WINTERISATION / INSULATION
The objectives of winterisation are to maintain personnel and operational safety and to prevent the interruption to plant operation due to the
extreme weather conditions. Winterisation is required for piping components, instruments and equipment outside heated buildings.
Winterisation is a broad term definition to cover heat tracing and insulation.
A further issue is the need to house some equipment in heated buildings where the cost of using non-standard materials of construction suitable for
the minimum ambient condition is too high or impractical.
Maintenance requirements and operator comfort are also to be considered.
The winterisation facilities shall ensure that suitable heat sources are available with the required redundancy so that the equipment minimum
survival temperature is not violated. In general, equipment shall be maintained at a temperature higher than minimum operating temperature.
Under certain conditions, the ambient temperature may fall below the required minimum operating temperature.
In such cases, a heat source shall be made available to return the unit to a margin in excess of the minimum operating temperature.
The provision of Winterisation from extreme site conditions shall consider the effect of failure on the availability of process and utility systems.
In specific cases where the items to be winterised are Safety Critical, consideration of fully redundant winterisation such as ‘smart’ heat tracing,
duplication of supplied heat source and supply from reliable source, should be considered.
Winterisation is required where:
• The fluid has a pour point, 10°C above the minimum ambient temperature.
• The fluid is water contaminated. Water will settle out and collect in instrument tappings, low points and dead legs.
• The fluid can freeze or form hydrates or lead to wax formation above minimum ambient temperature, including chemicals which solidify.
• The fluid contains a solution where the solute could precipitate at an undesirable location.
• The fluid contains a vapour which upon condensation forms a corrosive liquid or may cause operational problems.
This occurs specifically when CO2, SO2 or SO3 are present with water vapour in the gas stream.
• The fluid has normal operating temperature below the dew point of the surrounding air and condensation of water vapour may form on the
external surfaces of pipes and equipment.
• There could be fluid stagnation in pipe segments for long time causing drop in fluid temperature leading to any of above mentioned situations.
• Suitable protection or sunshades should be considered where excessive solar radiation temperatures may cause operational problems, e.g. fluid
vaporisation in pumps, instrument malfunction, etc.
Winterisation Temperature
The winterisation temperature is the minimum maintained temperature and depends on the physical properties of the fluid, such as pour point,
freezing point, cloud point and maximum tolerable viscosity, whichever gives the higher temperature. In general:
• 5°C shall be used for aqueous systems and HVAC systems.
• 25°C for process fluids where wax or hydrates might form.
• 10°C for Glycol Systems.
• Minimum ambient temperature to be used for heat loss calculation shall be -10 °C
METHODS
• Tracing
• Heated Flow bypass
• Heated Enclosures
• Insulated Enclosures (Un-Heated)
• Heat Retention
• Maintenance Draining.
Heat Tracing
The requirement for tracing for all equipment, piping, instruments, etc. shall be determined by the process fluid it contains.
Tracing may be employed where isolated items of piping and equipment require protection.
It shall be used as a method for temperature conservation and not as a method for raising equipment temperature.
The need for raising equipment temperature shall be met by process heaters and heat exchangers.
The heat input for tracing may be from electrical tapes or a heated fluid (Steam).
Heat tracing by these methods shall be accompanied by heat conservation insulation.
Electric Tracing
All tracing within the process and utility units shall be electric and normally supplied from the area heat tracing distribution boards.
Heat pads may be used to protect the low sections of vessels containing water which may freeze.
When tape is used for electric tracing, there shall be a means by which to test the installation.
The use of self regulation tape shall be considered together with ‘smart’ heat tracing which will be self diagnostic and alarm on failure.
Pressure relief valves inlet and tail pipes, emergency shutdown valves, blowdown valves and fire fighting systems are defined as Safety Critical Items.
Winterisation to these items if required using electric tracing shall be duplicated & supplied from area trace heating emergency distribution boards.
Electric tracing on piping and instruments in Safety Critical service should consider the application of surface temperature monitoring, in addition to
‘smart’ tracing, to ensure the correct functioning of the tracing.
Steam Tracing
For all offsite piping and equipment requiring winterisation, tracing shall be provided by either electric tracing or steam.
If steam tracing is applied, the lines shall have an appropriate design temperature for pipe stress calculation.
This is to prevent excess stress when operating temperature of steam traced pipes, under no flow condition, exceeds normal flowing conditions.
As per international standards, the electrical tracing is not permitted in zone-0.
The steam tracing is the only acceptable method that is permitted in zone-0.
Heated Flow Bypass
Maintaining a heated flow at all times through bypass lines if practical may be used to avoid heat tracing, e.g. maintaining stream flow in lines to
isolated equipment by provision of a bypass local to the equipment, flow controlled using manual globe in bypass line.
