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Crude Oil Bath Heater Information

Bath Heater Location :- The bath heater installer in GGS is between the well header and the separator.

Crude Oil Bath Heater: Full Information

At the Group Gathering Station (GGS), crude oil is transported from the well head through pipelines that cover a maximum distance of 20 km, causing a significant drop in temperature. To ensure smooth flow and efficient separation, a bath heater is used to preheat the crude oil before it reaches the separator and heater treater. The bath heater maintains the oil temperature between 55°C and 65°C, preventing viscosity-related problems and ensuring optimal processing.

A crude oil bath heater works as an indirect heat exchanger with a fire tube that heats a surrounding water bath. The crude oil, which is waxy and thick when it arrives from the well, flows through a coil submerged in this bath, where it is warmed and thinned. This heating process prevents the oil from clogging in the pipeline, allowing it to flow smoothly to the next stages in the processing facility, such as the Gathering Station (G.G.S.). Crude oil is a complex mixture of hydrocarbons, primarily paraffins, naphthenes, and aromatics, along with trace elements like nitrogen, sulfur, and oxygen, and is refined into products like gasoline and jet fuel.

Bath heater real view

Crude oil bath heaters are widely used in the upstream, midstream, and downstream sectors, such as at refineries and compressor stations, to ensure oil and gas remain fluid during transportation and processing. By using an indirect heating method, crude oil bath heaters enhance safety and energy efficiency, reducing environmental impact and avoiding direct flame contact. With vertical cylindrical or box-type designs, these heaters ensure efficient heating of hydrocarbon fluids, maintaining oil and gas flow and enabling continuous processing while meeting eco-friendly standards.

Purpose of crude oil bath heater

Viscosity reduction: Crude oil often needs to be heated to reduce its viscosity. The low viscosity ensures that the oil flows smoothly, reducing the risk of pipeline blockage and simplifying pumping procedures.

Dehydration: Heating crude oil also helps to separate water and other impurities. This dehydration process is necessary to prevent corrosion in pipelines and equipment, ensuring that oil quality meets process requirements.

Emulsion Breakdown: Crude oil often forms emulsions, which are mixtures of oil and water. A bath heater helps break this emulsion, making it easier to separate the water from the oil before further processing.

Wax Prevention: In some reservoirs, crude oil may contain wax, which can solidify at low temperatures, leading to blockage. By keeping the oil warm, bath heaters prevent wax from solidifying in pipelines and equipment.

Applications in Oil Industry

Upstream Operations: Bath heaters are used in production facilities, particularly at wellheads, where crude oil is often heated before being transported.

Midstream pipelines: They ensure smooth flow in long-distance pipelines, especially in cold regions, preventing bottlenecks due to cold temperatures.

Downstream Refineries: In refineries, they help prepare the crude oil for various processing stages by maintaining the required temperature and viscosity.

Working principle of crude oil bath heater

Bath heaters work on a relatively simple principle:

Indirect Heating: Crude oil bath heaters generally use an indirect heating method to avoid direct contact between the flame and the oil. A heat transfer medium, such as water, glycol or thermal oil, is heated in a bath around the oil pipe, allowing for uniform temperature distribution without direct exposure to high temperatures.

Firetube Design: The firetube, which is a metal tube heated by a burner, passes through the bath. This firetube heats the bath medium, which in turn heats the crude oil flowing through the coil pipe immersed in it.

Controlled heating: These heaters are equipped with thermostats and control systems to monitor and maintain the temperature of the bath, preventing overheating and ensuring that the crude oil is heated within safe and efficient limits.

How it Works:

The heater consists of three main components:

• 1.Fire-tube – This is the heat source, submerged in a bath of a heat-conductive medium (usually water, glycol, or oil).

• 2.Bath – The heat-conductive medium transfers heat indirectly to the process fluid, avoiding direct flame contact.

• 3.Process Coil – Crude oil flows through coils submerged in the bath. The heat from the medium warms the oil, which is then ready for further processing.

Key Functions:

• Flow assurance: Prevents crude oil from thickening or solidifying, especially in cold climates or during transportation.

