SKIN-SYSTEM

(SKIN-EFFECT BASED HEATING SYSTEM FOR LONG PIPELINES)

1. Destination of the skin-system
SKIN-SYSTEM also referred as Induction-Resistance Heating System (IRHS) is designed for heating,
temperature maintenance, and frost protection of pipelines of various purpose having length 2 to 200km
and more. The purpose of heated pipeline can be any, but among the basic types the following should be
outlined:
-

water conduits (at gas field development and operation);

discharge pipelines (transporting crude oil);
sulfur lines (transporting liquid sulfur);
pipelines transporting viscous chemical substances
(in-plant interdepartment pipelines of chemical and petrochemical enterprises).

2. Design styles of the skin-system

Depending on operating temperature and maximum allowable pipeline temperature three design styles
of the skin-system can be outlined:
1.

low-temperature;
maintaining temperature 3 to 5C;
basic destination frost protection of water conduits;

2.

medium-temperature;
maintaining temperature up to 60C;
basic destination crude oil transporting pipelines;

3.

high-temperature;
maintaining temperature up to 200C;
basic destination pipelines transporting viscous oil products, sulfur, chemical substances.

Design styles depending on type of pipelining are as follows:

- above-ground;
- buried (subsurface, underground);
- subsea (submarine, underwater).
One system can include combination of various design styles, e.g. in the case of passing above roads
and passages (above-ground) or under rivers (underwater). Each of these style requires special
decisions and materials used. Method of pipeline insulation is an important factor. It can be:
- preinsulation (factory insulation) of pipeline fragments;
- sectional insulation at site.
Depending on required heating power skin-systems consisting of 1, 2, or 3 heating elements (tubes) are
used.

3. Description of the skin-system and principle of its operation

Special heating elements are used in the SKIN-SYSTEM that operation is based on skin-effect (proximity
effect) in ferromagnetic conductive materials on alternative current of commercial frequency (50Hz).
The heating element is specially treated tube of low-carbon steel having 20 to 60mm outer diameter and
wall thickness not less than 3mm with special conductor of non-magnetic material (copper or aluminum)
having 10 to 50mm2 cross section placed inside. The conductor is reliably connected to the steel tube at
far end of heated pipe run; at near end of the run alternative voltage is supplied between the conductor
and the tube that value is calculated basing on power output needed and the length of the heated pipe
run.

When the voltage is supplied in this manner, the current in copper conductor flows in one direction and
returns
through
the
steel
tube
in
the
opposite
direction.
The alternative current flows through the whole cross-section of the inner conductor because on
commercial frequency there is no noticeable skin-effect in non-magnetic material having low electrical
resistance. In contrast, in ferromagnetic outer conductor (steel tube) skin-effect is pronounced, i.e. the
whole current flows not in the whole depth of the tubes wall but in thin surface layer about 1 mm thick.
At that this current conducting layer is situated at the inner surface of the steel tube.
As described above, the current flows in inner surface of the skin heaters tube, in its outer surface the
current is virtually absent and there are no electrical potentials that makes the system safe for
maintenance staff. This effect allows to earth the tube at any place. The tube is obligatory earthed at the
near
and
at
the
far
end
of
the
heating
circuit.
When the system is powered by high voltage (3 to 5kV) heat output occurs in both conductors. If the
system is properly designed, 60 to 80% of heat output takes place in the steel tube, and only 20 to 40%
in
the
inner
(copper)
conductor.
Electrically the skin-system is arranged to ensure continuity of both the inner conductor (skin conductor)
and the tube of the skin heater being the return conductor of the system.

4. Advantages of the skin-system

Virtually the only economically sound method of heating pipelines having length 5 to 6km and
more.
Lower investment cost as against other heating systems for pipelines. Even for pipelines 3 to
5km long the cost of the SKIN-system is still comparable with that of other applicable heating methods
(serial-resistance or self-regulating heating cables).
Long lifetime because heavy-gauge skin conductor in the SKIN-system is released from heat
generation function and is practically used as built-in parallel power supply line. Metal heating tube is
also long lived in case of proper treatment since it is installed under a layer of thermal insulation and

protective casing of the pipeline. Solid heat-producing elements in the form of steel tubes provide
mechanical stability and protect current-carrying conductors from damage. Operating lifetime of the
SKIN-system is not less than 25 years.
Electrical and explosion safety. Outer surface of heat-producing element (skin tube) has zero
potential to ground, the tube is earthed and completely screens and protects the current carrying skin
conductor. Properly designed connections, pull boxes and connection boxes also provide system safety.
Good thermal contact provided. Metal heat-producing element (skin tube) is directly welded to the
product transporting pipeline or is fixed to it by means of special element. Special heat conducting paste
is used to improve heat transfer from the skin tube to the heated pipeline.
Balancing of currents. Supply unit patented by SST LLC is used in power supply system that provides
balance in primary three-phase network when feeding single- and two-phase induction-resistance load.
Using this unit solves phase unbalance problem uneven current distribution to phases). Phase unbalance
is principal defect of all single- and two-phase systems installed up to now.
Simple installation. Heat producing elements have no outer electrical isolation that can be damaged at
installation. To ensure supplementary protection of the conductor corrugated polymer tube is
preliminarily pulled into the SKIN-tube. At that force required for conductor pulling into the tube is also
reduced (the method is patented).