Similarly, long headers which may at times have no flow may be provided with a bypass line with manual globe valve to maintain a minimum flow
and avoid the requirement for tracing.
Back flow through off-line equipment may also be used, e.g. back flow through standby pump by means of bypass around discharge check valve.
One globe valve and an RO should be provided in the bypass to restrict the flow.
When a heated flow bypass is specified, heat conservation insulation must be specified.
If heated flow cannot be maintained for operational reason, e.g. process unit shutdown, then isolated equipment is drained to prevent freezing.
Heated flow bypasses shall not be used where the plant safety is critical.
Heated Enclosures
Only instrumentation and small items of equipment which require periodic attention during the normal course of operations, e.g. regular calibration,
shall be provided with a heated enclosure, if not already located within a building.
A means of space heating shall be provided to maintain the inside air temperature.
Similarly cooling may be required in the summer period.
Insulation shall be provided to the enclosure walls and roof to mitigate heat loss in the winter months and heat gain in the summer months.
The temperature within the enclosures shall only be maintained at a temperature suitable for equipment operation and maintenance.
Insulated Enclosures (Unheated)
Where equipment is to be enclosed for environmental protection and the heat emitted from the equipment in normal operation is sufficient to
maintain the enclosure temperature, the space is not required to be heated during normal operation.
During periods of extended equipment shutdown during cold ambient conditions it may be necessary to temporarily heat the enclosure.
It may be the case that under summer conditions the heat emitted from the equipment is too great and the enclosure needs cooling.
Consideration should be given to variable ventilation shutters to maintain a suitable operating environment for equipment and personnel.
For insulated enclosures, the structure shall be permanent.
The exterior walls and roof shall have suitable insulation to minimise heat lost to the surroundings in winter.
If required habitat for both summer and winter operation and maintenance cannot be met using variable ventilation shutter and temporary heating,
a HVAC system shall be provided.
Temporary Enclosures
Temporary enclosures may be provided to protect equipment or provide shelter while Operations and Maintenance activities are carried out.
The requirement for heating shall be considered on a case by case basis.
Mechanical handling and time for erection and dismantling shall be considered.
Consideration shall be given to the use of pre-designed enclosures to allow particular operations to be carried out such as removal or motor pull.
Partial Enclosures and Shelters
Partial enclosures may be provided in cases where personnel protection is required for routine maintenance and operations.
These are to be designed to provide wind breaks for maintenance personnel.
This can be done by cladding two or three sides of the shelter or by providing gaps along the full length of the sides to allow air circulation.
These structures will be suitable for sour service equipment as the open sides will ensure that toxic chemicals do not accumulate without the need
for electrical powered ventilation systems.
Heat Retention
This winterisation type covers local items with insulation and thermal boxes.
In general, heat retention type shall be fitted to pipes and instrumentation.
Maintenance Draining
Draining down systems, equipment and pipes when not in use may be considered to reduce the amount of heat tracing required for winterisation.
Facilities remote to plant should not rely on maintenance draining, as Operators may not always be present when an operational shutdown occurs,
heat tracing should be used for these systems
Maintenance draining shall not to be used where plant safety is critical.
INSULATION
Insulation of piping components and equipment is a major part of winterisation.
Heat Conservation (HC)
Insulation for heat conservation shall be used when the process fluid is above the minimum ambient temperature and it is intended to minimise the
heat loss to avoid condensation, freezing or other process reasons.
The main material used for insulation are:
• Fiberglass • Cellular Glass • Foamed Plastic • Mineral Fiber • Insulating Cement • Low/Medium/High Density Rock Wool Blankets
To function efficiently & extend service life, most insulation must be protected from damage and degradation by application of an cover or jacket.
A jacket is defined as any material, except cements and paints, that can be used to cover or protect insulation installed on a pipe or vessel.
The choice of jacketing will depend upon its use, which can be divided into six functional categories:
• Weather barriers are used to prevent entry of liquid water into insulation & also entry of chemicals that would affect inside/outside of insulation.
Materials include plastic, aluminum, and stainless steel etc.
• Vapor barriers are used to reduce entry of water vapor into surface of the insulation.
In order to be effective, the vapor barrier must be completely sealed at every opening.
A vapor barrier is used on cold surfaces primarily for eliminating the possibility of entrapped water vapor condensing on the pipe.
• Mechanical abuse-resistant coverings are used to protect insulation from mechanical damage due to accidental contact by personnel/equipment.
The compressive strength of the insulation used should be considered when selecting a jacket. Metal products are most commonly used.
