Over the years, our team has answered thousands of questions about catalytic heater startup, gas pressure verification, preheating procedures, and low-temperature shutoff valve operation. While we’re always ready to support our partners, we saw an opportunity to make installation clearer from the start.

So we built something better.

We created the CATCO Heater Set-Up Guide — a structured, field-ready document designed to simplify installation and reduce guesswork.

The guide walks technicians through a straightforward 5-step process:

• Proper mounting

• Fuel connection

• Verifying natural gas pressure (approximately 4.5” W.C.)

• Preheating and initiating fuel flow

• Confirming steady radiant operation

It also includes a troubleshooting FAQ section built directly from real-world field questions — helping reduce preventable issues and unnecessary downtime.

This guide was designed to support installers, distributors, and technicians working in demanding environments where clarity matters.

You can download the CATCO Heater Set-Up Guide now in the Resources section of our website.

More structured setup and troubleshooting guides are coming soon as we continue expanding our technical resource library.

Because at CATCO, we don’t just build heaters.

We build clarity.

And clarity drives performance.

The post CATCO Heater Installation Guide | Setup & Troubleshooting appeared first on Catco.

The shift ended like any other.
The wind cut across the yard, frost gathering on every surface.
“Nothing we haven’t seen before,” one tech said, locking up and heading out.

By sunrise, the yard was silent.
No hum, no movement — just the hollow stillness of a regulator sealed in ice.

Crews arrived to find the line frozen stiff, pressure gone, and time slipping away.
It didn’t take long to see what happened: trapped moisture, rapid cooling, and a cold front that didn’t wait for morning.

Someone finally said the words no one wants to hear:

“We’ll deal with it tomorrow.”

But tomorrow had already cost them.

⚙️ The Lesson Beneath the Ice

Freeze-ups don’t appear out of nowhere — they build up quietly.
A few degrees, a bit of moisture, one overlooked detail.
And suddenly, everything stops.

It could’ve been prevented with one thing: preparedness.
A quick temperature check. A protective heater.
Even a single heated enclosure could’ve kept that line alive.

It’s not just about what failed — it’s about what was ignored.
Because in this industry, doing nothing is the fastest way to freeze everything.

🟦 CATCO helps operators stay one step ahead — preventing freeze-ups before they ever begin.
No tricks. Just resilience.

🔗 Explore More

• CATCO Heated Enclosure Packages

• CATCO Catalytic Heaters

The post Field Frights: Episode 1 — The Regulator That Froze Overnight appeared first on Catco.

The oil and gas industry runs like a finely tuned machine. Every valve, regulator, and control point plays a role in keeping energy flowing—across states, across borders, and across industries.

At CATCO, we focus on the parts that keep that machine from freezing up—literally. Our mission is to make sure that when temperatures drop, production doesn’t.

We’re attending PBIOS 2025 in Odessa, Texas to highlight how CATCO’s solutions strengthen the performance and reliability of this global energy system, helping operators prevent downtime and maintain flow year-round.

The Hidden Gear in the System

CATCO isn’t just another heater manufacturer. We’re the small but critical gear that keeps the oil and gas machine turning smoothly.

Our heated enclosures, instrument gas heaters, and accessories protect the sensitive equipment that drives production and distribution—components like regulators, valves, and measurement assemblies.

When these elements freeze, operations slow. When they stay protected, the system thrives. That’s the difference CATCO makes.

Why PBIOS Matters

The Permian Basin International Oil Show connects the people who make the global energy industry run. For CATCO, it’s an opportunity to demonstrate how our heating systems fit into the bigger picture of reliability and resilience—two of the most important words in modern energy.

Our goal is to show that freeze prevention isn’t just maintenance—it’s protection for production. When energy flows uninterrupted, the entire network benefits—from operators in West Texas to distribution teams overseas.

A Global Role in Energy Resilience

Our work extends far beyond Texas. CATCO products are trusted across the U.S. and internationally—from North Dakota to Norway, from Alberta to the Gulf Coast.

