heating system project
(assuming a 20-year life span). Despite the higher capital costs for a medium voltage system, the
installation and life cycle savings amount to $493,790, while the annual operating and maintenance
savings amount to $653,200.

Cost of Ownership Low Voltage Medium voltage

480V 4160V
Installation $ 995,850 $ 1,050,000
Structural savings - $ (500,000)
Operation $ 703,200 $ 101,000
Maintenance $ 61,200 $ 10,200
10-Year Replacements $ 134,700 $ 86,760
20-Year Costs $ 1,894,950 $ 747,960

A total cost of ownership savings of $1,146,990 was realized through the choice of a 4160V system
versus a low voltage system.
The case study analysis shows that the platform is in a far better financial position by choosing medium
voltage system over the traditional low voltage design. In this particular case, the installation cost savings
more than paid for the incremental capital spend for the medium voltage equipment, making the payback
period immediate. In general, the payback on almost all installations will be less than one year
Conclusions
Medium voltage electric heating systems offer reduced installation cost and increasing efficiency for
multi-megawatt oil and gas heating applications as compared to low voltage systems. For offshore
applications there exists the added benefit of both space and weight reductions, along with a positive
impact on risk and safety if the system is designed properly. The technology is based on the same
principles as low voltage electric resistance heating that has been used in industry for the past century, but
reapplied for medium voltage use. Medium voltage heating technology capable of very large heating
demands opens the door for a wide variety of new applications for offshore, downhole, and subsea
applications previously not possible with low voltage systems.
OTC-26389-MS 11

Acknowledgements
A special thanks to Mark Wheeler for seeing the need for this technical solution in the oil and gas industry
and providing direction and guidance in its development. Also, thanks to David Riley for doing much of
the research and development on materials, manufacturing, and testing methods to create a viable medium
voltage solution.

References
Mosman, Mike. 2009. Correcting the False Perceptions of Medium Voltage Data Centers. Datacenter Dynamics.