Winterization Design Guide

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PROCESS TECHNOLOGY PROCEDURES
OF
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52
PREPARED BY
DATE
W. McMechen
13 November 2003
APPROVED BY
DEPARTMENT:
PROCESS ENGINEERING
A. Bourji
SUBJECT:
WINTERIZATION DESIGN GUIDE
REVISION DATE
30 June 2004
REV.
Table of Contents
1.0 SCOPE.............................................................................................................................1
2.0 RESPONSIBILITIES........................................................................................................3
3.0 DEFINITIONS..................................................................................................................5
4.0 PROCEDURE..................................................................................................................7
4.1 General Information............................................................................................7
4.2 Protection Methods.............................................................................................8
4.3 Evaluation Considerations...............................................................................10
5.0 HEAT TRACING............................................................................................................13
5.1 General...............................................................................................................13
5.2 Steam Tracing...................................................................................................15
5.3 Electric Tracing.................................................................................................19
6.0 PROTECTION OF PIPING............................................................................................20
6.1 Underground Piping.........................................................................................21
6.2 Process Piping Above Grade...........................................................................21
6.2.1 Protection Guidelines............................................................................21
6.2.2 Protection with Heat Tracing and Insulation.........................................22
6.2.3 Protection with Other Methods.............................................................29
6.3 Water Piping......................................................................................................30
6.3.1 Protection Guidelines............................................................................30
6.4 Utility Piping......................................................................................................36
6.5 Fire Water systems...........................................................................................37
7.0 PROTECTION OF EQUIPMENT...................................................................................38
7.1 Tanks..................................................................................................................38
7.2 Vessels...............................................................................................................39
7.3 Pumps.................................................................................................................41
7.4 Air Cooled Heat Exchangers............................................................................43
7.5 Machinery...........................................................................................................44
8.0 PROTECTION OF INSTRUMENTS..............................................................................46
8.1 General Requirements......................................................................................46
8.2 Specific Requirements.....................................................................................48
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1.0 SCOPE
This design guide covers minimum general requirements for design of cold weather
protection for piping, equipment and instruments. Specific requirements for protection
devices or installation details are not covered in this guide.
The purpose of winterization is to provide a facility that is both operable and maintainable
during extended periods of low ambient temperature, giving due consideration to the design
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of equipment and piping systems such that low temperatures do not impair performance or
operation. The facility should be designed to protect against the following conditions:
Freezing of process and utility fluids

Congealing of viscous fluids
Pour point suppression
Condensation that may lead to corrosive compounds
Any undesirable separation that may occur at low ambient temperatures
Start-up problems under severe winter conditions
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Hydrate formation
2.0 RESPONSIBILITIES
The Process Engineer establishes requirements with the Client for winterizing and the
minimum design and maximum ambient temperatures to be used in designing the piping,
instrumentation, and equipment. The Process Engineer also determines where thermal
insulation is required and describes the details on the P&IDs and line lists for piping,
instrumentation and equipment.
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The Mechanical Engineer prepares the specifications for insulation materials and
thickness, coordinates the winterizing/insulation requirements with the equipment
suppliers and reviews the P&IDs/vendor drawings to ensure the correct depiction of
equipment requirements.
The Control Systems Engineer reviews the P&IDs and instrument drawings to ensure the
correct depiction of the instrument winterization/insulation requirements.
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Piping Design establishes the configuration details for winterizing pipe, indicates the
insulation and winterizing requirements on its drawings, and assists in the final review of
winterizing and insulation design.
3.0 DEFINITIONS
Process. The term Process is used to denote the department, group or engineer who
develops the PFDs and P&IDs. The term Process could refer to Process Engineers,
Process Systems Engineers or Mechanical Systems Engineers.
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Mechanical. The term Mechanical is used to denote the department, group or

engineer who handles the static and rotating equipment.
Control Systems. The term Control Systems is used to denote the department, group
or engineer who handles the instrumentation.
The words Instrumentation or
Instrument are often substituted for Control Systems.
Piping. The term Piping is used to denote the department, group or engineer who
handles the design of the piping as will as tie-in locations.
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4.0 PROCEDURE
4.1
General Information
The requirement for winterization and the minimum design ambient temperature should
be established with the client before winterizing or insulation is applied.
The project specified thermal insulation criteria and specifications should be obtained before
insulation thickness requirements for heat traced lines and equipment are added to the line
summary or equipment descriptions. In absence of project specified insulation tables for
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heat tracing applications use the insulation tables for heat conservation provided in the Line
List Input Design Guide, PTD-DGS-128.
4.2
Protection Methods
The following methods should be considered for cold weather protection of piping,
equipment, and instruments:
a.
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Draining of piping and equipment when not in service.
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b.
Recirculation and bypass lines to maintain partial circulation.
c.
Agitation or intermittent flow through idle piping and equipment.
d.
Sheltering.
e.
Insulating to retain heat.
f.
Flushing, purging, or displacing process fluid with a nonfreezing fluid.
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g.
Heat tracing to apply heat and insulating to retain it.
h.
Heaters.
i.
Using antifreeze solutions or diluting streams with lighter, nonfreezing

