Boiler Blog | Nationwide Boiler Inc.

At Nationwide Boiler, we’ve spent more than four decades helping industries meet demanding emissions requirements with solutions that deliver reliability, performance, and proven results. Our CataStak™ Selective Catalytic Reduction (SCR) System is one of those solutions—engineered to achieve ultra-low, single-digit NOx emissions on package boilers and a wide range of fired equipment. As air-quality regulations continue to tighten, understanding NOx and the importance of emissions control is more critical than ever.

What Is NOx?

NOx, or nitrogen oxides, represents a group of highly reactive gases formed when nitrogen and oxygen combine during high-temperature combustion. These emissions are common in industrial boilers and fired equipment, including:

• Package boilers
• Fired heaters
• Gas turbines
• Heat recovery steam generators

The amount of NOx produced depends on several operational factors:

• Fuel type
• Burner design
• Peak combustion temperature
• System configuration
• Use of emissions-control technology such as an SCR

Why Reducing NOx Emissions Matters

Once released into the atmosphere, NOx contributes to a series of reactions that impact both environmental quality and human health. Even at low concentrations, these gases can significantly affect regional air quality.

• Ground-Level Ozone (Smog)
  NOx reacts with volatile organic compounds (VOCs) in the presence of sunlight to form ground-level ozone—a major component of smog. Unlike the protective ozone layer, this type of ozone is harmful, contributing to crop damage, reduced visibility, and stressed vegetation. 

• Acid Rain Formation
  When NOx combines with moisture in the atmosphere, it forms nitric acid, a leading cause of acid rain. Acid rain can accelerate the deterioration of buildings, deplete soil nutrients, and disrupt lakes and streams.

• Water Quality Concerns
  Nitrogen compounds from NOx emissions can wash into waterways, fueling algae growth. These algal blooms reduce oxygen levels, harm aquatic life, and create lasting ecological imbalances.

• Climate Influence
  While NOx itself is not a greenhouse gas, it contributes indirectly to climate change by forming ground-level ozone, which is considered a greenhouse gas. Reducing NOx helps minimize an operation’s overall environmental footprint.

• Human Health Considerations
  Exposure to NOx can irritate the respiratory system and worsen existing lung conditions. Elevated levels may increase asthma attacks, aggravate bronchitis, and reduce overall lung function. Children, older adults, and individuals with respiratory sensitivities face the greatest risk.

Nationwide Boiler’s Role in Emissions Compliance

Since the early days of federal emissions legislation, Nationwide Boiler has been a trusted partner in helping facilities meet—and exceed—air-quality requirements. Our team provides engineered solutions tailored to each application, supporting reliable performance and long-term compliance.

For operations that require deeper emissions reduction or consistent performance across a wide operating range, our CataStak™ SCR System delivers emissions compliance without compromise. The CataStak has been proven across hundreds of installations on boilers and fired equipment in demanding industrial environments. Its modular design supports both ammonia and urea-based reagent systems, allowing facilities to choose the solution that best aligns with their operational and safety requirements. With horizontal and vertical configurations, the CataStak can be engineered to fit a wide variety of system layouts, space constraints, and performance needs. Regardless of the application, the result is the same: reliable, near-zero NOx emissions and a system built for long-term, cost-effective operation.

Ultra-low NOx burners are another viable option, designed to minimize NOx formation at the source by optimizing air–fuel mixing and reducing peak combustion temperatures. These burners have consistently demonstrated the ability to achieve ultra low NOx emissions, as low as 5 ppm in many firetube boiler applications. Through ongoing research and development, we’ve also seen promising results at even lower levels in select operating conditions—particularly on smaller firetube boiler systems. While these advancements continue to be refined, they highlight the potential for future solutions that push emissions performance even further.

And lastly, for facilities looking to eliminate combustion-related emissions entirely, electric steam boilers offer a viable, zero-emissions-at-the-source alternative. Because they operate without fossil fuels, electric boilers do not produce NOx, CO, or greenhouse gases at the point of use. While they are not the right fit for every application—particularly where high steam capacities are required—they can be an effective option in regions with clean, reliable electricity or for processes with strict emissions or permitting requirements.

 Nationwide Boiler remains committed to helping facilities operate cleaner, more efficiently, and more sustainably. Our decades of experience—and the proven performance of our environmental solutions—ensure that your operation can meet today’s air-quality standards and future requirements with confidence.

Originally posted in July 2017, this blog has been updated to reflect current information and evolving air-quality regulations.

In industrial settings where boilers are vital to operations, safety and reliability are non-negotiable. One often overlooked component is the fuel train, or gas train, which plays a critical role in controlling fuel delivery. During budget cuts, maintenance of this system is frequently deferred—an oversight that can lead to gas leaks, combustion failures, and serious safety hazards. For facilities operating high-pressure steam systems, regular gas train maintenance is essential to prevent incidents and ensure safe, reliable performance.

