Seasonal Maintenance Overview for Freezing Conditions
This information is intended to assist in maintaining equipment during seasonal shutdowns when temperatures fall below 32° F. Please note that every site is different and required winterization actions may vary. Kahler Automation is not responsible for equipment damage, nor will equipment be under warranty due to freezing product in equipment.
Last Updated: 10/19/2022
Common Cause(s)
Cold weather and exposed components
Environment/Applies to
- Liquid facilities that will be ceasing operations for the season
- Chem inject systems of dry facilities
Solution Summary
Prepare for freezing temperatures by removing from the system bulk products that freeze or crystallize.
Remove power from systems where possible, locking out control panels, unplugging equipment, or switching breakers.
Note: Panels containing PLC's and scales/meters should not be disconnected from power. Their internal battery can protect against power loss in most circumstances, but not for extended periods of time.
Solution In-Depth
Take inventory of all parts of your facility that will be exposed to freezing temperatures. Create a plan to protect those parts from damage that can be brought on by below-freezing temperatures.
Piping:
Pipes should be emptied of product. Long runs of pipe may require planning and air purge(s) to fully clear their length of product.
Pumps:
Pumps should not be left empty for extended periods of time. Their housing should be filled with a product that will remain liquid in the expected temperatures. Place a catch basin below a pump if a pump needs to be drained, then remove both the upper and lower plugs in the housing. Once drained, replace the plugs and flood pump with a product that will not freeze in the expected temperatures.
Note: There are many types of pumps, and procedures for draining and winterizing vary by model.
Mass flow sensors:
Mass flow meters should generally be blown clear or emptied of product for winterization purposes. Winterization protects the sensitive meter from damage due to freezing.
If fully emptying your mass flow meters is not practical, filling/flushing the meter with a product that will not freeze, crystalize, or salt out is acceptable.
Electrical:
RB panels, meters, and scales should not be disconnected from power. Their internal battery can protect against power loss in most circumstances, but not for extended periods of time.
Power to pumps should also be locked in the off position or a disconnect used. If motor starter panels are equipped to do so, power to pumps can be turned off at the electrical breakers or MCC. This is done for added safety during shutdown times to help prevent pumps from being started with no product at pump inlet, as well as isolate equipment from power fluctuations (brownout, blackout, or spikes).
KA-2025 systems, TSA panels, and other exterior panels should not be powered down. These systems contain heater units that help protect them from cold temperatures.
KA-2000 panels should be left powered on.
Air compressors:
Air compressors and all separators should be checked and drained regularly as temperatures fall to keep lines free of moisture, so they won’t freeze. Make note of regulator settings. Check for any existing leaks in the air lines. Disconnect the air compressor(s) from power and empty the tank.
Site level:
Review the site. Is everything disconnected that should be? Is there power where it needs to be? Now is a good time to write out a list of what has been done and what needs to be done to reopen the facility. Do any parts need to be ordered? Is there maintenance to schedule?
Backups:
Post season is a great time to grab a backup of your system which will get your site up and running faster if something were to happen. For information about backups, see our Terminal Management Backup article.
Still Need Help?
Submit an online web ticket or call us at Kahler Automation 507-235-6648 Option 2.