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Application Brief Direct Electrical Heating )ORZDVVXUDQFHLVRIWHQYLWDOWRVXFFHVVIXOGHYHORSPHQWRIGHHSZDWHUǮHOGV$VWKHLQGXVWU\ H[SORUHVGHHSHUZDWHUZHOOVORQJHUWUDQVSRUWDWLRQGLVWDQFHVKDYHEHFRPHPRUHFRPPRQ WKLVSUHVHQWVDVSHFLǮFFKDOOHQJHIRUVXEVHDSURGXFWLRQǯRZOLQHV7KHFRPELQDWLRQRIORZ WHPSHUDWXUHVDQGKLJKSUHVVXUHSUHVHQWRQWKHVHDEHGFDQUHVXOWLQK\GUDWHIRUPDWLRQRUZD[ GHSRVLWVLQVLGHǯRZOLQHVOLPLWLQJRUHYHQEORFNLQJWKHǯRZ6RPHPHWKRGVIRUǯRZDVVXUDQFH UHO\RQWKHUPDOLQVXODWLRQDQGFKHPLFDOLQMHFWLRQ%XWWKHGLVDGYDQWDJHLVWKDWWKH\UHTXLUH ODUJHDPRXQWVRIFKHPLFDOVWREHLQMHFWHGLQWRWKHZHOOVWUHDPZKLFKWKHQPXVWEHUHPRYHG WRSVLGHLQFUHDVLQJUXQQLQJFRVWVDQGHQYLURQPHQWDOULVNV $QRWKHUSRVVLEOHDSSURDFKIRUǯRZDVVXUDQFHLQYROYHVFRQWUROOLQJWKHWHPSHUDWXUHRQWKHSLSH GLUHFWO\(OHFWULFDOWHUQDWLQJFXUUHQWFDQEHSDVVHGWKURXJKWKHSLSHZDOOWKHSLSHDFWVDVD FRQGXFWRULQDVLQJOHSKDVHFLUFXLWDQGWKHUHIRUHKHDWLVJHQHUDWHGWRPDLQWDLQWKHǯXLGvV WHPSHUDWXUHDERYHFULWLFDOYDOXHVXVXDOO\DURXQG& Keywords (OHFWULFKHDWLQJSLSHKHDWLQJVXEVHDSRZHUV\VWHPǯRZDVVXUDQFH direct electrical heating (DEH) Products Used ANSYS® Maxwell® 15.0, ANSYS Simplorer® 10.0, ANSYS Fluent® 14, ANSYS Workbench™ 14 Description Electric heating of pipelines is attractive for long step outs, as running costs can be considerably lower compared to the expense of using chemicals. Three possible methods to heat pipe with electric current (Figure 1) are: s Pipe in pipe: closed-current loop into one pipe and return on other s Open loop: current loop into cable (piggyback cable) and return in pipe and seawater s Induction: three-phase cable with no return path, induced currents only 1 Direct Electrical Heating Pipe in pipe 2SHQORRS'(+ 7KHHǰFLHQF\RIWRWDOKHDWLQJWRGLVVLSDWHGKHDWRQWKHPDWHULDOFDUU\LQJ pipe varies for each of the above methods. Figure 2 shows results from 2-D electromagnetic simulation in which a power density of 85 W/m is used to heat the pipes. The current is varied until the same 85 W/m is achieved LQHDFKGHVLJQDQGWKHHǰFLHQF\LVPHDVXUHGE\WKHUDWLREHWZHHQSLSH losses and total losses. There are several challenges in electrical design of a DEH system, such as determining the power loss for a given input current and determining DEH electrical impedance for rating the top-side power supply. Induction )LJXUH9DULRXVGLUHFWHOHFWULFDOKHDWLQJFRQǮJXUDWLRQV Pipe in pipe $ǯRZOLQHFXUUHQW SHUFHQWHǰFLHQW 2SHQORRS'(+ $ǯRZOLQHFXUUHQW SHUFHQWHǰFLHQW Induction $ǯRZOLQHFXUUHQW SHUFHQWHǰFLHQW )LJXUH/RVVGLVWULEXWLRQVZLWKHǰFLHQFLHVIRUYDULRXV'(+ FRQǮJXUDWLRQVH[FLWHGWR:PRQSLSH )LJXUH&LUFXLWGLDJUDPIRUSRZHUGLVWULEXWLRQQHWZRUN ZLWKORDGEDODQFLQJDQGSRZHUIDFWRUFRUUHFWLRQIRU VLQJOHSKDVHRSHQORRS'(+FRQǮJXUDWLRQ 2 Applying ANSYS Maxwell, a user can: s Perform electromagnetic simulations of a 3-D model or 2-D cross s s section of the pipe cable considering nonlinear and frequencyGHSHQGHQWFKDUDFWHULVWLFVVXFKDVVNLQDQGSUR[LPLW\HǭHFWIRU GHWHUPLQLQJSRZHUORVVǮHOGGLVWULEXWLRQV Automatically extract the impedance matrix of a given cable structure