To address flow assurance challenges, Integrated Production Bundle (ETH-IPB) and Heating Cables Replacing Armour Wires (ETH-HCRAW) have been developed. These two technologies use electrical cables, which provide heat to the fluid by Joule effect. They are different in their design, efficiency and cost, and thus on their application domains. This paper details the design, the qualification and the identified envelop of use of the ETH-HCRAW. The pioneer flexible pipe with active heating technology was ETH-HCRAW, i.e. flexible pipe with electrical cables integrated in the tensile armour layers for active heating and such application is developed in the paper. The integration of the active heating in the flexible and the terminations is presented. The overall qualification of this technology is described considering two different levels. Firstly, the qualification of the components of the electrical system through extensive electrical and mechanical tests is developed. Then, the global mechanical behavior and the reliability of the overall system are demonstrated by a phase of full scale tests. Such solution based on integrated electrical cables has been demonstrated to be a safe and effective technology for active heating on flexible pipe through dedicated R&D development back in the early 2000’s. This paper presents the latest developments that enable to position the ETH-HCRAW technology as leading solution for active heating with the advantages of flexible pipes. ETH-HCRAW facilitates the exploitation of deep water projects and long tie back by limiting the temperature losses along the lines. Active heating, by increasing the temperature of the fluid, enhances flow assurance for complex and viscous fluids by reducing the viscosity and reduces wax appearance in the lines. Finally, this technology tackles the formation of hydrates by maintaining a minimum temperature during shut down and start-up phases allowing to remain outside the hydrate formation conditions. ETH-HCRAW is an attractive and cost effective active heating solution with a broad possible domain of application. This technology offers many advantages in terms of flexibility of operation especially for hydrate and wax management. This paper details the numerous advantages and the limitations of this technology compared to other active heating technologies.
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