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Hollywood Turns to Nationwide Boiler During Filming of Titanic

Shortly before midnight on April 14, 1912, the “safest and most luxurious passenger ship ever built” hit an iceberg off the Newfoundland coast. After lying dead in the water for about two-and-a-half hours, her bow began to submerge. In just minutes, this giant ship was nearly vertical, her stern soaring hundreds of feet in the frigid night air. Great plumes of steam billowed from her four stacks as she began her long descent to the bottom of the sea. More than 1,500 people stood on the decks singing “Nearer My God to Thee” as she slid beneath the waves taking them with her to their watery grave, thousands of feet below. That was the maiden voyage of the most famous luxury liner ever built, the White Star Lines’ Titanic. And it was the worst disaster in commercial naval history.
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Fifty-five years later, almost to the day, a crew of Hollywood actors, technicians, directors, camera operators, and the myriad others required to make a modern motion picture gathered a few miles south of Rosarito Beach on the west coast of Mexico’s Baja, California peninsula to recreate that dreadful night. To duplicate the steam erupting from the Titanic’s exploding boilers, Warner Brothers, 20th Century Fox and Paramount Pictures – all of whom are involved in the picture – turned to Nationwide Boiler.

A few weeks before filming of the sinking sequence began, Nationwide Boiler sales engineer, Russell Rabago received a call from one of the film’s special effects coordinators inquiring about the availability of a steam plant for use in the film. Within days, Russ was on his way to Mexico to examine the location and make sure about all the details. By late January, two of Nationwide’s mobile steam plants were loaded on trucks and headed to the border. Within days of their arrival, they were making steam. During filming, the steam provided by Nationwide Boiler’s equipment was used to simulate the effect of exploding boilers as the Titanic sunk. During filming of the Titanic’s sinking, “Even the stunt people looked scared when they saw the dailies of the 90-degree angle shot,” reported Francis Fisher, one of the lead actors in the film.

Titanic is one of the most expensive movies ever made. Currently, the estimated cost is $150 million. Although originally scheduled for a summer release, it is now planned to be in theaters this winter. To get a better idea why Titanic required such an enormous investment, consider the facility where the sinking sequence was simulated. First, new studio facilities were built. Next, an 80-foot-long model of the ship was constructed. Then the model was floated in a 180-million-gallon tank, constructed specifically for this sequence. And all this construction was only for the exterior shots. Interior sequences were filmed earlier over a period of many months.

“We’re not sure if Nationwide Boiler’s name will appear when the screen credits roll, but we’ll be watching,” says Mr. Rabago. “From everything that’s been reported so far, it will be a film like Gone with the Wind, which everyone will view sooner or later, and one they’ll be talking about for years to come.” Someday, Mr. Rabago will probably tell his grandchildren about the important part he played in making one of the greatest motion picture spectaculars of all time.

This article was originally featured in the Summer 1997 edition of our Steamlines newsletter.

Essential Steps for Safe and Efficient Rental Boiler Equipment Return

At the end of a rental boiler project, proper decommissioning is key to ensure safe transport back to the rental boiler supplier and to avoid any unforeseen costs. It’s not just about disconnecting and moving the equipment - taking a few simple precautions can prevent potential damage and ensure everything is ready for return. Review and follow the steps below for a smooth, hassle-free pick-up and return of your rental boiler equipment.

Drain & Flush

Start by thoroughly draining and flushing all the boiler lines with clean water, making sure all water drain valves are fully opened. This step helps eliminate any remaining water that could cause corrosion or freeze damage, potentially harming the system during transport or storage. Flushing the lines also removes debris and buildup, improving the boiler’s performance for future use.

Inspect

Next, take the time to carefully inspect both the fireside and waterside surfaces for any visible damage, scale buildup, or issues with the refractory lining. These areas are crucial to the boiler’s efficiency, and any damage or buildup could lead to serious problems later. It’s also a good idea to take clear photos of the boiler’s condition at the end of the rental period. This way, there is a record to reference in case there are any questions or concerns about its condition when returned.