• Corrosion and fire-resistant coverings are used as part of a complete hazard resistance system.
The most successful corrosion jackets are plastic or stainless steel depending upon the nature of the spill, leak, or atmosphere expected.
• Jackets capable of being disinfected are used to present a smooth surface that will resist fungal and bacterial growth.
They must withstand cleaning with powerful detergents coupled with steam and high pressure water.
This requires a jacket with high mechanical strength.
• Plain jackets are used on hot services and in other cases when a jacket is desired for ease of installation and appearance.
Aluminum jackets have the following advantages:
• Easy application in any weather
• Easy formation into different shapes
• Good resistance to abuse
• Ready availability
Aluminum jackets have the following disadvantages:
• Low resistance to pH ranging from 7 to 11
• Low fire rating
• Low emittance value
• High initial cost
• Low resistance to strong cleaning chemicals
Steel jackets have the following advantages:
• Excellent fire rating
• High resistance to mechanical abuse
• Excellent corrosion and weather resistance
• Easy application in any weather
• Excellent hygienic characteristics
Stainless steel jackets have the following disadvantages:
• High initial cost
• Corrosion cracking where chlorine or fluorine exists
• Low emittance value
• Long lead time
Plastic jackets have the following advantages:
• Lowest cost of any solid jacket
• Best resistance to chemical corrosion
• Excellent resistance to bacterial and fungal growth
Plastic jackets have the following disadvantages:
• Poor fire rating
• Low impact resistance
• Softening at high temperatures
• Vulnerability to infrared and ultraviolet rays and ozone
• Cold weather embrittlement
Cold Conservation / Anti-Condensation (C / AC)
Insulation for cold conservation / anti-condensation shall be used when the process fluid is below the dew point of the surrounding air.
Cold insulation prevents condensation or icing on the outside surface of the insulating system, conserve low temperatures or controls heat input into
the contained fluid within a temperature range of ambient and below.
The cold conservation services is required for:
• Conservation
• Heat flux control of processes and product lines.
• Preventing vapor condensation on outside surface of insulating system of piping/equipment having temp. below dew point of surrounding air.
• Personnel protection from cold surfaces (cold burns and falling ice).
An important requirement of a cold insulation system is to prevent water ingress into the insulation.
The presence of water as vapor, liquid or ice in the insulation will decrease its insulating value and may eventually lead to underlagging corrosion of
the insulated metal surfaces.
In order to prevent water ingress and underlagging corrosion, the vapor barriers and metallic jacketing should be properly selected and applied and
all insulated metal surfaces shall be suitably painted.
Personnel Protection (PP)
Insulation for personnel protection shall be used on all lines not otherwise insulated and accessible to personnel where the process fluid normally
operates above +60°C or below 0°C.
Where personnel protection is specified for uninsulated process piping/equipment having an operating temperature of above +60°C or below 0°C
and whose location presents a personnel hazard, the surfaces shall be determined and provided with a suitable protection.
The extent shall be limited to within confines of a normal working area bounded by distances of not more than 2.0 m vertically or 0.8 m horizontally
beyond access ways, ladders, platforms and work areas at ground level or elevations used by operating and maintenance personnel.
Insulation should only be used for personnel protection if other alternative protective measures such as expanded metal shields, handrailings or
other physical barriers are not suitable.
Acoustic Insulation (A)
Acoustic insulation shall only be used under exceptional circumstances to reduce noise levels of equipment to below 85 dBa at 1 metre distance.
Normally items shall be designed to operate below these levels without acoustic insulation.
The noise radiated by the wall of a pipe is usually generated by equipment connected to the pipe, such as compressors, pumps, valves, or ejectors.
The noise sources may cause long sections of pipe to radiate noise because noise will travel in the pipe with little reduction.
The noise radiation may be reduced by acoustical insulation.
The control of noise in a plant is required for the following reasons:
• To conserve the hearing of personnel
• To reduce speech and work interference
• To ensure that warning signals are audible
• To allow adequate speech, telephone, radio communication
• To maintain working efficiency
• To provide quiet accommodation for personnel
• To prevent annoyance to the neighboring community.
Porous Layer
The porous layer serves the following purposes:
• This layer represents a vibration-isolating support for the cladding.
• This layer converts acoustical and vibrational energy into heat and should therefore have an optimum flow resistivity for the oscillatory flows which
occur in sound waves.
Cladding
The cladding serves the following purposes:
• The cladding is a barrier to the noise radiated by the pipe and therefore be completely sealed.
• The cladding protects porous layer from mechanical damage & provides a weather protection for the porous layer & the pipe surface underneath.
It shall therefore have sufficient strength and durability for these purposes.