Understanding the Role of the Gas Train

The gas train is a system of mechanical and electrical components that regulate fuel flow and pressure to the burner. It includes shut-off valves, regulators, pressure switches, solenoids, and piping—all working together to ensure safe fuel delivery and immediate shutdown in unsafe conditions.

Gas trains are designed to:

• Prevent unburned fuel from entering the combustion chamber
• Shut off fuel flow in the event of unsafe operating conditions
• Maintain consistent gas pressure for efficient burner operation
• Enable both manual and automatic control of fuel delivery

Even in systems equipped with modern burner management systems and interlocks, the effectiveness of these safety measures depends on proper maintenance and operator awareness.

Risks of Inadequate Maintenance

Neglecting gas train inspection and testing can lead to component failures that may not be immediately apparent but can compromise the entire combustion system. Common issues include:

• Leaking or sticking safety valves
• Inaccurate or failed pressure switches
• Improperly functioning regulators
• Worn or bypassed interlocks
• Electrical wiring faults

In many documented incidents, failures were not due to a lack of safety devices, but rather a lack of routine testing and operator training. Preventive maintenance is essential to avoid these scenarios.

Best Practices for Gas Train Safety

Implementing a structured maintenance and safety program can mitigate risks and improve system reliability. The following practices are strongly recommended:

1. Staff Training and Competency

Operators must be trained not only in basic boiler operation but also in combustion safety and hazard recognition. Training programs should include hands-on system reviews, mock upset drills, and instruction on emergency response procedures. Even when maintenance is outsourced, in-house personnel should have a fundamental understanding of the systems they oversee.

2. Written Startup and Shutdown Procedures

Many combustion incidents occur during equipment startup or shutdown. Standardized, clearly written procedures ensure consistency across shifts and personnel. These procedures should include purge verification, valve testing, and system readiness checks.

3. Routine Testing and Documentation

Facilities should establish a regular schedule for testing gas train components, including:

• Valve leak and tightness testing
• Functional testing of pressure switches and interlocks
• Flame safeguard system checks
• Compliance with applicable NFPA, ASME, and local code requirements

Documenting all tests and inspections ensures traceability and supports compliance efforts.

4. Third-Party Equipment Reviews

When acquiring new equipment or undergoing significant upgrades, a third-party review can help verify compliance, confirm correct installation, and identify design deficiencies. This is especially important when retrofitting legacy systems with modern controls or safety components.

5. Proactive Equipment Upgrades

Waiting for failure is not a viable safety strategy. Facilities should establish a timeline for replacing aging components and upgrading outdated systems. Modern PLC-based burner management systems and digital flame safeguards offer improved diagnostics, safety, and reliability.

Building a Culture of Safety

The safe operation of permanent boilers, rental boilers, and boiler combustion equipment depends not just on hardware, but on the culture and procedures that support it. Gas train maintenance should be treated as a critical operational task—not an afterthought. Investing in training, testing, and system upgrades enhances reliability, reduces unplanned downtime, and most importantly, protects personnel.

This blog post was originally published in September 2011 and has been updated to reflect current best practices, safety standards, and advancements in gas train maintenance.

When timing is everything, Nationwide Boiler's in-stock boiler program delivers the solutions today’s industry demands. In 2025, ourteam successfully delivered a fast-track project including a 180,000 lb/hr, 500 psig B&W package watertube boiler with CataStak™ SCR system to a major West Coast food processing plant, overcoming logistical and regulatory challenges to keep production on track.​

This delivery exemplifies our philosophy of “Boiler Procurement, Redefined” — giving customers immediate access to high‑capacity steam without the delays typical of traditional equipment sourcing.

Meeting Urgent Customer Needs with Strategic Boiler Procurement

The project began when a long-term customer faced a critical capacity challenge. As production needs outpaced their older equipment, the prospect of waiting a year for a new boiler was not viable. Thanks to our strategic in-stock boiler program, a high-capacity B&W package watertube boiler was available for immediate shipment, transforming a potential bottleneck into a rapid success story.​

Nationwide Boiler maintains a broad range of in-stock solutions such as this 180,000 lb/hr model, enabling rapid shipping and installation across the United States and globally. Inventory covers everything from compact 50 HP vertical units to large 255,000 lb/hr superheated watertube boilers, including essential ancillary equipment like feedwater systems, blowdown separators, water softeners, and CataStak™ SCR Systems for ultra-low NOx compliance. This diversity enables customers to access rapid replacements or planned upgrades without lengthy lead times and fabrication delays.​

This is exactly what “Boiler Procurement, Redefined” means: eliminating the long lead times and uncertainty typically associated with major steam equipment purchases.

Overcoming Logistics and Delivery Challenges

Transporting equipment of this scope requires both engineering expertise and logistical finesse. Because the 180,000 lb/hr boiler was too large to transport upright, it was rotated 90 degrees and shipped on its side from Kansas to California, with police escorts ensuring both public safety and on-time arrival. When trucking emerged as the optimal solution over rail due to control and delivery timeline concerns, the engineering and logistics teams coordinated every phase to maintain speed and reliability.​

Preparation also extended beyond transport. Early piping and foundation work enabled site teams to quickly tie in connections and reduce installation timeframes once the boiler arrived.​ By managing complex moves like this, we continue redefining what boiler procurement can look like — faster, smoother, and engineered for control.

