Power regulators for electric heaters
In the petroleum industry, where efficiency and responsibility in resource extraction are crucial, power controllers play a key role. CD Automation offers an advanced line of thyristor units and SCR power controllers designed to easily handle both simple and complex heating applications. These technologies improve the efficiency of electrical heating systems, essential for thermal processes in the oil and gas industry.
New electric heating technologies can enable significant improvements in the decarbonisation of processes, helping to reduce consumption and improve power quality. CD Automation supports its partners in electrifying applications, offering solutions that reduce operational complexity and improve energy efficiency.
Our products include static power units, temperature controllers and supporting software for thermal process control. With these solutions, oil companies can achieve greater operational efficiency and reduce their environmental impact, while maintaining high standards of quality and reliability.
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Oil & Gas Industry: CD Automation offers state-of-the-art power controllers for heater management
In the Oil & Gas industry, CD Automation offers state-of-the-art solutions for the management of electric heaters through the REVO S and REVO C product families. These power controllers and thyristor units are designed to improve the efficiency and performance of industrial machinery.
REVO S Family
The products in the REVO S family are actuators operating in open loop, ideal for maintaining the required set by compensating for fluctuations in mains voltage. These power regulators are CE certified and can be supplied with cUL us certification up to 700A. They support maximum voltages of 480V, 600V and 690V and a short-circuit current of 100kA. They offer load diagnostics and support zero-crossing logic inputs. In addition, they are compatible with the use of diesel generators thanks to the Soft Start 1-3PH functionality.
REVO C Family
The power controllers of the REVO C family are extremely versatile, suitable for single-phase (1PH) and three-phase (3PH) applications. These devices not only maintain the required set by compensating for mains voltage fluctuations, but also offer advanced functions such as ramp starting in phase angle, control of inductive loads or transformer primaries with current limitation and phase angle switching. They are CE certified and can be cUL us certified up to 700A and UL certified from 800A to 2100A. Supported voltages are 480V, 600V and 690V, with a short-circuit current of 100kA. In addition, REVO C offers advanced connectivity options such as Bluetooth, Modbus RTU, Profibus, Profinet and Ethernet IP, as well as a Bake Out function to remove moisture from insulated resistors.
The REVO C family is particularly suitable for solving peak power and poor power factor issues, making it ideal for generator applications.
REVO S and REVO C in comparison
Product type
Actuator, works in open loop.
Power controller maintains the required set by compensating for mains voltage fluctuations
CE Certification
Yes
Yes
cUL us or UL certifications
Option until 700A
cUL us Option until 700A, UL Option from 800A to 2100A
Max voltage
480, 600 and 690V
480, 600 and 690V
100KA Short Circuit Current
Yes
Yes
Bluetooth & smartphone App
No
Option
Ideal with Diesel generators
Yes, with Soft Start 1-3PH
Load Diagnostics
Yes
Yes
Digital Input and Zero Crossing
Yes
Yes
Analog Input and Burst Firing
Option, settable in the factory
Yes, settable from PC or Keypad
Ramp and start in phase angle
No
Yes, settable from PC or Keypad
Control of inductive loads or primary loads
No
Yes, 1-3PH with current limit and phase angle firing
Local operator panel
No
Option
Configurator software PC for remote assistance and analysis
No
Yes
Modbus RTU
No
Standard
Profibus, Profinet, Ethernet IP
No
Option
Retransmission
No
Option
Bake Out
No
Yes (1-3PH)
BAKE OUT function against humidity
The isolated MgO type heating elements, if not used for a long period of time (or if left in storage for a long period), can absorb humidity. If maximum power is applied to the elements, excessive current can damage them or blow fuses to protect the unit.
With the BAKE OUT function present on the new REVO C 1PH and 3PH it is possible to start the firing gradually, so as to remove the humidity present on the heater and avoid damage.
UL508 Listed for greater fire safety
The REVO S and REVO C single-phase and three-phase series up to 600V, can be purchased with the UL 508 certification, this allows to reduce the associated costs of plant certification and shorten project realization times. On these units the short-circuit current is 100kA.
