Northern Pipeline Freeze Prevention System
Challenge
A major oil operator was experiencing frequent winter shutdowns due to pipeline freeze-offs in a 47-kilometer network crossing northern Alberta. Temperature drops below -40°C caused wax buildup and flow restrictions, resulting in production losses exceeding $2.3 million annually. Their existing heat trace system was inefficient, consuming excessive energy while failing to prevent freeze events.
Solution
We designed and installed a comprehensive thermal management system featuring self-regulating electric heat tracing with advanced aerogel insulation. The solution included:
- Distributed temperature sensors every 500 meters providing real-time monitoring
- Smart controllers automatically adjusting heat output based on ambient conditions
- Redundant heating zones ensuring backup protection during equipment failures
- Remote diagnostics and alarm systems for proactive maintenance
- Weather-resistant cladding protecting system components from harsh conditions
Results
95%
Reduction in Freeze Events
32%
Energy Savings Achieved
$2.1M
Annual Savings
18 mo
Return on Investment
"The transformation has been remarkable. We went from multiple freeze shutdowns every winter to virtually zero disruptions. The energy savings alone paid for the system faster than we expected." — Operations Manager, Northern Energy Transport Ltd.