Each design targets the Joule-Thomson effect, a major cause of freezing in natural gas applications. By addressing it directly, our systems ensure stability even when temperatures plunge to -40°F or soar in humid coastal heat.

No matter the environment, our focus remains the same: protect the system, preserve the flow, and strengthen the industry.

Building the Future of Reliability

Energy resilience is a shared goal across every corner of the industry. CATCO’s part in that mission is ensuring the smallest components—the regulators, valves, and measurement points—stay operational when conditions turn extreme.

As the energy landscape evolves, reliability and efficiency will continue to define success. CATCO is here to make sure both remain possible through proven, field-tested heating solutions and a commitment to keeping the energy machine running strong.

Key Takeaway:
CATCO is the part of the oil and gas machine that keeps everything moving—quietly, reliably, and efficiently. Our presence at PBIOS 2025 is about showing how freeze protection and energy resilience keep the entire system turning.

The post How CATCO Fits Into the Oil & Gas Machine — and Why We’re Heading to PBIOS 2025 appeared first on Catco.

That’s why Catco designs catalytic heaters and enclosures for the full range of vulnerable equipment. From regulators and control valves to electronics and meters, our solutions deliver focused, flameless heat that keeps systems online. We’ve seen firsthand how downtime impacts both production and T&D, and how the right protection restores flow quickly and reliably.

The Winter Challenge: Freeze-Ups in the Field

The Joule-Thomson effect—where gas rapidly cools as it expands—creates ice inside regulators, valves, and other pressure-sensitive components. Combine that with freezing moisture in fuel lines or exposed instruments, and entire systems can grind to a halt.

• Production Sites: Wells lose efficiency, cutting into daily output.

• T&D Systems: Distribution stations fail to maintain pressure, interrupting delivery to downstream customers.

In winter, this isn’t just inconvenient—it’s a major threat to reliability, safety, and revenue.

The Cost of Downtime

When critical equipment freezes, the ripple effect is immediate:

• Lost Production – Every frozen regulator or valve means revenue left in the ground.

• Emergency Repairs – Crews dispatched in storm conditions drive up costs.

• Customer Interruptions – Homes, power plants, and industrial clients depend on steady gas supply.

• Safety Hazards – Pressure swings and unplanned shutdowns put people and equipment at risk.

For operators across both production and distribution, the price of inaction during winter is simply too high.

How Catco Restores Flow

Catco heaters and enclosures are engineered to fight freeze-ups and keep equipment running:

• Catalytic Heaters – Flameless infrared heat for safe use in hazardous areas.

• Instrument Gas Heaters (IGHs) – Deliver steady BTU/hr output right where it’s needed.

• Custom Enclosures – Built to protect regulators, valves, pilots, or full skids in unique setups.

• Accessories – Thermostats, steady heat controllers, and weather covers for added performance.

From the Permian Basin to the Midwest, Catco solutions protect against the worst winter conditions so operators can keep gas moving without interruption.

Conclusion: Be Ready Before the Freeze

Winter freeze-ups don’t just stall equipment—they can cripple entire operations. With Catco’s proven heaters, enclosures, and accessories, you can protect your regulators, valves, pilots, and electronics from freezing and avoid costly downtime.

👉 Don’t wait for the next cold front. Explore Catco’s winter-ready solutions today and keep your systems flowing all season long.

The post Prevent Oil & Gas Equipment Freeze-Ups | Catco Winter Solutions appeared first on Catco.

This blog will break down the Dash 10, Dash 20, and Dash 40, helping you choose the right catalytic heater for your application.

🔹 Dash 10: Simple Heat for Simple Sites

The CATCO Dash 10 Heater comes with a basic junction box. It is not weather sealed and is not rated for hazardous locations.

Best uses for Dash 10:

• Everyday non-hazardous applications

• Simple sites without harsh conditions

• Projects where cost-effective, reliable heating is all you need

👉 If your setup doesn’t require certifications or weatherproofing, the Dash 10 is your go-to catalytic heater.

