Protecting Your and Mill from Winter Storms When you think of the hazards that equipment is located outside, where threaten a facility, fire, windstorm, it’s exposed to low temperatures. earthquake and flooding are undoubt- edly among the first that come to However, experience also has taught mind. But what about freeze-ups and us that certain occupancies are more snow loading? If you’re located in an prone to suffer large freeze losses area that tends to experience rela- than others, and pulp and paper is one tively mild winters, chances are, both of them. Historically, the largest loss- these perils were omitted from your es from freezing have occurred in the list. A common fallacy about winter , which uses weather is that freezing temperatures a high volume of water in its daily and heavy snow are confined to parts operations. While such losses have of the world where harsh winters are occurred in all parts of the world, the the norm. But, unusual changes in the most severe involved mills with open weather do occur and these changes construction in the southern United are capable of casting warmer locales States an area generally unprepared into a deep freeze that can rupture for extreme winter weather. Historically, the largest pipes and collapse roofs. If you’re Although such harsh conditions can’t losses from freezing have not prepared when these changes take be avoided no matter where you’re place, you could find yourself facing occured in the pulp and located, their destructive impact property damage, business inter- on your facility and its operations paper industry. ruption or maybe even lost market can be prevented—or at least con- share—all the makings of a multimil- trolled—through sound preplanning. lion dollar loss. If you happen to be At FM Global, our engineers have a pulp and paper mill, your odds are the know-how and the resources they even worse. need to help you develop strong lines Experience has taught us that facili- of defense against unexpected severe ties in areas unaccustomed to severe winter weather. With nearly 170 years cold and deep snow accumulation of property loss prevention expertise tend to suffer the largest and most guiding them, they can identify and costly winter weather losses because recommend general measures that they’re not equipped to endure such will prepare and protect your facil- harsh conditions. Many have little or ity against the problems brought on no insulation or heating equipment, by freezing temperatures. And, their and much of their process or service recommendations take into account the specific needs of your facility.

This brochure is made available for informational purposes only in support of the insurance relationship between FM Global and its clients. This information does not change or supplement policy terms or conditions. The liability of FM Global is limited to that contained in its insurance policies. Protecting Your Pulp and Paper Mill from Winter Storms 2 of 10 A Case Study in Loss Prevention

Still not convinced freezing tempera- Over the next few days, lack of To make matters worse, piping and tures pose a threat to your facility? available steam hampered attempts instrumentation in the demineralized Then think about the impact an impair- to restart operations. Residual pulp water plant froze, and the plant could ment would have on your business stock was depleted and intermittent no longer produce enough water to operations from beginning to end. downtimes were reported on the paper keep all boilers on line. As a result, machine as a result. Soon, wood chips steam production—and, in turn, Many associate freeze losses with stored in silos froze, making it difficult production in the pulp and paper automatic sprinkler and domestic water to get them to the digesters, and the areas of the mill—was affected. piping. However, frigid temperatures also can affect other vital areas of your facility, including process piping, Damage to one area can often result in damage to compressors and compressed air lines, other areas. Before you know it, the whole chain of instrumentation and control lines, events has resulted in a large loss that could have valves and fittings, heating and air conditioning equipment, steam piping, been avoided. boilers, water tanks, fire pumps and underground water mains. bleaching process cooled. Brightness Eventually, the combination of low requirements could not be met; cold temperatures and loss of heat that Now, think about how each of these temperatures and lack of steam caused resulted from such boiler and equip- impairments would affect your day- an incomplete reaction of bleaching ment shutdowns proved too much to-day operations. Chances are, they chemicals. for the plant’s industrial fire brigade would cause equipment damage that personnel. Despite their continued could shut down your entire facility. Gas curtailment was ordered by gas efforts to protect sprinkler systems, And, as the following example illus- supply companies. And, when the various components began to freeze trates, damage to one area can often mill began to switch over to alternate and, in the end, the whole chain of result in damage to other areas. Before fuels, it discovered problems in these events had caused significant business you know it, the whole chain of events areas as well. The cold weather froze interruption and physical damage to has resulted in a large loss that could instrumentation on fuel oil systems, various instruments, piping systems have been avoided or controlled. impaired fuel oil flow at the oil heaters, and finished product—a catastrophe and caused bark fuel to freeze or slide that could have been avoided with a When a severe cold front with ambient off conveyors. As a result of this lack little preplanning. temperatures between 0 and 5 F (-18 of fuel, fuel-fired equipment, such as and -15 C) moved through the southern kilns, bark boilers and power boilers, United States one December, moisture shut down. Black liquor recovery boilers in instrument air lines throughout a eventually came off line due to lack of local pulp and paper mill froze, forc- liquor, and various boiler instruments ing a complete shutdown of the pulp and controls began to freeze, despite process. efforts to protect equipment.