for use in circuit simulation with the top-side power supply Parameterize geometry, input excitations, or materials, then sweep these variables to calculate losses vs. parameters curves, and compare GLǭHUHQWWRSRORJLHVVHDUFKLQJKLJKHǰFLHQF\GHVLJQV 2QFHWKHFDEOHWRSRORJ\DQGSRZHUUDWLQJVDUHLGHQWLǮHGWKHSRZHUVXSSO\ needs to be designed to guarantee that the DEH system will receive the correct amount of current. ANSYS Simplorer can be used to determine the necessary supply voltage considering the DEH impedance, and then size and rate passive electrical components to ensure correct phase balancing and power factor correction. Figure 3 shows a basic schematic for a given supply-DEH structure. A load-balancing network and power factor correction capacitors are designed to distribute current among phases and to increase power factor close as close to 1 as possible, respectively. Direct Electrical Heating )RUDǮQDOYHULǮFDWLRQRIWHPSHUDWXUHVLQFOXGLQJKHDWWUDQVIHULQWR WKHVXUURXQGLQJVHDZDWHUDFRPSXWDWLRQDOǯXLGG\QDPLFVPRGHO of the pipe can be coupled with the electromagnetics to predict the ǯRZOLQHWHPSHUDWXUH8VLQJWKHORFDOL]HGORVVGHQVLW\FDOFXODWHGE\WKH HOHFWURPDJQHWLFVROYHU$16<6)OXHQWVLPXODWHVWKHǮQDOWHPSHUDWXUH FRQVLGHULQJPDWHULDOSURSHUWLHVIRUDOOVROLGDQGǯXLGUHJLRQV)LJXUH 5 shows the resulting steady-state temperature for a given current and ambient conditions. )LJXUH0XOWLSK\VLFVVFKHPDWLFLQ$16<6:RUNEHQFKIRU FRXSOLQJHOHFWURPDJQHWLFORVVHVWRǯXLGǯRZIRUKHDWWUDQVIHU $16<6FRXSOHGǮHOGVROXWLRQVDUHXVHIXOIRUHǰFLHQWO\GHVLJQLQJ HOHFWULFDOO\KHDWHGǯRZOLQHVDQGHOHYDWLQJPXOWLSK\VLFVVLPXODWLRQWRD KLJKHUOHYHO8VLQJLWVEHVWLQFODVVIHDWXUHVRIHOHFWURPDJQHWLFVDQGǯXLG G\QDPLFVVRIWZDUHDXVHUFDQWRH[DPLQHǮHOGGLVWULEXWLRQFRPSDUH GHVLJQHǰFLHQFLHVFRQǮJXUHWKHEHVWRSWLRQVIRUWKHSRZHUVXSSO\V\VWHP GHWHUPLQHRSWLPXPSRZHUGLVWULEXWLRQZLWKGLǭHUHQWǯRZFRQGLWLRQVDQG perform studies on transient start-up or shut-down operations. Authors Leandro Percebon, [email protected] Ryan Magargle, [email protected] )LJXUH7HPSHUDWXUHZLWKVXUURXQGLQJVHDZDWHUFRQYHFWLRQIRU RSHQORRS'(+FRQǮJXUDWLRQ ANSYS, Inc. Southpointe 275 Technology Drive Canonsburg, PA 15317 86$ 724.746.3304 [email protected] © 2013 ANSYS, Inc. All Rights Reserved. 3 ANSYS, Inc. is one of the world’s leading engineering simulation software providers. Its technology has enabled customers to predict with accuracy that WKHLUSURGXFWGHVLJQVZLOOWKULYHLQWKHUHDOZRUOG7KHFRPSDQ\RǭHUVDFRPPRQ platform of fully integrated multiphysics software tools designed to optimize product development processes for a wide range of industries, including aerospace, automotive, civil engineering, consumer products, chemical process, electronics, environmental, healthcare, marine, power, sports and others. Applied WRGHVLJQFRQFHSWǮQDOVWDJHWHVWLQJYDOLGDWLRQDQGWURXEOHVKRRWLQJH[LVWLQJ GHVLJQVVRIWZDUHIURP$16<6FDQVLJQLǮFDQWO\VSHHGGHVLJQDQGGHYHORSPHQW times, reduce costs, and provide insight and understanding into product and process performance. Visit www.ansys.com for more information.