🔹 Dash 20: Weather Sealed for Harsh Environments

The Dash 20 Heater is one step up from the Dash 10. While the front looks identical, the back features an explosion-proof junction box with weather sealing.

Key advantages of Dash 20:

• Weather-sealed junction box

• Electrical protection in outdoor environments

• Designed for exposed sites that require extra durability

⚠️ Note: The Dash 20 is not certified for hazardous locations, but it bridges the gap between simplicity and durability.

🔹 Dash 40: Built for Hazardous Locations

The CATCO Dash 40 Heater is designed for the most critical environments.

Safety and compliance features include:

• Explosion-proof junction box

• Low temperature shutoff valve

• Thermocouple

• Certified for FM Class I, Division 1 & 2 hazardous locations

This heater is built for maximum safety, compliance, and protection, ensuring safe operation in hazardous areas where reliability is critical.

Comparison Table

Every heater in CATCO’s Dash Series delivers the same flameless, infrared heat you can count on. The difference lies in the junction box, sealing, and certifications that make each model suited to specific environments.

Need help choosing? Contact CATCO — we’ll guide you to the right solution for your application.

The post Understanding CATCO Dash Series Heaters: Dash 10, Dash 20, and Dash 40 appeared first on Catco.

What Is a BTU?

A BTU, or British Thermal Unit, is a unit of energy that measures the heat required to raise the temperature of one pound of water by one degree Fahrenheit. In heaters, BTU/hr refers to the rate at which heat is produced per hour.

For example:

• An 8×8 catalytic heater generates 2,667 BTU/hr.
• A 6×24 catalytic heater delivers 6,000 BTU/hr.
• Pipeline Pack models range from 3,000 to 24,000 BTU/hr, depending on the number and size of heaters installed.

Multiple units can also be installed in series for applications requiring higher BTU output.

How Catco Catalytic Heaters Work

Catco heaters use a flameless catalytic reaction. When fuel (natural gas or propane) and oxygen pass over a heated catalyst, they react to produce infrared heat—without a flame.

This process makes Catco heaters safe to use in hazardous environments while still delivering reliable, consistent heat.

Key Features:

• Flameless Operation – No open flame, reducing explosion risk.
• Durability – Stainless steel enclosures provide protection in tough conditions.
• Easy Installation – Secure directly onto pipes or inside enclosures with U-bolts and hand tools.
• Controlled Heat – Add a thermostat or steady heat controller to regulate output and prevent overheating.

Applications in the Field

Catco heaters are used across a wide range of energy and industrial applications, including:

• Pipeline Packs
• Instrument Gas Heaters
• Gas Conditioning Systems
• Space Heating for small enclosures and work areas

By understanding BTU/hr ratings and how catalytic heaters function, you can confidently choose the right Catco solution for your system’s needs.

👉 Whether you need targeted heat for a regulator or large-scale heating for a pipeline pack, Catco heaters are designed to deliver safe, efficient, and reliable performance.

The post Why BTU/hr Matters in Catalytic Heater Performance appeared first on Catco.

1. Fuel Filters – Keep Your Gas Clean

A fuel filter is one of the simplest yet most effective instrument gas heater accessories. By removing dirt and debris from your gas lines, fuel filters:

• Prevent unexpected clogs

• Deliver cleaner, more efficient fuel

• Reduce downtime caused by contaminated gas

Clean fuel means your instrument gas heater runs more smoothly and lasts longer, giving you consistent results when you need them most.

2. Thermostat or Steady Heat Controller – Maintain the Right Temperature

Both devices help keep your gas temperature within the optimal range:

• Steady Heat Controller – Perfect for hands-off operation, it automatically regulates temperature output.

• Thermostat – Allows manual temperature control with a probe to monitor system heat.

These instrument gas heater accessories prevent overheating or underheating, protecting your equipment and ensuring consistent performance in all conditions.