Why choose CD Automation SCR units for the oil and gas industry
CD Automation’s SCR units offer advanced and reliable solutions for the oil and gas industry, optimising energy efficiency and ensuring precise control of electric heaters in demanding applications. Discover why these units are the ideal choice to improve the performance and safety of your industrial processes.
- 1Power and safety
When converting a process to electric heaters, it is crucial to ensure that they can provide the necessary power to meet temperature requirements. Precise heater control is essential to run processes safely, preventing overheating and protecting equipment and operators.
- 2Flexibility
During commissioning, unexpected application needs may emerge, such as changes in functional requirements compared to the initial design. Discovering that control panel components are ‘rigid’ can complicate the rapid adaptation of the system to the new requirements. System flexibility is therefore essential to meet these challenges, allowing modifications and adaptations without significant delays, while ensuring efficiency and business continuity.
- 3Effective service
In large systems, with units between 200 and 2000 A, maintenance can be complicated. Conventional units are often difficult to replace. However, CD Automation systems offer modular and easily removable components, simplifying maintenance and reducing downtime, improving operational efficiency.
- 4Remote access
Thanks to secure remote access systems, it is possible to monitor temperature control and check the operation of all components. In the event of malfunctions or misalignments, action can be taken in real time, resolving problems quickly and ensuring continuous and efficient operation of the system.
- 5Compactness
Reducing space and simplifying installation is crucial for operational efficiency. With power units equipped with integrated fuses, up to 50 per cent of the physical space occupied by the cabinet can be saved, making installation neater and more compact. In addition, multi-zone units significantly reduce the number of wires required. Each resistor can be connected directly to the unit’s output, simplifying wiring. Digital communication allows more variables to be monitored than analogue retransmission, improving efficiency and facilitating system management.
- 6Power optimization
To avoid disturbance generation in the network, we use Dynamic Burst Firing technology. When using many electric heaters, it is essential to synchronise the switching on. This keeps the total power input as constant as possible, avoiding peaks that can cause inefficiencies and stability problems. Synchronising the ignitions ensures a uniform energy flow, improving system reliability and reducing the impact on electrical components. With these solutions, we optimise the use of power, ensuring more stable and efficient operations.
CD Automation static units can regulate power in the following applications, which use heating elements
Power controllers for Midstream process applications
Circulation heaters for pipelines, immersion heaters for pumping and compression systems, electric heating systems for large storage tanks, electric vaporizers for gas stabilization and conditioning, explosion-proof heaters for classified areas, and pre-assembled heating skids for fluid treatment and transfer units.
Oil conditioning
- Heating of crude oil in the wellhead to increase viscosity
- Heating of suction lines in storage tanks
- Fuel transport for boiler or turbine
- Used oil heating
Oil splitting and polymerization
- Regeneration of the continuous catalyst
- Control of the temperature of the reactor catalyst beds
- Hydrotreating
- Hydrocraking isomerization
- KO / Flare Drum Vapor / Liquid separator
- Conditioning of fuel gas for auxiliary start-up systems for boilers and gas turbines
Gas treatment
- TEG, MEG Dehydration
- Natural gas heating to avoid freezing before pressure reduction (compression and dosing stations)
- Liquefied natural gas heating and vaporization
- Gaseous / amine gas treatment
- Molecular sieve regeneration
- Gas dehydration unit
- Sulfur recovery unit
Oil conditioning
- Heating of crude oil in the wellhead to increase viscosity
- Heating of suction lines in storage tanks
- Fuel transport for boiler or turbine
- Used oil heating
Oil splitting and polymerization
- Regeneration of the continuous catalyst
- Control of the temperature of the reactor catalyst beds
- Hydrotreating
- Hydrocraking isomerization
- KO / Flare Drum Vapor / Liquid separator
- Conditioning of fuel gas for auxiliary start-up systems for boilers and gas turbines
Gas treatment
- TEG, MEG Dehydration
- Natural gas heating to avoid freezing before pressure reduction (compression and dosing stations)
- Liquefied natural gas heating and vaporization
- Gaseous / amine gas treatment
- Molecular sieve regeneration
- Gas dehydration unit
- Sulfur recovery unit
Frequently Asked Questions about SCR Power Controllers for Oil & Gas Applications
Why are SCR Power Controllers used in Oil & Gas applications?
