Introduction to Skin

effect heat tracing

system

BY BEVARA VIVEK
Index
Introduction
Brief theory about STS
STS system used in HPCL-VR
Components in STS system
Cause of failures and its rectification system
Major repair jobs
Reference
Why Skin effect heat tracer
system
Conventional Electric heat tracer are not reliable when product pipeline length is increased
certain limit
Skin effect heating is another way to heat pipeline using electricity
It can be used for long runs of pipe lines up to 15 miles
Only needs one power supply connection compared to heat tracer system with self heated
tracer.
Theory of Skin effect heating
Pipeline electrical heating system in which unique technique is released using skin-effect
phenomenon is designed for heating long and extra long pipe lines.
In STS system heating element will be heated with Skin effect and proximity effect in ferro
magnetic conductors at alternative power current.
Heating element is low carbon steel tube with wall thickness not less than 3mm, inside of which
non-magnetic conductor is placed.
At the end of run the conductor is connected to steel pipe, and at beginning of the run
alternating voltage applied between pipe and conductor.
As shown in diagram power cable phase and
neutral are connected return path of current is
through heat tube which will be heated in this
process.
Alternative current runs through internal layer
with about 1mm thickness due to skin effect
and proximity effect
The potential of pipe surface is being virtually
Zero
Due to light thickness of skin layer basic heat
generating is being performed in steel pipe
At beginning and at end of circuit outer
surface of skin tube is reliably grounded which
ensures additional safety.
STS system used in HPCL-VR
design parameters
STS system is used to maintain temperature for 16” Bitumen shipping line which is originated
from refinery Tanks 500 T 001 and 002 to Oil Warf end where product will be exported to
external vessel.
Total length of BCLF line is approximately 4350 meters of each circuit
Design temperature- 190 C
Area of classification : Zone -2
Components which are used as intermediate JB and power JB are IP-65 specification and Ex-e
type.
Voltage of existing system Ph- Neutral is 1.6 KV
Components in STS system
Power transformer (Scott connection)
Control panel
Sensors- which monitors process temperature
Skin effect cabling (Which carries voltage over length of system)
Heat tube (Which actually generates heat and transfer it to pipe line)
Junction boxes – Pull boxes (allow for wire connection and pulling points)
 Power transformer
Incomer supply is feeding through two transformers of 650 KVA rated scott connection transformer
This transformer secondary will be two set of phase and neutral which will feed each side of pipe line
(Warf side and refinery side)
Outgoing cable of size 2 runs of 3C, AL,185 SQ mm cables are connected from transformer to IJB
which are located at LLPH road after BOT takeoff.
Control panel
As continuous heat transmission from heat tube to pipe line temperature is monitored
through temperature sensors for each circuit which are kept on pipe line
AS per design control circuit will cutoff electrical supply to heat tube when temperature
raised more than 140 ̊C
Also Power supply Auto cut in when temperature reached below 120 ̊C to maintain
adequate product temperature while there is no product shipping.
 STS-2 185 Sqmm 3C AL

2* 1C 21 Sqmm CU
IJB-1 IJB-2
STS-1 Warf
PJB-1 PJB-2

SS-63

PJB-3 PJB-4

IJB-3 IJB-4

Refinary
IJB PJB
Cause of failures in system
and maintenance methods
As heat tube temperature is higher and due to aging insulation of conductor failure or previously
installed joint failure will cause short circuit path for return current which will increase the load
current hence system will detect fault though overcurrent
Heat tube is to be replaced as some areas as it is badly corroded.
Installation of new pull box as tracer joint required to replace short cable length
Failure at Junction box
While cable jointing is done ensure to use
proper ferrol and use proper glass tape for
heat insulation after scotch-70 self fusing
silicon rubber for placing in hole piece.

For jointing of heat tubes through coupling and

360 ̊welding which is to be air tight and
ensuring full continuity of heat tube for making
return path for current through heat tube.
As for pull box installation also same as heat tube
welding both sides of pull box end to be
360 ̊welding and proper electrical continuity to
be maintained.
Major repair jobs
Warf side conductor observed and noted there are 19 no of joints present and by changing
200m tracer total 9 no of joints are reduced.

Busbar installation done at IJB to remove direct connection which reduced heating issue
Referance:
http://www.chromalox.com/catalog/heat-trace/XtremeDuty/skin-effect-heat-trace-system

https://www.nventthermal.com/products/engineered-products/skin-
effect/index.aspx?id=tcm:432-27855&catid=tcm:432-17788-1024

https://www.valin.com/documents/FAQ.pdf