3. Regulator – Control Your Fuel Flow

A regulator ensures your heater receives the correct amount of fuel for steady, safe operation. It prevents over-fueling, which can cause damage, and under-fueling, which can reduce heat output. Quality regulators improve both safety and heater lifespan, making them one of the most important instrument gas heater accessories to install.

Why Instrument Gas Heater Accessories Matter

When selecting instrument gas heater accessories, choose components that are rated for your system and environment. Quality accessories ensure compatibility, reduce wear, and help avoid costly downtime.

For more tips and product insights, check out our Catco YouTube channel or visit our Heater Accessories page to explore all available options.

By adding the right accessories—fuel filters, thermostats or steady heat controllers, and regulators—you’ll ensure peak performance, maximum reliability, and a longer heater life in the field.

The post Top 3 Instrument Gas Heater Accessories for Better Performance appeared first on Catco.

Freezing in gas systems can happen any time—not just in winter. The common cause? The Joule-Thomson Effect.

When gas expands from high to low pressure, temperatures can drop dramatically, resulting in frozen valves, blocked pipelines, and costly shutdowns.

Catco heater enclosures and catalytic heaters are the proven solution to prevent these failures before they happen.

What Is the Joule-Thomson Effect?

The Joule-Thomson Effect occurs when gas passes through an orifice, regulator, or valve from high pressure to low pressure. This rapid expansion causes an immediate temperature drop.

Key facts:

• Gas temperature drops by about 7°F for every 100 psi of pressure loss.

• It happens regardless of outside weather conditions.

• It causes frost, ice, and even total blockage of vital gas flow components.

Learn more about the Joule-Thomson Effect.

How the Joule-Thomson Effect Impacts Equipment

Without protection, freezing can:

• Seize valves and regulators

• Freeze liquids out of gas, clogging lines

• Cause brittle pipes and welds

• Lead to over-pressurization or under-pressurization

• Create no-flow conditions and full system shutdowns

The result? Expensive downtime, safety risks, and repair costs.

How Catco Battles the Freeze

Catco tackles gas regulator freeze-offs with a field-proven two-part system:

1. Enclosures
   Our enclosures block wind, rain, and cold air, creating a microclimate that protects critical components from extreme temperature swings.

2. Catalytic Heaters
   Our flameless catalytic heaters provide consistent, safe heat to prevent frost and ice buildup on regulators and valves.

Combined, this system keeps gas flowing reliably—even under the harshest conditions.

👉 Explore our catalytic heaters.
👉 Learn more about custom heater enclosures.

The Catco Solution: Your Answer to Freezing

At Catco, we understand the freeze risks.
Our engineered solutions provide:

• Protection from wind and environmental exposure

• Even, steady heat output to prevent ice buildup

• Proven performance across North American oil and gas fields

👉 Contact us today to get your freeze prevention system started.

Why Choose Catco?

• Specifically designed for natural gas valves, regulators, and pipelines

• Trusted across the energy industry for reliability and performance

• Simple to install and maintain

• Proven to reduce freeze-related downtime and failures

Conclusion

The Joule-Thomson Effect poses a serious risk for gas system reliability.
With Catco enclosures and catalytic heaters, you can prevent gas freezing and keep your operation running smoothly—anywhere, anytime.

The post Joule-Thomson Effect: Gas Regulator Freeze Prevention | Catco appeared first on Catco.

An orifice exchange kit is a component that allows you to change the fuel type used by a catalytic heater or derate the heater for use at high altitudes. This small but essential part controls the fuel input and ensures the heater operates at its best efficiency.

By swapping the orifice, you can fine-tune the heater’s performance to match your specific needs, whether that means adjusting for altitude or switching between natural gas and propane.

Why Would Someone Use an Orifice Exchange Kit?

• Switching Fuel Types – Different fuels require different orifice sizes for proper combustion.
• Adapting to Environmental Conditions – Adjusts performance for high-altitude locations or extreme cold.
• Improving Fuel Efficiency – Prevents wasted fuel and maximizes heat output.