fluids.
4.3
Evaluation Considerations
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a.
Sealing, purging or displacing process fluid with nonfreezing fluid or

heat tracing have significantly higher initial, operating, and maintenance costs than
other alternative winterization methods.
b.
Draining of piping, intermittent flow, sealing, purging, or displacing

process fluid with nonfreezing fluid require coordination with operational procedures
and careful selection of block valve location. Block valves should be accessible,
and they should eliminate dead legs or permit lines to be self-draining. Additionally,
they should be located so that idle pipe or equipment can be fully drained or
displaced.
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c.
Recirculation lines maintain back-flow through spare pumps for cold

weather protection or to keep the temperature of the pump at a certain level due to
mechanical requirements.
d.
In order to protect piping when the connected equipment is isolated, a

minimum-flow continuous bypass line can be installed around the equipment.
e.
Insulation is an economical method for cold weather protection. Adding

heat tracing increases the degree of protection.
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f.
Insulation without heat tracing requires the use of non-wetting

insulation, cellular glass or perlite
5.0 HEAT TRACING

5.1
General
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5..1.1 For process systems that carry fluids with critical temperatures (pour point, freeze
point, flow point) above 50C, the heat tracing system should have sufficient
capability to maintain the fluid 30C above the critical temperature.
5..1.2 For process systems that carry fluids with critical temperatures (pour point, freeze
point, flow point) above the design cold weather temperature, but less than 50C,
the heat tracing system should have sufficient capability to maintain the fluid
temperature 5-15C above the critical temperature.
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5..1.3 The heat tracing system should have the capability to heat a line sufficiently within
a twelve-hour period to permit initial circulation after the line has cooled to the
winter design temperature, if steam tracing is used. Electrical tracing systems will
not need to meet this requirement unless otherwise specified.
5.2
Steam Tracing
Note that steam tracing is not temperature controlled and, if used exclusively for
winterization, should be turned off once the threat of freeze is over.
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5.2.1 Steam tracing systems should be designed in accordance with specifications

issued for a particular project.
5.2.2 In systems where the process fluid is heat sensitive, volatile, or corrosive at the
tracer temperature, the tracers should be separated from the pipe by approximately
" with insulation tape wrapped around the tracer or with insulation blocks at
approximately 2-foot intervals.
5.2.3 Steam tracing systems should have the capability of raising the temperature of the
stagnant fluid from the specified project cold weather design temperature, to either
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30C (paragraph 5.1.1) or 15C (paragraph 5.1.2) above the critical temperature in
a twelve-hour period.
5.2.4 The use of heat conductive cement or steam-jacketed lines should be considered
where applicable. Heat conductive cement eliminates hot spots and should be
considered.
5.2.5 Depending on the process temperature, the design should consider piping steamout and associated temperatures if they are higher than the normal operating level.
5.2.6 Selection of design steam pressure should consider the following factors:
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a.
The stability of the process fluid at steam tracing temperatures during

periods of low flow.
b.
The lower cost of low-pressure steam balanced against the higher capital
and maintenance costs of a low-pressure system.
c.
Pressure at the steam traps should be adequate to get the condensate into
the collection system especially if the collection system is in elevated pipe
racks.
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d.
5.3
Low-pressure steam (1 bar g) should be used only when the condensate

discharges to atmospheric pressure.
Electric Tracing
5.3.1 Electric tracing should be designed in accordance with guidelines for a particular
project.
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5.3.2 Electric traced systems should adhere to the twelve-hour heat-up requirement only
when specified (paragraph 5.1.3).
5.3.3 Occasionally a situation arises where the traced piping can experience high
temperatures. The temperature tolerance of the tracing should be checked to
ensure that the tracing will not be damaged at the pipe design temperature.
6.0 PROTECTION OF PIPING
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6.1
Underground Piping
All piping should be buried to the project specified depth for freeze protection.
6.2
Process Piping Above Grade
6.2.1 Protection Guidelines

a.
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All winterization methods should be tailored to meet but not necessarily

exceed the maximum anticipated duration of freeze threat.
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b.
General process lines 6 inches and larger with continuous flow greater than
0.3 m/s do not need any type of freeze protection. This should be evaluated
for the specific project and process materials.
6.2.2 Protection with Heat Tracing and Insulation