3. The equipment being delivered

The set of equipment being delivered for electrical heating system installation includes all materials and
equipment required for system installation and connection.
Skin-conductor (induction-resistance conductor, IRC) is highly reliable stranded copper conductor
manufacturing specially for skin-systems. The conductor has double isolation made of thermal-resistant
materials. Its operating lifetime is at least 25 years.
Skin-heater (induction-resistance heater, IRH) or SKIN tube is metal ferromagnetic tube having
normalized value of magnetic permeability. The tube is delivering ready to install. Its operating lifetime
is at least 25 years.
Fixing of the skin tube to the main pipe is performed with the help of point welding (if this welding is
permitted) or with collar clamps by means of special tool. The method of fixing is determined after
consultation with the customer.
Connection boxes are used for facilitation of pulling of the skin-conductor into the skin tube and for
installation of connection couplings between sections of the skin-conductor.
Connection couplings of the skin-conductor are multiplayer highly reliable high voltage connecting
elements used for connection of sections of the skin-conductor.
Step down transformer - single-, two-phase step down transformers are used that are specially
manufactured for the specific project.
Control cabinets are designed for giving out signals controlling heating system turn ON and OFF and for
system parameters monitoring. Control of temperature parameters is performed by means of air
temperature sensors and heated pipeline temperature sensors using PSTAB multifunction controller. The
remote control panel provides the possibility to get information regarding skin-system condition and to
send it to dispatching point. Control system permits to optimize electric energy consumption depending
on the ambient air temperature.
Packaged Transformation Substation (PTS) for system power supply (delivering by additional order) is
designed for installation of the step-down transformer and also protection devices and system start up
devices from both high voltage and low voltage sides. The PTS has modular closed design, the
equipment inside is protected against atmospheric impact. Spare pats for electrical heating system and
special installation tools can be included in the delivery by additional agreement.
Balancing unit is additional high voltage device using as a part of single-tube skin systems that allows to
connect them to industrial three-phase networks without overloading of some individual phases.

SPECIFICATION
Operating temperature range

- 50 C to +200 C

Electrical power supply

up to 4.0 KV, 50Hz

Linear heat output

up to 100 W/m for one heating element

Construction:
Heat-producing element

urrent-carrying conductor
Anticorrosion protection of the skin heater
Pulling and connection boxes
High voltage connectors
Completed Packaged Transformation
Substations(PTS)
Balancing equipment
Thermoconductive paste

Tube of low-carbon steel,having diameter 20 to

60mm, wall thickness 2.5 to 4mm, its
electrophysical parameters being tasted and
stabilized
Special conductor with high voltage(up to 4 kV)
endurance resistant to thermal load (up 200 )
and to mechanical loadings during installation
Painting, epoxy or other coating (at the request
of the customer)
Protected rooms for special transformers and
devices for regulation,control and communication

Heating of return bend

Heating of expansion-pipe

Heating arrangement in near-support

region

Heating of pipe branching by the

SKIN-system

Connection box

Installation of clamps

Heating system simulation

Cable production plant

Control cabinets assembling

Braiding machine in SST LLC factory

Thermostat circuit boards

Test specimen of the SKIN-system

Demonstration of pipe fragment heated by SKIN-system

The installed SKIN-system

Dear Sirs! We ask you to fill-in and forward to our address this form, where to indicate the parameters
needed for design of Skin-effect based heating system for PIPELINE.
The Customer

Company
Name

Fax

Name
Site(location)
Design
documentation
Object to be heated available
Design work required

Heating system
purpose

Installer
Responsible
representative
Freeze protection
Anti-condensation
heating
Temperature maintenance

Tel

Initial heating
Temperature
conditions

C Temperature required
C Minimum ambient temperature

Tel

C Maximum ambient temperature

C Normal processing temperature
C Maximum processing temperature
C Maximum permissible product temperature
C Minimum cut-in temperature

Streaming

Yes

No

Outdoor

Maximum temperature of steam

Buried

Submerged

Other

Pipeline location
depth of laying:

Mineral wool (mats)

Thermal insulation

Installation of
thermal insulation

Mineral wool (tubes)

Polyurethane foam

Thermal conductivity factor at +10C

C
Pre-insulated pipes

At site

Diesel generator

Power supply
prameters

Other

Supply voltage

Power transmission line

Other

Nimber of phases

Frequency

Hz

W/m

from one end

from both ends

other

feed points location

distance from feed point to the pipeline
Area classification
Pipe material

not explosive
Carbon steel

explosive
Plastic

Ctainless steel

Other

Designation of line Pipe diameter, mm Heat-insulation thickness

Pipelines parameters

Valve gates, pcs.

Flanges, pcs

Supports, pcs

Submit

Tel/fax +7(495) 728-80-80, 627-72-55

E-mail: info@skin-trace.com

Pipe length, m