Equipment Prep for Removal

The stack and other components that were installed upon arrival to the jobsite should be removed and mounted back on the rental boiler trailer and/or shipping skid. Be sure to securely bolt the stub stack, non-return valve, safety valves, and vent valve back into place, just as they were when the equipment was delivered. Aligning everything properly ensures that each component stays in place during transport, avoiding movement or potential damage.

Additional equipment prep should be completed as follows:

  1. Cover all boiler openings: this includes the stack, steam, gas, and water connections, electrical panel, and safety valve openings.
  1. Reattach running gear and gooseneck: If the trailer was taken apart for transport, ensure that the running gear and gooseneck are properly reattached before moving the trailer.
  1. Check tire pressure: Before transport, it's important to check the tire pressure of the trailer. Make sure the tires are inflated to the manufacturer’s recommended levels for optimal performance and safety.

By following these steps the return process becomes seamless, protecting the rental boiler, feed system or auxiliary equipment and ensuring that everything is handled properly from start to finish. If you have questions about preparing for the return delivery of your rental boiler equipment, don't hesitate to call Nationwide Boiler at 800-227-1966.

Wet and Dry Storage Methods

Boilers are important components in many industrial settings and ensuring their longevity and efficiency requires proper maintenance, even during out-of-service periods. To prevent corrosion and other forms of damage when a boiler is offline, it is important to protect both the fireside and waterside of the boiler. There are two methods in achieving this – the dry method and the wet method.

Dry Storage

When a boiler is expected to be out of operation for an extended period of time and needs to be ready for service quickly, dry storage is advised. The dry storage method for industrial boilers involves draining, thoroughly cleaning, drying, and sealing the boiler to prevent moisture and air entry during extended periods of inactivity.

NOTE: If you are placing your boiler in storage for less than one month, follow steps 1 and 2 only. Be sure to follow your company guidelines and, at a minimum, label it as an oxygen-free atmosphere.

The following general procedure is advised for placing a unit into dry storage:

  1. Shut down and secure the boiler. Once the pressure decreases to 20 psig, drain the boiler and header valves under air. Once the pressure is reduced to 0, open the drums to allow air to circulate and facilitate the drying of all internal surfaces.
  1. If the unit is cold and filled with water, drain it under air, blow out non-drainable tubes with compressed air, and use external heat sources to aid in drying internal surfaces. Install non-porous trays with moisture absorbent (preferably silica gel) into the drums, ensuring they don't touch the drum's metal surface. Use at least one pound of absorbent per 1,000 pounds per hour of steam capacity.
  1. Attach nitrogen to the steam drum vent, close all other vents, and pressurize the boiler to reach 10-15 psig with nitrogen, adjusting the amount based on the unit's volume.
  1. With the boiler and superheater pressurized, alternately open all drains to purge air until the pressure drops to zero, repeating as needed to minimize oxygen levels.
  1. The unit should now be stored with a nitrogen pressure of 5-10 psig in the steam drum. To maintain this pressure, ensure all connections and valves are sealed or tightly closed, and check the gas pressure daily for proper protection.
  1. Boiler inspections are recommended every 3 months to ensure no corrosion is occurring and to replenish the absorbent as needed. During these inspections, air will enter the unit so you will need to repeat steps 3 and 4 to expel the air.

Wet Method

Wet storage prevents corrosion by keeping the boiler fully submerged with the right chemicals. Volatile chemicals are recommended to avoid increasing dissolved solids in the water.

The following general procedure is advised for placing a unit into wet storage:

  1. Fill the boiler with deaerated, demineralized water treated with 200 ppm hydrazine and enough ammonia to reach a pH of 10.
  1. Pre-mixing chemicals with water is recommended, using the blend-fill method to ensure uniform distribution in the boiler. Simply adding chemicals through the drum manhead may not adequately disperse them unless the boiler is heated to induce circulation.
  1. Fill the unit with treated, demineralized water up to the normal centerline of the steam drum, then stop the filling process.
  1. Refill the superheater with treated demineralized water until the steam drum level rises. Keep filling until water starts to flow from the steam drum vents. Once the filling is complete, make sure all connections are securely sealed.
  1. Attach a low-pressure nitrogen source to the steam drum to maintain 5 to 10 psig and prevent air from entering the unit during storage.
  1. When the boiler is ready for use, drain the superheater and the boiler drum to the normal start-up water level and resume operation.
  1. Analyze the treated demineralized water weekly and add chemicals as needed through the chemical feed line to maintain recommended levels. Water samples can be collected from the continuous blowdown line or a suitable drain.
  1. A boiler should not be stored wet if there is any risk of temperatures dropping to freezing, unless adequate heating is provided. Adequate heating will prevent water from freezing and avoid damage to the pressure parts.

