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Innovative Leaders: Virtual FAT Testing

Nationwide Boiler is known as being an innovative leader in the rental boiler industry. Over fifty years ago we pioneered the mounting of a 24,000 lb/hr package watertube boiler to a highway-legal trailer, and followed with many other firsts including the world’s largest trailer-mounted saturated and superheated steam boilers (125,000 lb/hr and 110,000 lb/hr, respectively).

In this age of digital technology and pandemic isolation requirements, Nationwide Boiler’s control division, Pacific Combustion Engineering, realized the need for virtual factory acceptance testing (FAT). An FAT is an essential element of the testing and acceptance of new critical control systems. The main goal of this test is to prove and certify performance built for a specific application and ensure all design requirements are attained.

Pacific Combustion’s new test gear consists of a 19” HMI that replaces toggle switches, indicating lights, potentiometers, and analog gauges. A PLC drives relays and consists of contacts that can be configured for the voltage that is required for input simulation. Outputs are displayed via selectable 120vac and 24vdc terminals. Analog 4-20ma inputs are selectable as either loop or self-powered.

During the virtual FAT, a web portal is accessible by the client through an audio/video link to the testing, and the client can actually operate the test rig HMI screen from their location. Links are also furnished to the burner management / combustion control system PLC and HMI.

This is a truly unique innovation at a time where travel can be difficult, providing an alternative to the traditional FAT and allowing business to continue even in heightened times like a global pandemic.

For more details on our virtual FATs, be sure to check out our upcoming feature in Process Heating Magazine. We will post the direct link as soon as it's available. And be sure to give Pacific Combustion Engineering a call to assist with your next control system upgrade. 360-335-1443

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Ramping Up Our Stock Boiler Program

At Nationwide Boiler, we are known for our relationship with B&W as a partner and stocking distributor. The FM-120-124 B&W D-Type Package Watertube Boiler, also known as our “World Boiler”, is always in stock and has been sold to six of the seven continents in the world. In recent years, we have ramped up our stock boiler program to also include new Superior firetube boilers in a variety of configurations.

To start off, we added two specialized, factory integrated packages. These 47.5 hp and 119 hp skid-mounted package boilers are pre-piped and wired and include a duplex feedwater system and blowdown separator with after-cooler. The 47.5 hp boilers are pre-certified for use in the most stringent California air districts, while the 119 hp packages are PEER compatible for both the SCAQMD and SJVAPCD jurisdictions. Our 475 hp, 150 psi design Superior skid-mounted firetube boiler, equipped with a Webster 7ppm NOx burner, is also ideal for customers in the most stringent areas of California. All three of these systems are currently available from our shop in Fremont, CA. 

To round out our stock inventory of pacakge firetube boilers, we now have the following brand new Superior boilers available for quick ship and immediate needs: 

These stock boilers are pre-built with the burner left purposely un-mounted to allow for greater flexibility in matching the unique fuel, emissions, and combustion needs of each customer. The burner can be quickly mounted prior to delivery or installed at the site, based on customer preference. The boilers are designed for indoor and outdoor applications, with most currently being stored at the manufacturing facility in Hutchison, KS. All units are now available for immediate shipment upon customer request.

We also have our very first, zero emissions electric boiler now available for rent or for sale. This boiler, built to provide 50 hp steam at a design pressure of 150 psig, is another one of our factory integrated units, with feedwater system and blowdown separator pre-piped and wired as a skid-package.

In addition to the new boilers that we purchase specifically for our stocking program, our fleet of rental boilers and auxiliary equipment range in size and in age. We are always open to providing a solution from our rental fleet as well, if the opportunity arises. Be sure to check out or complete inventory of boilers available for sale to find a unit that fits your unique needs. 

Please give us a call at 800-227-1966 if you have an immediate boiler need that can be fulfilled from our stock of brand new boilers, reconditioned boilers, or equipment from our rental fleet.

And check out our latest Steamlines newsletter, to find this article as well as other recent project highlights, equipment spotlights, and company updates.

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CataStak SCR System Exceeds NOx Guarantee

Nationwide Environmental Solutions is a division of Nationwide Boiler, formed over a decade ago to provide emissions and efficiency solutions to our wide range of customers. In today's day and age, protecting the environment and reducing the production of greenhouse gases is more important than ever, which is why we are so proud to have a product that exceeds expectations time and time again. 

Most recently, we teamed up with MDH Boiler Serviced to supply a food processing facility in Southern California with a new burner and CataStak SCR system retrofit for their existing 475 hp firetube boiler. With lower than typical exhaust temperatures for an SCR application, a more robust system was designed to ensure adequate performance. We are happy to report that the system not only met the guarantee of 5 ppm NOx, but actually exceeded expectations and tested at just 1 ppm NOx and 1 ppm ammonia slip! Exciting news for the team, solidifying future orders that will support the end-user efforts in reducing their company's overall greenhouse gas emissions. Check out our latest press release for the full story.

If your facility is under an air district mandate to reduce the NOx and/or CO output from your boiler or other fired equipment, give us a call at 1-800-227-1966 to learn how we can help.

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New 110,000 lb/hr Superheat Boiler Provides Increased Steam Capacity

With short summers and weather as unpredictable as it is charming, much of Newfoundland and Labrador relies on NARL Refining’s ability to provide warmth and clean fuel. We were able to assist with the refinery’s needs by providing them with one of our new in-stock 110,000 lb/hr trailer-mounted superheat boilers. The 750 psig design watertube boiler was manufactured by Babcock & Wilcox, who recommended Nationwide Boiler for the job per our stock boiler program.

To learn more about the boiler sale and how we were able to accommodate the customer’s need for an immediately available unit, read our latest case study. (PDF will download in a new window.)
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