RTOs operating in extreme cold face challenges that affect combustion, pneumatic systems, and mechanical performance. Subfreezing temperatures increase air density, cause condensation, and shift material tolerances. Without proper winterization, startups can be unstable, instrumentation unreliable, valves restricted, and non-productive time (NPT) elevated.

Cold air alters fuel-to-air ratios, creating lean mixtures, delayed ignition, or flame instability. In a recent case, an RTO showed pressure fluctuations and erratic ignition during winter startup. The issue was not burner failure but improper calibration for dense combustion air.

Precision burner tuning stabilizes ignition, improves ramp control, reduces oxygen variability, and enhances fuel efficiency in cold conditions. Yet combustion adjustment alone cannot protect exposed mechanical components.

Heat tracing is critical for pneumatic lines, actuator cylinders, control valves, and transmitters to prevent freezing, condensation, and delayed response. Proper tracing ensures accurate instrumentation and reliable poppet valve operation during prolonged cold exposure.

External insulation on poppet housings and actuator assemblies prevent ice formation and minimizes heat loss. Protective enclosures further stabilize temperatures and preserve valve alignment.

Moisture control is equally important. Temperature differentials between hot process gases and freezing air increase condensation during startup and turndown. Upstream Knock Out Tanks (KOTs), ideally indoors, remove moisture, improving thermal efficiency. Insulated ductwork, proper drainage, and controlled warm-up reduce dew point risks and prevent internal condensate.

Ship & Shore Environmental recommends semi-annual inspections. Every six months, burner performance, heat tracing, insulation, and moisture management systems should be verified to maintain reliable winter operation and minimize NPT.

In cold climates, consistent RTO performance requires engineering preparation. Combining burner tuning, winterization, and preventive maintenance ensures safe, compliant operation, protects capital investment, and maintains continuous system reliability.

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