Protecting Your Pulp and Paper Mill from Winter Storms 3 of 10 Assessing Your Vulnerability What does the upcoming winter ■■ Would wind direction or season have in store for your facility? windchill affect your facility’s ■■ Freezing temperatures that ability to withstand freezing damage piping systems? temperatures? ■■ Mounding or drifting snow that ■■ Has your locale ever experienced collapses roofs? freezing temperatures or an ■■ Violent storms that disrupt accumulation of snow or ice? operations? ■■ Do you ever shut down opera- tions during the winter holidays? To prevent a significant freeze loss ■■ Does heat generated by process from unfolding at your facility, equipment also supply or determine your exposure and then supplement building heat? establish an emergency plan that ■■ Do building temperatures drop meets your specific needs. The fol- when process equipment is lowing questions can help you assess shut off? your vulnerability to severe winter weather: If you answered yes to any of our ■■ Does your locale usually experi- questions, then you’re at risk of loss ence temperate winters? due to freezing.

Protecting Your Pulp and Paper Mill from Winter Storms 4 of 10 Property Loss Prevention Solutions Each mill should develop a plan that or instruments were frozen so that addresses the question “what if?” fuel parameters (e.g., flow, pressure) To protect your facility, it’s important and lists all counteractive measures could not be controlled accurately. that mill personnel review opera- to be taken. The plan should include tions to determine key areas vital to lines of authority and personnel as- Check alternate fuel supply equip- your business continuity, protect signments, areas of the plant to be ment, such as oil tanks, pumps, pip- equipment against freeze damage specifically addressed, priority order ing, instrumentation, heat exchang- whenever possible, and plan accord- of operation and shut down of equip- ers and filling stations, for proper ingly. The following is a list of key ment, any outside contractors needed operation. Protect against freeze prior areas that could impact your business to implement the plan, and alterna- to the winter season, and monitor to operations in the event of a freeze-up tive supplies of fuel and power. For ensure that freezing does not pre- at your pulp and paper mill. Whether example, if fuel gas is curtailed, fuel vent operation when needed. Guard that impact is positive or negative oil supplies should be ready within a against heat exchanger equipment depends on how well you incorporate few hours. This plan will enable you freeze-up if fuel oil is being used suggested measures into your emer- to respond effectively, rather than des- only as emergency fuel and the sys- gency plan. perately, to an emergency situation. tem is idle for extended periods. Chip storage, either pile or bin, can Contingency Planning Alternate Fuel Supply freeze as well. When mills were Develop a contingency plan that Fuel curtailment, primarily natural able to get chips onto belt feeders, addresses the following items gas, has been a major factor at pulp smooth-surfaced belts did not provide in detail for each location: and paper locations during freezes. In ■■ enough surface friction to carry Fuel curtailments many cases, mills were asked to re- ■■ frost-covered chips up relatively steep Loss of boiler feedwater supply duce fuel usage by almost 75 percent. inclines. Arrange chip and bark fuel (including raw water supply) The ability to switch over to alternate ■■ supplies for continued operations Loss of critical fuel supplies, namely fuel oil and during inclement weather conditions. plant instrumentation wood/bark chips, was hampered by ■■ For example, use ribbed belts when Alternate on-site fuel supplies problems with otherwise idle fuel surface friction is reduced due to equipment. Fuel oil systems freezing conditions.

Protecting Your Pulp and Paper Mill from Winter Storms 5 of 10 Critical Process Piping Outdoor construction can be millwide Protect critical liquid process piping in many locations, making it neces- with heat tracing. Electric heat trac- sary to protect key areas of the mill ing is more reliable than steam heat against freezing. The water treatment tracing (see “Testing” on 7). plant is one of those areas. The plant should be protected so continuous Feedwater Supply operations will not be affected. To protect against loss of boiler Heat-traced piping and instrumenta- feedwater: tion will help the water treatment personnel maintain supplies during On new construction: freezing conditions. ■■ Provide enough demineralized feedwater storage capacity to Critical Instruments survive a 24-hour period of unin- Protect the following critical instru- terrupted plant demand consider- mentation and instrument-sensing ing loss of condensate return. lines by heat tracing and heated insulated instrument cabinets: On existing construction: ■■ Feedwater controls ■■ Provide electrical heat tracing ■■ Deaerator controls for instrumentation and piping ■■ Boiler drum level controls located outside. ■■ Fuel line instrumentation ■■ Provide space heating for the ■■ Water plant instrumentation water treatment plant. This provision may include the need for building enclosures as well.

Protecting Your Pulp and Paper Mill from Winter Storms 6 of 10 Frozen instrumentation is a problem respond properly to changing ambient in most outdoor areas of the mill temperatures. Electrical heat tracing because instrument-sensing lines and is preferred over steam tracing. Idle instrument air lines freeze, espe- steam-tracing circuits collect conden- cially in the steam plant. Without the sate and experience has shown such boilers on line, plant operations will circuits can freeze, rendering the heat come to a halt and process piping will tracing ineffective. However, where freeze. Heat-tracing vital instruments, they are installed, make every effort as identified, will help to avoid down- to verify proper working order prior stream operating problems. to and throughout the winter season.