Navigating Emissions Compliance and Customization

Permitting requirements are often the major hurdle for large steam projects, especially in states like California with strict air district requirements. In this case, the replacement boiler required compliance with stringent emissions standards including 2.5 PPM NOx, 10 PPM ammonia slip, and 25 PPM CO. Our project team worked closely with both the end-user and regulatory authorities, customizing the system with Nationwide’s CataStak™ SCR technology and an enhanced heat-recovery economizer to minimize emissions and maximize operating flexibility.​

The ability to match technical solutions such as fully metered controls and customized economizers to each customer’s needs establishes Nationwide Boiler as a trusted partner for food processors, petrochemical companies, and manufacturers with tight project windows and demanding performance expectations.​

Proactive Planning Pays Off for Mission-Critical Steam

A key takeaway for plants facing urgent steam shortages is that planning ahead is vital. Boiler owners and operators should consult with their team early to establish tie-in points, assess site needs, and prepare for seamless installation should an emergency arise. With standardized drawings, in-stock units, and engineered ancillary packages available, facilities can trust Nationwide Boiler to help them avoid costly downtime and accelerate timelines when every hour counts.​

This proactive approach aligns with our vision of “Boiler Procurement, Redefined” — enabling facilities to prepare for the unexpected and deploy solutions without delay.

The Nationwide Advantage: Inventory, Experience, and Customer Commitment

Whether the need is for new, reconditioned, or rental boilers, Nationwide Boiler’s extensive  inventory and experienced technical staff enable companies to address equipment failures or fast-track expansion plans. Our in-stock inventory spans a wide range of capacities, support equipment, and compliance solutions, ready to ship and ready to solve real-world challenges.​

Looking for a boiler solution ready on your schedule? Nationwide Boiler delivers on site and on time, backed by decades of expertise, redefining the traditional model for boiler procurement.

Celebrating Diversity, Connection, and Leadership in the Boiler Industry

Nationwide Boiler recently participated in the inaugural Women in the Boiler Industry (WIBI) Symposium, held in Minneapolis, MN, on October 15-17^th, 2025. Hosted by the American Boiler Manufacturer Association (ABMA), the event joined women and men within the boiler industry to celebrate diversity, foster connections, and advance the future of the boiler industry. Our company proudly sponsored the Welcome Networking Reception for this event, and we were thrilled to have Chelsey Ryker, Director of Marketing & Communications, represent our team.

Bringing together professionals from across North America, the WIBI Symposium was a two-day event full of inspiration and learning. Attendees participated in industry tours, keynote sessions, interactive workshops, and roundtable discussions focused on shaping a more inclusive and dynamic industry. The event included keynotes and fireside chats for building leadership presence and personal mastery, as well as roundtables and panels with trailblazers whose impact is igniting change throughout the boiler community.​ The event also included sessions on boiler code changes, financial management, boosting creativity and productivity through AI, positive communication, and boiler safety.

Nationwide Boiler’s Commitment to Visibility and Advancement

In addition to her participation, Chelsey also served on the WIBI Advisory Committee to help shape the impact of the event. She expressed  the importance of Nationwide Boiler’s support of events like this through a video interview in the weeks leading up to the WIBI Symposium. “Supporting WIBI means we’re investing in visibility, empowerment, and advancement of women in our field,” she noted, underscoring Nationwide Boiler’s dedication to fostering innovation through inclusion. “It’s about creating space for new voices, showing that Nationwide Boiler stands behind the people who are shaping our future.”​

She also shared her excitement about connecting with fellow women in the boiler industry and the value of building a community where stories, experiences, and diverse perspectives can be shared. “Women can be leaders in this industry; an industry that [is evolving to embrace greater diversity], and women bring a unique perspective,” she said. “Events like WIBI matter because they shift the narrative. They show that women not only belong in the industry but they’re already leading, innovating and driving change.” The WIBI initiative goes beyond networking; it's about opening doors to new opportunities and inspiring women to pursue leadership roles, fostering a more inclusive and forward-thinking industry.

Leadership, Recognition, and Looking Ahead

The WIBI Symposium concluded with a dynamic panel of distinguished leaders sharing philosophies and lessons learned, and new awards celebrated trailblazers and rising stars who are shaping the future of the sector. As one event organizer noted, “The 2025 WIBI Symposium was more than a meeting, it was the beginning of a movement.” This year’s event reinforced a powerful truth: progress happens when diverse voices lead the conversation and collaborate toward shared goals.

Nationwide Boiler is proud to champion this progress, continuing to lead initiatives that foster diversity, innovation, and an inclusive future for all professionals in the industry.