Protection of External Surfaces:

Protection of external surfaces is also necessary during periods of extended downtime. Fireside corrosion in idle boilers can cause damage to components due to sulfuric acid from flue dust and ash. To mitigate this, remove deposits using air blasting, washing, scraping, or brushing, and neutralize any residual acid with alkaline water until the water is fully neutralized. Once flushing is complete, fill the boiler with treated water and fire it with low sulfur fuel to ensure complete drying.

Auxiliary heaters and blowers may be needed during storage to keep the metal temperature above the dew point and prevent freezing, especially with wet storage in cold conditions. Additionally, protect machined surfaces with preservative coatings and ensure there are no fuel leaks by disconnecting all oil and gas connections.

The choice between dry and wet storage depends on different factors. Although wet storage is often preferred, factors such as water quality, weather conditions, storage duration, and heat availability may make dry storage a more practical option. Be sensible when considering the conditions and needs of your boiler and choose the best storage method to ensure your equipment remains in excellent condition and is ready for use when needed.

Preventing Slips, Trips, and Falls

In honor of National Safety Month, our next safety topic is focused on preventing slips, trips, and falls which are common causes of workplace injuries. Below are some essential steps you can take to mitigate these risks and ensure a safer workplace.

Keep Work Areas Tidy: Ensure that all work areas are free from clutter. Clean and organized spaces significantly reduce the risk of tripping by minimizing obstacles that could cause falls. Inspect and tidy up your workspace, making it a habit to return tools and materials to their designated storage areas. This practice not only enhances safety but also improves overall efficiency and productivity.

Proper Waste Disposal: Dispose of waste materials promptly and place them in designated bins. Proper waste disposal supports environmental sustainability efforts by facilitating recycling and reducing landfill waste. Remember, a tidy work area is a safer and more efficient one.

Immediate Cleanup of Leaks and Spills: Clean up any spills or leaks immediately to prevent slippery surfaces. Prompt action is crucial in preventing potential accidents and maintaining a safe work environment. Leaving spills unattended can lead to slips, trips, and falls, which are among the most common workplace injuries. Ensure that you use appropriate cleaning materials and methods for different types of spills to effectively remove the hazard.

Wear Appropriate Footwear: Use suitable footwear, such as anti-slip shoes, and ensure compliance with protective footwear requirements, especially in shop and service areas. Remember, proper footwear is a key component of personal protective equipment (PPE) and plays a vital role in injury prevention.

Manage Cords and Cables: Keep cords and cables out of walkways and use covers or secure them to avoid creating tripping hazards. Loose or improperly managed cables can cause someone to trip and fall, leading to potential injuries and disruptions in the workplace. By ensuring that cords and cables are neatly arranged, you help maintain a clear and hazard-free walking area.

Stay Aware of Your Surroundings: Be mindful of your environment and focus on your tasks. Awareness is key to avoiding accidents. Staying alert of your surroundings helps you identify potential hazards before they become problems. This includes being aware of the location of equipment, other people, and any changes in the environment that might present new risks.

Adapt to Weather Conditions: Adjust your work practices according to the weather conditions. Exercise extra caution on wet or icy surfaces. Weather can impact workplace safety, so it's important to adapt your routines accordingly to minimize risks.

If you see a hazard with the potential to cause a slip, trip, or fall, take immediate action to address it and do not wait for someone to intervene.  By following these guidelines, we can create a safer workplace for everyone. Remember, safety is a shared responsibility, and your actions play a vital role in safeguarding the work environment.

Celebrate National Safety month with us and stay tuned for another safety topic next week!