Fuel Types & Their Corresponding Orifices

The orifice size must match the fuel type to ensure proper combustion and efficiency:

Natural Gas

• Requires a larger orifice due to its lower energy density.
• Burns at a lower temperature compared to propane.
• Ideal for low-altitude applications where oxygen levels are higher.

Propane

• Uses a smaller orifice since it burns hotter and requires less fuel flow.
• More energy-dense than natural gas.
• Commonly used in high-altitude or cold-weather environments.

Altitude Adjustments & Orifice Selection

At higher altitudes, air pressure and oxygen levels decrease, requiring orifice adjustments to maintain optimal combustion.

Low Altitude (0 – 2,000 ft)

• Standard orifice sizes for both natural gas and propane.

Medium Altitude (2,000 – 5,000 ft)

• Slight reduction in fuel flow may be needed to compensate for thinner air.
• Adjust orifice size if combustion becomes inefficient.

High Altitude (5,000+ ft)

• Use a smaller orifice to prevent excess fuel from being burned inefficiently.
• Helps maintain heater performance in oxygen-depleted environments.

✅ If you need help selecting the right orifice for your location, give us a call! Provide your area details, and we’ll ensure you get the correct one for optimal performance.

What Are the Benefits of Switching Out an Orifice?

• ✅ Fuel Flexibility – Easily switch between natural gas and propane.
• ✅ Location Flexibility – Use your heater wherever you need heat.
• ✅ Quick and Easy Installation – Orifice swaps take minutes with minimal tools.
• ✅ Cost-Effective Upgrade – No need to replace the entire heater—just change the orifice.

Upgrade Your Heater Today

For more details on how orifice exchange kits can improve your heater’s performance, watch our step-by-step video:

📺 Watch Now: Catco Orifice Exchange Kit Explained

🔗 Browse Orifice Exchange Kits Now: https://www.catcousa.com/orifice-exchange-kits

The post What is an Orifice Exchange Kit and Why Does it Matter? appeared first on Catco.

Texas is known for its unpredictable weather patterns, with significant fluctuations in temperature throughout the year. These climate shifts can have substantial implications for both natural gas facilities and the population of Texas as a whole. Extreme hot and cold swings pose challenges for maintaining the reliability and stability of natural gas infrastructure and can potentially impact the availability of electricity for Texans.

Recognizing the need to address these issues and prevent future energy crises, the Railroad Commission of Texas (RRC) introduced new regulations aimed at the natural gas industry, specifically designed to safeguard the flow of gas to power generators, ensuring that Texans have access to electricity, especially during times of natural disasters or severe weather conditions. These regulations were officially put in place in December 2022. 

What is a “winterization regulation”? 

Winterization regulations focus on ensuring the reliability and resilience of power generation, transmission and distribution systems during winter months and include specific measures to protect equipment and infrastructure from freezing, prevent ice buildup and maintain the stability of energy supply. 

Typically, winterization regulations require companies and facilities to take various actions, such as insulating pipes and equipment, implementing heating systems or anti-freeze measures, developing contingency plans to address potential weather-related disruptions and conducting regular maintenance and inspections.

Why are there new regulations?

In February 2021, Winter Storm Uri brought extremely cold weather to Texas, with some areas experiencing highly unusual subzero temperatures. The extreme cold temperatures and freezing conditions caused a surge in demand for natural gas for heating purposes. At the same time, the freezing temperatures caused issues with wellheads, pipelines and processing facilities, hampering the extraction and distribution of natural gas. 

With limited supply, many gas-fired power plants faced difficulties operating at full capacity or had to shut down altogether. This reduction in power generation capacity contributed to the widespread power outages experienced across the state during the winter storm, leaving millions of people without electricity for days or even weeks. 

