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Keeping It Safe: Why Gas Train Maintenance Should Never Be Overlooked

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.

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How Nationwide Boiler Maintains High-Performance Rental Boiler Systems

Reliability and Versatility of Nationwide Boiler’s Rental Fleet

Nationwide Boiler operates and maintains one of the largest and most versatile rental boiler fleets in the industry. Our purpose-built rental inventory includes over 100 temporary boiler systems ranging from 47.5 HP to 200,000 lb/hr, stored in multiple locations across the country. We offer multiple configurations including complete mobile boiler rooms, trailer-mounted watertube and firetube boilers, skid-mounted systems, factory-integrated skid packages, fully electric boiler systems designed for zero-emissions operations, and a suite of boiler auxiliary equipment options. This diverse inventory allows us to respond quickly and effectively to emergency outages, planned maintenance, or increased seasonal demand.

Reliable Steam Solutions for Diverse Industries

One of the key advantages of renting from Nationwide Boiler is our ability to provide fast, reliable steam solutions that are tailored to your application. Whether your facility requires low or high capacity, saturated or superheated steam, boiler-only or a complete temporary steam plant, our rental boiler fleet is engineered to support continuous, dependable operation. Our solutions support a wide range of industries including food processing, petroleum and chemical refining, power generation, pulp and paper, manufacturing, and more.

Maintenance and Refurbishment of Rental Boilers

As with any heavily utilized piece of equipment, rental boilers often return to our shop in need of service. Not every rental requires major repairs, but every unit goes through a standard inspection and maintenance process before being returned to service. Our skilled technicians perform routine tasks such as gasket and valve replacements, tube brushing, burner tune-ups, and safety control testing to ensure each system meets the high quality standards we’ve set over the years. These preventative and corrective measures address normal wear and tear that naturally occurs over the course of a rental. Having a disciplined approach to maintenance helps us minimize future service calls, ensure performance reliability, and reduce the total cost of ownership for our customers.

In rare cases, a unit may be damaged beyond repair and must be retired from service. However, thanks to our experienced fabrication team and dedicated Quality Control Department, most boilers are restored and returned to service in like-new condition. With proper maintenance, boilers can provide reliable performance for decades.

Why Retube a Boiler?

A complete boiler retube is one of the most effective ways to extend the life of a heavily damaged boiler, particularly in demanding industrial environments. Over time boiler tubes naturally wear down due to constant use, high temperatures, and exposure to impurities in the water. However, the lack of proper maintenance and water treatment can quickly accelerate this, leading to major damage to the internal boiler tubes and creating an immediate need for retube or complete system replacement.

When boiler tubes become corroded or damaged, overall performance, efficiency, and safety can decline, causing costly downtime or even system failure. Retubing restores the boiler’s internal components, significantly improving efficiency and returning the system to like-new condition.

A Commitment to Reliability, Sustainability, and Performance

At Nationwide Boiler, we take pride in our ability to perform quality service and maintenance on our rental fleet, as well as refurbish and repurpose equipment whenever the need arises. Retubing not only extends the useful life of our boilers but also plays a key role in our sustainability efforts. Instead of scrapping boilers that still have a solid pressure vessel and frame, we focus on restoring their core components. This approach reduces waste, conserves resources, and helps us maintain a high-quality, cost-effective rental fleet.

Our commitment to maintaining a high-performance rental boiler fleet ensures that our customers receive dependable, code-compliant, and cost-effective steam solutions every time. Whether you need a short-term rental for a few weeks or a long-term solution for several months, Nationwide Boiler has the equipment, expertise, and service to keep your operations running smoothly.

This blog post was originally published in June 2021 and has been updated to reflect the latest advancements in boiler maintenance, sustainability practices, and the continued expansion and modernization of Nationwide Boiler’s rental fleet.

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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.

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Nationwide Boiler Raises More Than $63,000 At 43rd Annual Charity Golf Tournament!

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Last month Nationwide Boiler hosted our 43rd Annual Charity Golf Tournament at the renowned Pebble Beach Golf Links and it was another great success! Drawing in participants from across the nation, the event gathered a diverse and enthusiastic crowd ready to support two great causes.

The tournament kicked off with a practice round and a scramble competition at Poppy Hills Golf Course, where the golfers enjoyed pleasant sunshine throughout the day. As evening approached, golfers and guests gathered for a welcome reception to enjoy drinks and appetizers, socialize, and purchase tickets for the highly anticipated raffle for 1 oz. of gold. Our tournament round took place the following morning at Pebble Beach Golf Links followed by a Hawaiian Luau themed awards banquet and buffet dinner later in the evening.

At the awards banquet, guests donned floral Hawaiian attire with real orchid leis while enjoying live island music by the Ho ‘Omana Trio. Guests also participated in online and live auction events as well as our unique Deck of Cards Raffle.  Don Thiry was our big winner that night, taking home the raffle prize of 1 oz. of gold in addition to having the winning card for the Deck of Cards Raffle! However, in a surprising twist of events, he sold his winning card for $200 and the remaining $800 prize was generously donated back to the charities. These acts highlight the sportsmanship and goodwill that make our tournament special.

In addition to the fun and fundraising activities of the banquet that evening, Nationwide Boiler’s President and CEO, Larry Day, announced the winners of the tournament. Matt Whittington of Hurst Boiler took home the Callaway Flight Championship, Mitch Frank of HTS took home the Handicap Flight Championship, and Geoff Wilkinson Jr. of GT Wilkinson Companies took home the Low Gross Championship. Nationwide Boiler’s Jack Valentine took home the award for Closest to the Pin, and, for the first time in the history of this tournament, Longest Drive was awarded to a women golfer, Emily Forth of Tulsa Heaters Midstream.

With the aim of benefiting two impactful causes, Make-A-Wish® Greater Bay Area and ABMA’s Randy Rawson Scholarship Fund, the tournament was a resounding success with a total amount raised exceeding $63,000! This achievement was made possible by the support of roughly 100 attendees and the generous contributions of nearly 60 sponsors and donors. Nationwide Boiler is proud to continue raising funds for these two great organizations, and we extend heartfelt gratitude to everyone who supported the event this year.

Make-A-Wish® Greater Bay Area is all about making dreams come true for children facing critical illnesses, giving them unforgettable experiences and much-needed hope.  This chapter serves 17 counties in Northern California and has granted over 9,500 wishes to date, providing approximately 350 life-changing wishes each year. The ABMA’s Randy Rawson Scholarship Fund supports students aiming for careers in the boiler industry. This fund plays a crucial role in nurturing the next generation of professionals in this important field by offering scholarships that ease the financial burden of education.

Save the Date! Our 44th Annual Pebble Beach Charity Golf Tournament is scheduled for May 7 – 8, 2025 at Pebble Beach and Spanish Bay. As we reflect on the memories made and the differences we created, we extend our deepest thanks to all who participated in making this event a success. We look forward to another incredible tournament next year!

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