Introduction

In the  oil and gas industry, immersion heaters play a crucial role in maintaining optimal temperatures for various processes. Marathon thermal solutions support original equipment manufacturers (OEMs), after-treatment system integrators, retro fitters of over-the-road, medium and heavy-duty vehicles, and off-road construction. Integrated with application-specific sensors, controllers, control panels and heater components, it is an ideal solution for processing oil and gas. Understanding the different types of immersion heaters used in this sector is essential for efficient operations and enhanced productivity.

From heating plain water to corrosive solutions, highly viscous oils, and many specialized applications such as high-pressure and hazardous locations, immersion heaters are one of the most important sources. Based on the principle of direct heating, you can quickly attain the required temperatures, whether you use a flanged or screw plug. They have a lot of importance in almost every industry where companies need fast heating-up time. Immersion heaters also help keep liquids above freezing temperature, especially in winter when fluids freeze faster and maintaining their condition becomes difficult.

Types of Immersion Heaters Used in Oil and Gas Industries

1.  Flanged Immersion Heaters

a. Description:  Flanged immersion heaters are commonly used in oil and gas applications due to their ease of installation and high heating capacity. Flanged immersion heaters are useful for water-based, chemical, and petroleum industries to directly transfer heat to the liquid. ANSI-rated flange provided with bugle tubular elements or many hairpin elements maintains the desired temperature. A thermocouple or RTD often maintains the desired target temperature within the bundle of elements.

b. Benefits: Provide quick and uniform heating, are suitable for high-pressure environments, and are compatible with a wide range of fluids. For instance, steel flanges are used for deionized water, lubricant oils, heavy and light oils, waxes, as well as mildly corrosive liquids and low-flow gas and water tank heating.

2.  Circulation Immersion Heaters

a. Description: Circulation immersion heaters are designed to heat fluids as they pass through the heating element, ensuring efficient heat transfer. A circulation heater (a.k.a. inline heaters) is basically an immersion heater covered by an anti-corrosion metallic vessel chamber. It is accompanied by a National Pipe Thread (NPT) screw plug or ANSI flange heater assemblies mated with a pressure vessel. The vessel is mainly used to provide insulation to prevent heat loss in the circulation system.

b. Benefits: Ideal for applications requiring precise temperature control, uniform heating, and consistent circulation of fluids. Heaters are ideal for processing fluid, including hazardous liquids that require intermediate heating while maintaining viscosity and flow rate, waste oil, steam, gases, and liquids like deionized water for the semiconductor and electronics industries.

3. Over-the-Side Immersion Heaters

a. Description: Over-the-side immersion heaters are mounted over the side of a tank or vessel, making them easy to install and remove. Over-the-side immersion heaters are installed where holes or spaces are not available for insertion in the medium. Famed for practical, commercial, and economic purposes, these heaters are available in different sizes and shapes to complement the requirements of the customer. It consists of multiple tubular elements and a precision instrument that holds the temperature probe. Control panels can also be used with high-limit controllers to help stabilize temperatures for improved performance.

b. Benefits: Suitable for applications where tank access is limited, provide a cost-effective heating solution, and can be customized for various tank sizes.

4. Screw plug heater

a. Description: Screw plug immersion heaters are the easiest source to heat liquids in small containers. Digital controllers or thermostats are normally used to sustain the target temperature with effectiveness and accuracy. Screw Plug Heaters are a smaller version of Immersion Heaters in which the heater flange is replaced with a threaded plug. Used as a direct heating element.

b. Benefits: They are ideal for heating gases and liquids in tanks or vessels, process water heating, oils, and heat transfer processes, and heating flammable liquids or gases that require explosion proof housing.

Applications in the Oil & Gas Industry

The oil and gas sector has undergone significant transformations in recent years, both onshore and offshore. Innovations have revolutionized the industry, enabling the extraction of resources more efficiently, even in remote locations and at greater depths. Advanced thermal technology solutions play a crucial role in supporting these innovations, benefiting the entire oil and gas supply chain. High temperatures are essential in petrochemical processes to maintain viscosity in external environments and in various processing applications.

Key Applications Include:

1. Offshore Drilling

Offshore drilling operations rely on advanced thermal technology solutions to maintain optimal temperatures in challenging marine environments. Immersion heaters are often used to heat fluids and maintain viscosity in offshore drilling applications.

2. Onshore Drilling

Onshore drilling sites also utilize thermal technology solutions to heat fluids and maintain operational efficiency. Immersion heaters play a vital role in heating fluids during the drilling process, ensuring smooth operations on land-based drilling rigs.

3. Downhole Heating

Downhole heating is essential in oil and gas extraction processes to optimize production rates and enhance recovery from reservoirs. Immersion heaters are deployed downhole to heat the surrounding formations and reduce the viscosity of the oil, facilitating its flow to the surface.

4. Hydraulic Fracturing

Hydraulic fracturing, a technique used to stimulate oil and gas production from reservoirs, requires precise temperature control. Immersion heaters are employed to heat fracturing fluids, ensuring optimal viscosity and enhancing the effectiveness of the fracturing process.

Factors to Consider When Choosing an Immersion Heater

• Temperature Requirements: Select an immersion heater that can achieve and maintain the desired temperature range for the specific oil and gas application.
• Material Compatibility: Ensure the heater material is compatible with the fluid being heated to prevent corrosion and contamination.
• Heating Element Design: Consider the design of the heating element (such as open coil or tubular) based on the heating requirements and environmental conditions.
• Power Rating: Choose an immersion heater with the appropriate power rating to meet the heating demands of the application.

Conclusion

Understanding the different types of immersion heaters used in the oil and gas industries is essential for selecting the right heating solution for specific applications. By considering factors like heating capacity, installation requirements, and material compatibility, companies can optimize their processes and enhance operational efficiency.

Explore more about industrial heaters at Marathon Heater and experience the innovation in heating and sensing technologies.

Contact us at enquiry@marathonheat.com for your requirements for any industrial heater.