Unless otherwise specified, a combination of heat tracing and insulation should be used
for process piping above grade under the following circumstances:
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a.
On active lines containing liquids (excluding water) with a critical

temperature (pour point, freezing point, flow point) more than 30C above
the winter design temperature.
b.
On lines with continuous flow of a high-pour-point or a high-freeze-point

material where it is not practical to drain them or to quickly displace their
contents with a low-pour-point fluid, air, or gas during a power outage
condition.
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c.
On lines with intermittent flow where the set-up temperature of the fluid is
higher than the temperature that can be maintained without tracing.
d.
On lines containing a high-pour-point or a high-freeze-point material where it

is not practical to drain them or displace their contents during normal
shutdown.
e.
On lines in which the viscosity of the process fluid at the cold weather design
temperature does not permit one-half of the normal flow rate with the
available head for starting circulation.
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f.
Drains on knockout pots in gas compressor suction lines or in lines to

furnace burners should be reviewed on a case-by-case basis to determine
whether insulation or tracing is required.
g.
On compressor suction lines from knockout pots to compressors including

any pulsation dampers.
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h.
On spare devices, such as filters or strainers that contain high-pour-point or

a high-freeze-point material and have no flow for significant periods or where
no minimum circulation flow is provided and product is maintained in the line.
i.
On sample taps, sampling systems, and differential-pressure transmitters in

wet gas or vapor service, the primary protection criterion is normally to
prevent condensation rather than to avoid freezing. Dry gas services such
as nitrogen (dew point ~ -100C) or instrument air (dew point ~ -40C) do not
require such protection.
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j.
On seal pots and non-draining portions of lines, such as loop seals, unless
special operating provisions are made for draining at shut down.
k.
On systems containing vapor mixtures that cause corrosion if condensation

occurs.
l.
On water draw-off pots and water draw-off lines from tanks to the sewer
drain.
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m.
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On safety relief valves where the inlet or discharge line may become
plugged or viscous fluids might congeal at ambient temperature. Likewise
the relief valves themselves should be winterized if either the inlet or
discharge piping is winterized. Piping between a rupture disc and its relief
valve should be winterized in the same manner as the inlet piping. It is
particularly important to winterize the sensing line for pilot operated relief
valves if they have the potential to plug in cold weather.
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n.
Where relief valve discharges are open to the atmosphere, rain caps and
weep holes should be provided to prevent rain or ice accumulation down
stream of the relief valve.
6.2.3 Protection with Other Methods

On lines that are in intermittent service, (1) a nonfreezing flush system, (2) an air or
nitrogen blowing procedure with necessary vents and drains, or (3) insulation combined
with scheduled intermittent flow should be considered as alternates to heat tracing.
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6.3
Water Piping
Water piping should have cold weather protection if the winter design temperature is
below 0C. Unless otherwise specified, the following protection methods should be used:
6.3.1 Protection Guidelines
a.
Winterization methods should be tailored to meet but not necessarily exceed the
maximum anticipated duration of freeze threat.
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b.
Water lines with continuous flows of at least 0.3 m/s do not need any type of
freeze protection.
c.
Larger water lines generally do not need freeze protection. Often lines 6
and larger are designated to not need freeze protection, although this choice
will vary depending on the project site conditions.
d.
Dilute caustic lines with caustic concentrations between 8% and 25%

(by weight) have a reduced freezing point and often do not require
winterization.
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6.3.2 Water-cooled Inside Battery Limits (ISBL) heat exchangers will not have bypasses.
Freeze protection will be accomplished procedurally by draining lines when the
exchanger is shut down.
6.3.3 Outside Battery Limits (OSBL) cooling water and tempered water lines should be
reviewed on a case-by-case basis to determine whether freeze protection is
required when a heat exchanger is down for maintenance.
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Where freeze protection is deemed appropriate, exchanger bypass lines with a