Provide air dryers for instrument air Idle Equipment supply. Check the performance of Drain and store equipment that will the dryers before and periodically be idle for extended periods of time, throughout the winter season to avoid such as boilers and piping systems. condensation freezing problems in Use a desiccant to keep moisture instrument air lines. from building up in equipment. As part of contingency planning, decide Testing which equipment or piping should Test all electrically heat-traced be drained ahead of time and which circuits for proper operation prior equipment should be drained as it to the winter season to make sure comes off line during the freeze. wiring is intact and each circuit will

Protecting Your Pulp and Paper Mill from Winter Storms 7 of 10 An unprepared, unprotect- Training Sprinkler Systems Add freeze precautions to the Freezing of automatic sprinkler ed facility is an easy target operator’s training program so freeze systems is a major concern during for a winter casualty. contingency plans can be expedi- severe cold weather. Even facilities With sound preplanning, tiously implemented. Incorporate the protected by dry-pipe sprinkler information into operating manuals, systems are susceptible to frozen your facility stands the and conduct special review sessions sprinkler risers, frozen low points best chance of maintaining before winter to inform operators where water condensation occurs, a strong defense against of past problems and prepare them as well as accidental trips. Low-point for the upcoming season. drains should be checked regularly whatever the upcoming to prevent freezing. A fire that winter season has in store. Operating after the freeze condi- occurs when automatic sprinkler tion can be difficult as well. If some system protection is out of service instruments and piping freeze and can be devastating. rupture, thawing conditions can lead to faulty instrument readings and Consider frozen sprinkler piping an subsequent operating upsets. If it is impairment and give it top priority. known the freeze has affected certain To help with this matter, use instruments, they should be removed FM Global’s Red Tag Permit System from the control loop until they are to monitor any impairment to fire repaired. Therefore, operators should protection equipment. First, deter- be alert to these potential problems mine how much of the sprinkler and ready to take appropriate control system is affected. Lay out hoses and actions. portable extinguishers. Notify your FM Global office and the local public

Protecting Your Pulp and Paper Mill from Winter Storms 8 of 10 fire service. If only a small section After the storm has passed, it’s criti- of a system is affected, consider iso- cal to restore impaired fire protection lating the frozen section and immedi- systems quickly. Prohibit hot work ately restoring the rest of the system operations in areas where automatic to service. sprinklers are being repaired. Re- move combustible debris, and ban For larger freeze-ups, temporarily smoking in these areas. Keep an shut off the sprinkler system, turn up eye out for leaking flammable gas, the building’s heat, and bring in and flammable liquid, live power lines safely arrange portable heaters. and structures in danger of falling or collapse. Separate damaged from Avoid the use of torches, oil and undamaged goods, and cover equip- gasoline-fuel heaters where building ment and stock to protect it against construction or contents are further exposure. combustible. Check the following when preparing Be Prepared a facility for cold weather: Every winter storm has its own inher- ■■ Low points in sprinkler system piping ent twist. Naturally, you can’t predict what the upcoming winter season ■■ Adequacy of heat for dry-pipe valve riser enclosures might bring. However, there are some general preventive wmeasures you ■■ Fire pump rooms can take now to prepare and protect ■■ Water tanks your facility against the problems The Emergency Response Team brought on by cold weather (see A well-trained emergency response FM Global’s publication, Freeze-Up team (ERT), ready to deal with Checklist [P9521]). Discuss these prestorm precautions as well as measures with your FM Global en- events during and after the storm, is gineer and design a strategy that best essential. When storms loom for an suits your needs. extended period of time, have ERT personnel patrol the building, looking Remember, an unprepared, unpro- for cold spots, structural damage, tected facility is an easy target for a large leaks or sprinkler piping breaks. winter casualty. With sound preplan- Provide ERT members with phone ning, including the development of a numbers of outside contractors who winter emergency action plan, your can immediately repair breaks in the facility stands the best chance of sprinkler system, and remember to maintaining a strong defense against follow the FM Global Red Tag Per- whatever the upcoming winter season mit System to help monitor impair- has in store. ments to fire protection systems.

Protecting Your Pulp and Paper Mill from Winter Storms 9 of 10 Contact Us: Product Ordering Information: To report an impairment or to find an FM Global office For additional copies of this publication or other nearest you, visit fmglobal.com/contact. FM Global resources, order online 24 hours a day, seven days a week at fmglobalcatalog.com. Report a Loss: Dial (1)877 NEW LOSS (639 5677)* to report a Or, for personal assistance worldwide, contact our property or cargo loss 24 hours a day, seven days U.S.-based customer services team, Monday – Friday, 8 a.m. – 5 p.m. ET: P0049 © 2004 FM Global a week. Or, to contact your client service team n (Rev 10/2015) All rights reserved. or designated claims office directly, go to Toll-free: (1)877 364 6726 fmglobal.com fmglobal.com/claims or affiliatedfm.com/claims (Canada and the United States) n Phone: +1 (1)401 477 7744 FM Insurance Company Limited for location and contact information. n Fax: +1 (1)401 477 7010 1 Windsor Dials, Windsor, Berkshire, SL4 1RS n Authorized by the Prudential Regulation Authority *For clients of FM Global and AFM Email: [email protected] and regulated by the Financial Conduct Authority in Canada and the United States only. and the Prudential Regulation Authority.