• Separation process: Helps in separating water, gas, and other impurities from crude oil.

• Temperature control: Maintains an optimal temperature for smooth flow and further refining processes.

• Safety: Reduces risks by heating oil indirectly, keeping it away from direct flame.

Applications:

• Crude oil processing and production facilities.

• Oil refineries.

• Pipelines and transportation networks.

• Separation units for gas, water, and oil.

Advantages of using a crude oil bath heater

Efficient Heat Distribution: Indirect heating ensures uniform temperature throughout the oil without the risk of burning or degrading the crude.

Low maintenance: Bath heaters are generally low maintenance, especially with automatic controls that keep heating efficient and safe.

Cost-effective: They consume less fuel compared to other heating methods, making them a cost-effective solution in the long run.

In summary, crude oil bath heaters are required to maintain temperature and flow in pipelines from production sites and processing facilities. They ensure oil quality, increase transportation efficiency and are important in the overall oil processing chain.

Know about bath heaters in oil and gas

Know about bath heaters in oil and gas real view

Water bath heaters (WBHs) are widely used in the oil and gas industry for indirectly heating oil or gas to temperatures between 130-150°F. These heaters are typically found in Group Gathering Stations (G.G.S.) where they preheat fluids, such as oil or gas, before further processing or transportation. A bath heater operates as a heat exchanger, featuring a fire tube with gas combustion, surrounded by water, and a coil through which crude oil passes to be heated.

WBHs are used indirectly through a bath, which promotes uniform heating and reduces the chance of hotspots, as opposed to direct fire-tube heaters that heat directly by flame or furnace.

Heat Transfer Fluids: Transfer fluids are used to transfer heat between different parts of an oil and gas production system. Bath heaters are used to heat these fluids to the desired temperature, which helps ensure efficient operation of the system.

Regeneration gas heating: Regeneration gas is used to regenerate ion exchange resins, which are used to remove impurities from oil and gas. Bath heaters are used to heat the regeneration gas to the desired temperature, which helps ensure efficient operation of the regeneration process.

Evaporation and Superheating of LPG and LNG: LPG and LNG are Liquefied Petroleum Gas and Liquefied Natural Gas respectively. They are vaporized and superheated using a bath heater to make them easier to transport and use.

Heating sensitive gases and liquids: Some gases and liquids are sensitive to heat and can be damaged if heated too much. Bath heaters are used to heat these gases and liquids to the desired temperature while minimizing the risk of damage.

WBHs are used for a variety of applications, including:

• Heating process fluids.

• Heating crude oil.

• Vaporizing and superheating LPG and LNG.

• Regeneration gas heating.

• Heating heat transfer fluids.

• Heating heat sensitive gases and fluids.

• Preventing hydrate formation.

Here are some details about bath heaters in oil and gas:

• Bath heaters typically consist of a heated bath solution, a process coil, and a burner.

• The bath solution is heated by the burner, and the heat is transferred to the process coil.

• The process coil is then used to heat the process liquid or gas.

• Bath heaters can be used to heat a wide range of temperatures, from room temperature to over 1,000 degrees Fahrenheit.

• Bath heaters are typically used in closed systems, which helps to prevent the escape of hazardous gases.

Bath Heater normal diagram

Bath Heater normal diagram

The main parts of a bath heater used in oil and gas are:

• Bath Solution: Bath solution is the liquid that is heated by a burner. The type of bath solution used depends on the application. For example, water is often used as a bath solution for heating transfer fluid, while molten salt is often used to heat LPG and LNG.

• Process Coil: Process coil is a tube that is immersed in the bath solution. The process fluid flows through the process coil, and heat from the bath solution is transferred to the process fluid.

• Burner: A burner is used to heat the bath solution. The type of burner used depends on the application. For example, natural gas burners are often used to heat transfer fluids, while propane burners are often used to heat LPG and LNG.

• Control System: The control system is used to control the temperature of the bath solution. The control system usually includes a temperature sensor, a controller, and a heater.