gate valve will be installed. Cooling water supply lines 14 and larger require a 1.5
bypass line with a globe valve. Cooling water lines less than 14 require a 1
bypass line with a gate valve. Freeze protection of the bypass lines will be
accomplished procedurally by requiring that flow be maintained through the bypass
line during freezing conditions.
6.3.4 Intermittently operated lines and isolated dead legs or laterals should have
circulating bypasses, vents and drains, or heat tracing and insulation.
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6.3.5 Valves in vertical lines should have adequate drain facilities or heat tracing and
insulation.
6.3.6 Drinking water and emergency shower piping above grade should have appropriate
drains.
For potable water systems located below grade, showers should have stop and
waste cock located below grade with extension handle.
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6.3.7 Utility water lines should be arranged so that they can be completely drained in cold
weather.
6.3.8 Condensate lines and non-self draining steam traps should be insulated for
personnel protection but not traced. Inactive lines will be protected procedurally by
draining them at the onset of a freeze.
6.3.9 Drains and traps at low points in wet plant air lines should be protected by
insulation or steam tracing.
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6.3.10 Heat tracing should be used only if other protection methods are not effective or
cannot be utilized.
6.4
Utility Piping
If the winter design temperature is below 0C, utility piping should have cold weather
protection. Unless otherwise specified, the following protection methods should be used:
6.4.1 Strainers, automatic drains, and drip legs on air lines that may collect moisture
should have a valved drain or heat tracing and insulation.
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6.4.2 Steam line low points should be trapped.

6.4.3 Steam line dead legs should be trapped or blocked off and drained.
6.5
Fire Water systems
Design of cold weather protection for the fire water system should follow the above listed
guidelines.
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7.0 PROTECTION OF EQUIPMENT

7.1
Tanks
7.1.1 The water draw-off connections should be insulated or insulated and traced if the
winter design temperature is less than 0C.
7.1.2 Tank heaters should have the capability of maintaining the stored fluid temperature
such that the viscosity is adequate for an economical pumping operation. An
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exception is a material such as wax where the criterion is usually to maintain the
tank a certain number of degrees above the freeze point.
7.2
Vessels
7.2.1 All vessels having a diameter of 1000 mm or smaller and containing fluids that may
congeal or freeze during dormant periods should be winterized using one or more
of the following methods:
a. Insulation
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b.
c.
d.
e.
Heat Tracing
Heating Coil or Circulation Heater
Draining
Flushing
7.2.2 The water draw-off connection should be insulated or insulated and traced if the
winter design temperature is less than 0C.
7.2.3 Air and gas receivers or dryers that may collect water should have steam coils or
should be traced and insulated if the winter design temperature of is less than 0C.
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7.3
Pumps
7.3.1 Valved drains should be installed on water jackets if the winter design temperature
of is less than 0C.
7.3.2 Pumps containing fluids subject to freezing at the cold weather design temperature
should have valved drains.
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7.3.3 Heat tracing and insulation should be installed on pumps if the fluid becomes too
viscous to be pumped or freezes at the cold weather design temperature while
flowing.
7.3.4 Pumps that are normally idle and not subject to immediate start-up should have
flushing facilities and vents and drains if the fluid becomes too viscous to be
pumped or freezes at the cold weather design temperature or should be traced and
insulated.
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7.3.5 Spare pumps on ready standby which contain fluids which may become too viscous
to be pumped or may freeze at the winter design temperature should have a warmup bypass, with restriction, installed around the check valve to permit reverse
circulation.
7.4
Air Cooled Heat Exchangers
7.4.1 Design of cold weather protection for air-cooled heat exchangers should be in
accordance with API RP 632 and this design guide.
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7.4.2 Steam coils should be installed on exchangers that require preheating of the tube
bundle when starting the unit to prevent freeze-ups.
7.4.3 Design of hot air recirculation systems should be such that the minimum tube wall
temperature anywhere within the tube bundle, at 70% of design process flow,
should be a minimum of 30C above the pour or freeze point at the cold weather
design temperature.
7.5
Machinery
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7.5.1 Compressors, turbines, engines, and other major machinery (including auxiliaries)
installed in unheated shelters should be protected if the ambient temperature is
below -1C for periods exceeding 24 hours.
7.5.2 Where the dew point of the gas in suction lines of reciprocating compressors is
above the ambient temperature, the line between the knockout drum and the
compressor should be traced and insulated
7.5.3 Crankcases, oil reservoirs, and external oil and water piping should be investigated
for cold weather protection requirements.
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7.5.4 Exposed components such as cooling water lines, cooling jackets, lube and seal oil
lines, etc., should have drains or bypasses.
7.5.5 Unless otherwise specified, heated shelters should not be used
8.0 PROTECTION OF INSTRUMENTS
8.1
General Requirements
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Unless otherwise specified, a combination of heat tracing and insulation should be used
for instruments under the following circumstances:
8.1.1 For safety relief valves see paragraph 6.2.2 m.
8.1.2 On instruments and their associated leads located on vessels or towers, including
level transmitters and gauge glasses, pressure and differential transmitters, and
gauges where the fluid may congeal or freeze.
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8.1.3 On control valve or meter bypasses, non-draining sections of control valve or meter
stations where the fluid may congeal or freeze.
8.1.4 On instruments and their associated leads located on equipment and lines
containing liquid that may freeze or vapor that may condense. This includes
equipment and lines in steam, steam condensate, cooling water, compressed air,
or hot process vapor service.
8.2
Specific Requirements
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8.2.1 Instruments requiring insulation should be fitted with soft case enclosures that are
removable and reusable.
8.2.2 Instruments (transmitters, controllers, recorders, etc.) with external sensing
elements require partial enclosures. The enclosure need only enclose the sensing
element of the instrument; the electronics should remain outside of the enclosure.
8.2.3 Instruments (transmitters, controllers, recorders, etc.) with internal sensing
elements require complete enclosures. The enclosure should be sized to enclose
the instrument, valves, filters, regulators, junction boxes, etc, as required.
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8.2.4 Specific requirements for cold weather protection of instruments should be in