SCR Power Controllers (Thyristor Power Controllers) provide precise control of the electrical power supplied to industrial heaters used in Oil & Gas processes. They are employed to improve temperature stability, increase energy efficiency, reduce energy consumption, and ensure reliable operation in critical applications such as gas treatment, crude oil heating, LNG systems, reboilers, process skids, and heat tracing systems.
Which Oil & Gas applications use SCR Power Controllers?
SCR Power Controllers are used in a wide range of Oil & Gas applications, including:
- Immersion Heaters
- Circulation Heaters
- Tank Heating Systems
- Natural Gas Treatment and Conditioning
- TEG and MEG Dehydration Units
- Molecular Sieve Regeneration
- LNG Vaporizers
- Pipe and Valve Heat Tracing
- Electric Reboilers
- Process Skids
- Offshore Platforms and Onshore Facilities
- Heating Systems for Viscous Fluids and Bitumen
What are the benefits of electric heating in the Oil & Gas industry?
Electric heating provides more accurate temperature control than conventional combustion-based heating systems. In addition, it supports plant electrification and decarbonisation strategies by reducing direct emissions and improving the overall energy efficiency of the process.
Which CD Automation Power Controller is most suitable for Oil & Gas applications?
The choice depends on the load type and plant requirements:
- REVO S is ideal for standard applications with resistive loads.
- REVO C offers advanced features such as Fieldbus communication, closed-loop control, current limitation, extended diagnostics, and management of more complex loads.
- REVO PN and REVO PC are suitable for multi-zone architectures and plants requiring a high level of integration with industrial automation systems.
What is the difference between Burst Firing and Phase Angle control in the Oil & Gas industry?
Burst Firing control regulates power by switching complete cycles of the mains supply and is particularly suitable for resistive loads with high thermal inertia.
Phase Angle control regulates power within each half-cycle of the mains supply and provides a faster response, making it ideal for applications requiring precision, current limitation, or the management of transformers and inductive loads.
The choice depends on the type of heater and the process requirements.
Why is Current Limit important for electric heaters in Oil & Gas applications?
Many heating elements exhibit high current demand during start-up, especially when cold. The Current Limit function helps reduce inrush current, protect heating elements, preserve fuses and circuit breakers, and improve the stability of the plant electrical network.
What is the Bake Out function and why is it useful for industrial heaters?
Heating elements insulated with magnesium oxide (MgO) may absorb moisture during long storage periods or extended shutdowns. The Bake Out function available in REVO C gradually increases the power applied to the heater, removing moisture without damaging the heating elements or causing electrical protection devices to trip.
Can SCR Power Controllers be integrated with PLCs, DCS and SCADA systems?
Yes. CD Automation Power Controllers support industrial communication protocols such as Modbus RTU, Profinet, Profibus and EtherNet/IP, enabling integration with PLCs, DCS systems, SCADA platforms and Industry 4.0 monitoring and diagnostic systems.
Are CD Automation Power Controllers suitable for offshore applications?
Yes. Offshore applications require high reliability, management of large electrical loads, and integration with systems designed for harsh environments. CD Automation SCR Power Controllers are commonly used to control process heaters, tanks, HVAC systems and utilities installed on offshore platforms and floating units.
Which certifications are available for Oil & Gas applications?
REVO S and REVO C families are available with CE, cULus and UL certifications for numerous configurations. These certifications help panel builders and OEMs simplify the approval and compliance processes required for international Oil & Gas projects.
How can SCR Power Controllers improve energy efficiency in Oil & Gas plants?
An SCR Power Controller optimises the energy supplied to electric heaters according to the actual process demand. This helps reduce energy waste, improve product quality, maintain more stable temperatures, and lower plant operating costs.
Why choose CD Automation Power Controllers for the Oil & Gas industry?
CD Automation Power Controllers offer:
- Precise temperature control
- Management of loads up to 3000 kW
- Advanced firing modes
- Load and SCR diagnostics
- Industry 4.0 communications
- Bake Out and Current Limit functions
- High reliability for critical applications
- Specialised technical support for OEMs, EPC contractors and end users in the Oil & Gas industry
These features make CD Automation Power Controllers an effective solution for electric process heating applications in the Oil & Gas sector