Not only did the loss of power create issues with transportation, housing, water and food, the storm tragically resulted in multiple fatalities and injuries. To better protect Texas from experiencing events like this, 16 Texas Administrative Code (TAC) §3.66, relating to Weather Emergency Preparedness Standards, requires critical gas facilities to weatherize their operations and participate in regular government-led inspections.

What do the new regulations entail?

16 TAC §3.66 requires gas supply chain facilities designated as critical under 16 TAC §3.65 and included on the electric supply chain map to file a Weather Emergency Readiness Attestation and undergo annual inspections. 

16 TAC §3.65 defines critical gas supply chain facilities as “gas wells producing gas in excess of 250 Mcf/day; gas processing plants; natural gas pipelines and pipeline facilities including associated compressor stations and control centers; local distribution company pipelines and pipeline facilities including associated compressor stations and control centers; underground natural gas storage facilities; natural gas liquids transportation and storage facilities; and saltwater disposal facilities including saltwater disposal pipelines.”

Each year, these critical facilities must also submit Weather Emergency Readiness Attestation to the RRC by December 1 every year. This document must be prepared by an authorized representative of the operator or someone working under the authorized representative’s supervision and show that the facility has undergone appropriate weather emergency preparedness measures, including:

1. 1. correcting critical component failures that occurred during previous weather emergencies; 
   2. installing equipment to mitigate weather-related operational risks; and 
   3. internal inspection, self-assessment and implementation of processes to identify, test and protect critical components.

Have weatherization efforts helped the state of Texas since being implemented?

Since these regulations are still fairly new, their overall effectiveness is still unknown. Ramanan Krishnamoorti, vice president of energy and innovation at the University of Houston, told ABC News, “The tests to the grid these past two winter seasons have not acted as ‘true stress tests.’ The current freeze is ‘much less intense’ in terms of temperature and temperament, compared to the back-to-back winter storms of 2021 that caused a statewide energy catastrophe.” 

According to this article in Texas Monthly, the state still has trouble delivering the natural gas needed during the coldest winter months. Some power plants had difficulty obtaining enough natural gas to burn and had to rely on backup fuel oil (which is slowly being phased out because of its high carbon levels). 

While some consider the natural gas issue still not properly addressed by these legislative measures, the hope is that these efforts are more of an ongoing assessment to determine what is and isn’t working when delivering electricity to Texas citizens, especially in times of extreme need.

How can Catco help natural gas facilities with their winterization efforts?

Catco’s catalytic heaters generate heat without a flame, making them ideal for use in many hazardous environments, including helping Texas’s critical natural gas facilities comply with the previously noted state winterization regulations, specifically in mitigating weather-related operational risks. 

Catco’s full line of heaters and automation systems apply catalytic heating technology to all phases of the natural gas extraction and delivery process to help companies prevent downtime. For example:

• • Catco’s heated enclosure packages mount directly to valves to eliminate ice buildup when ambient temperatures are low or when there is a pressure drop across a regulator.
  • Catco’s instrument gas heaters preheat gas before it reaches the pilot in pilot-operated regulators. They can also be used to heat a stream of gas for measurement or instrumentation.
  • Catoc’s space heaters are perfect for situations that require heat but are not suitable for traditional heating because of the presence of explosive gases or lack of electricity. Wall or floor-mounted catalytic heaters can maintain a comfortable environment for personnel or prevent equipment from reaching critical temperatures.

They not only provide an additional source of heat to supplement a facility’s existing heating system, but during times of extreme weather, they can reduce the typical strain put on those heating systems and decrease the risk of equipment failure. 

Where ABC News reports some facilities have “installed hundreds of millions of dollars worth of updates to better winterize their facilities,” catalytic heaters are a fast and cost-effective solution when comparing the massive capital expenditure and amount of time that total equipment and pipeline upgrades can require.

If you’re operating a critical natural gas facility and are not using catalytic heaters, call one of our Catco representatives today to find out how we can help you comply with recent Texas regulations and more efficiently operate your business.

The post Texas’ Winterization Legislation appeared first on Catco.