accordance with all applicable project instrumentation specifications.
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PROCEDURE NO.

PROCESS TECHNOLOGY PROCEDURES

WINTERIZATION DESIGN GUIDE

WINTERIZATION DESIGN GUIDE

WINTERIZATION DESIGN GUIDE

Freezing of process and utility fluids

WINTERIZATION DESIGN GUIDE

WINTERIZATION DESIGN GUIDE

WINTERIZATION DESIGN GUIDE

WINTERIZATION DESIGN GUIDE

Mechanical. The term Mechanical is used to denote the department, group or

WINTERIZATION DESIGN GUIDE

WINTERIZATION DESIGN GUIDE

Draining of piping and equipment when not in service.

WINTERIZATION DESIGN GUIDE

Recirculation and bypass lines to maintain partial circulation.

Agitation or intermittent flow through idle piping and equipment.

Insulating to retain heat.

Flushing, purging, or displacing process fluid with a nonfreezing fluid.

WINTERIZATION DESIGN GUIDE

Heat tracing to apply heat and insulating to retain it.

Using antifreeze solutions or diluting streams with lighter, nonfreezing

WINTERIZATION DESIGN GUIDE

Sealing, purging or displacing process fluid with nonfreezing fluid or

Draining of piping, intermittent flow, sealing, purging, or displacing

WINTERIZATION DESIGN GUIDE

Recirculation lines maintain back-flow through spare pumps for cold

In order to protect piping when the connected equipment is isolated, a

Insulation is an economical method for cold weather protection. Adding

WINTERIZATION DESIGN GUIDE

Insulation without heat tracing requires the use of non-wetting

5.0 HEAT TRACING

WINTERIZATION DESIGN GUIDE

WINTERIZATION DESIGN GUIDE

WINTERIZATION DESIGN GUIDE

5.2.1 Steam tracing systems should be designed in accordance with specifications

WINTERIZATION DESIGN GUIDE

WINTERIZATION DESIGN GUIDE

The stability of the process fluid at steam tracing temperatures during

WINTERIZATION DESIGN GUIDE

Low-pressure steam (1 bar g) should be used only when the condensate

WINTERIZATION DESIGN GUIDE

WINTERIZATION DESIGN GUIDE

Process Piping Above Grade

6.2.1 Protection Guidelines

All winterization methods should be tailored to meet but not necessarily

WINTERIZATION DESIGN GUIDE

6.2.2 Protection with Heat Tracing and Insulation

WINTERIZATION DESIGN GUIDE

On active lines containing liquids (excluding water) with a critical

On lines with continuous flow of a high-pour-point or a high-freeze-point

WINTERIZATION DESIGN GUIDE

On lines containing a high-pour-point or a high-freeze-point material where it

WINTERIZATION DESIGN GUIDE

Drains on knockout pots in gas compressor suction lines or in lines to

On compressor suction lines from knockout pots to compressors including

WINTERIZATION DESIGN GUIDE

On spare devices, such as filters or strainers that contain high-pour-point or