By: Elisa Yates and Matt McKinney
This article details a significant winterization effort conducted by C2C Technical Services, an SI Solutions company, on behalf of a large petrochemical facility in Texas. The project, driven by ERCOT requirements imposed in the wake of a significant 2021 storm, involved a gap analysis to identify critical instruments, detailed engineering to select appropriate mitigation measures, and just-in-time field implementation on an accelerated timetable. These measures proved effective when the facility operated without any issues during a similar storm in January 2025.
C2C Technical Services provides Instrumental and Electrical (I&E) engineering and construction support for various critical industries, including the petrochemical and power generation sectors. C2C delivers solutions with a clear focus on personnel safety and technical excellence, while providing a responsive, high-quality solution that meets the demanding schedules and expectations of their clients.
In February 2021, an unprecedented winter storm brought Texas to a standstill, crippling the Electric Reliability Council of Texas (ERCOT) grid and exposing vulnerabilities across critical infrastructure. The event resulted in widespread power outages, frozen pipelines, and severe disruptions to industrial operations, forcing the energy sector to reevaluate its preparedness for extreme winter weather.
In response, leaders in critical industries (power, petrochemical, and others) took decisive action to align on a set of robust winterization requirements, and engineer then implement those solutions by the end of 2023. These measures included instrumentation and electrical (I&E) upgrades, freeze protection strategies, and system hardening measures. Applicable strategies included:
- Upgraded weather proof systems: heat tracing and enclosures ensure that vital piping and instrumentation remain above freezing temperatures.
- Improved installations: Upgrading technology and reducing deadlegs in impulse lines reduce areas that require protection.
- Enhanced Monitoring & Remote Sensing: Allowing real-time detection of temperature fluctuations and proactive intervention.
C2C was asked to support winterization efforts for a large petrochemical refining facility with an integral cogeneration plant. The project involved a gap analysis to identify critical instruments, detailed engineering to select appropriate mitigation measures, and just-in-time field implementation on an accelerated timetable.
Requirements Review and Gap Assessment
During this phase of the project, C2C worked with site operations and reliability engineering to create criteria to determine which equipment was critical to the operation of the facility. C2C reviewed standards and historical data from the facility operator, industry best practices, and ERCOT requirements to formulate a suitable mitigation plan. With criteria established, a comprehensive review of identified plant instrumentation was conducted, identifying more than 400 instruments that required freeze hardening. Notable observations from this effort included:
- In many cases, the operator’s standards went above/beyond the ERCOT requirements; C2C was able to optimize the instruments selected for hardening to eliminate unnecessary modifications.
- In other cases, lessons learned from the 2021 freeze event led to the inclusion of instruments that otherwise may have been overlooked.
Figure 1. Subset of Cogen Plant Winterization Dashboard with Smart Instrument Readouts
Engineering Design and Specifications
During this phase of the project, C2C’s engineering team generated construction packages to support installation of the selected hardening solutions. Given the 400+ instruments in question, this was a significant logistical effort, which involved specifying materials, assisting with procurement requirements, creating drawings, and documenting installation and calibration instructions. Noteworthy aspects of this support included:
- In some cases, custom fabrication was required for enclosures and heat tracing equipment to ensure fitment and intended function. C2C worked directly with the manufacturer to implement key considerations in procurement documents.
- The project scope included replacement of numerous transmitters. C2C specified “smart” instrumentation, which imparts a digital signature on top of the 4-20 mA primary signal. As a result, critical transmitters are now outfitted with localized temperature indication, informing operators about potential freeze concerns on a customized dashboard (Figure 1) without requiring any additional instrumentation wiring.
Figure 3. Winterization Packages for Pressure Indicators
Installation and Commissioning
C2C technicians completed field construction of the I&E upgrades either while online or using scheduled strategic outages. Commissioning was completed before the ERCOT-imposed year-end deadline. Key accomplishments during this effort included:
- Tight coordination with the operator’s scheduling department to support just-in-time construction activities while online. Technicians took advantage of planned maintenance and/or equipment issues to complete installation without added downtime.
- Integration of C2C engineering and construction resources enabled rapid response to field issues (e.g., variable equipment receipt schedules, in-situ changes to construction packages, etc.).
Figure 2. Winterization Package for Drum Level Transmitter
Conclusion
C2C Technical Services responded quickly to their clients’ need for a regulatory-driven winterization project and delivered a successful solution on an accelerated timetable. C2C’s in-house expertise and responsive workforce streamlined efforts and avoided unplanned downtime while completing this first-of-a-kind scope. In January 2025, the updates were tested when another significant storm impacted southern Texas. The facility was well prepared, armed with freeze-hardened equipment and real-time data, and remained fully operational during the storm.