In addition to these main parts, bath heaters may also include other components, such as a heat exchanger, a safety valve, and a pressure relief valve. The specific components included in a bath heater depend on the application and the manufacturer.

There are Several Types of Bath Heaters, Including:

1. Direct-fired bath heaters:

These heaters use a flame to heat the crude oil directly. The fire is created by consuming a fuel, like petroleum gas or propane, and the intensity is moved to the unrefined petroleum by direct contact. These heaters are commonly used in remote locations where electricity is not available.

2. Indirect-fired bath heaters:

These radiators utilize an intensity exchanger to move intensity to the raw petroleum.The heat exchanger is heated by a flame, steam, or hot water, and the crude oil is pumped through the heat exchanger, where it is heated. These heaters are commonly used in locations where electricity is available

Indirect-fired bath heaters, also known as process bath heaters, are used in the oil and gas industry to heat process fluids, such as crude oil and natural gas. They are installed at the well head, upstream of gas turbines, and at power generation locations. Indirect-fired bath heaters are made up of a burner-heated fire tube system and a manifold coil that contains the fluid to be heated. The coil is submerged in a bath of water or a water glycol mix, which acts as a medium to transmit heat from the burner to the gas.Some features of indirect-fired bath heaters include: Customized manufacturing and installation, Automation capabilities, and Burner options. 

03. Electric bath heaters:

These radiators utilize electric obstruction components to warm the raw petroleum.The electric resistance elements are located inside the bath heater tank and the crude oil is pumped through the tank, where it is heated. These heaters are commonly used in locations where electricity is available and natural gas is not.

The selection of the right type of bath heater depends on the specific requirements of the application, including the required temperature, the type of crude oil being pumped, and the availability of fuel and electricity. Factors such as cost, maintenance requirements and safety must also be considered.

Shower radiators are basic parts of the raw petroleum creation and transportation framework, and their dependability and proficiency are fundamental to guarantee the smooth and safe activity of the whole presentation process. Lately, innovation headways have considered the utilization of computerization, digitalization, and information examination to work on the presentation and diminish margin time of these warmers.

Outline of the Bath Heater Cycle:

 Indirect internal Bath heater system

Fluid Entry:The fluid component, such as oil or gas, enters the Bath Heater from the G.G.S. The fluid may need to be heated to a specific temperature for various reasons, including reducing viscosity, preventing the formation of hydrates, or meeting transportation specifications.

Heat Transfer Medium: A heat transfer medium, such as thermal oil or glycol, is circulated within the Bath Heater. The heat transfer medium is heated externally using burners or other heat sources, and it transfers heat to the fluid component through a heat exchanger.

Heat Exchange:The intensity move medium courses through the intensity exchanger, while the liquid part goes through a different way inside the radiator. The intensity exchanger considers productive intensity move between the two streams without direct contact.

Temperature Control:The Bath Heater is equipped with temperature control systems to maintain the desired temperature of the fluid component. This can be achieved by controlling the flow rate of the heat transfer medium or adjusting the burner output.

Combustion System:The Bath Heater includes a combustion system, typically fueled by natural gas or other hydrocarbon fuels, which provides the heat for the heat transfer medium. The combustion system is carefully controlled to ensure safe and efficient heating.

Bath Heater Fire Tube  

Emissions Control:Bath Heaters often have emission control measures in place to minimize the release of pollutants into the environment. These may include the use of low-emission burners, combustion air preheating, or the installation of emission control devices such as selective catalytic reduction (SCR) systems.

Safety Systems:Bath Heaters incorporate various safety features to protect against potential hazards. These may include flame detectors, temperature and pressure sensors, emergency shutdown systems, and fire protection measures.

Outlet and Further Processing:Once the fluid component has been heated to the desired temperature, it is discharged from the Bath Heater and directed to the next stage of processing, such as separation vessels, storage tanks, or transportation systems.

It's important to note that the specific design and configuration of Bath Heaters can vary depending on factors such as the fluid properties, required heating capacity, safety considerations, and operational requirements of the G.G.S.

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