Industry leading solutions to protect boiler components against high temperature erosion/corrosion

Power boilers in refineries are often overlooked components–until they have a forced shutdown that affects production. Refinery boilers suffer from the same failure mechanisms as power generation boilers: sulfidation corrosion, thermal fatigue cracking, water chemistry corrosion, flame impingement damage on waterwalls, and high temperature creep. In the power generation field, WSI is a leader in boiler tube overlay and the protection of boiler components against high-temperature erosion/corrosion and other damage. Our weld overlay product has been applied throughout the power generation industry. Our Unifuse® weld overlay shop and field applied products are the most common corrosion protection method for boiler erosion/corrosion.

Superior pressure boundary restoration and corrosion/erosion control

To overcome the potential challenges affecting nozzles in vessels, such as wall thinning, pitting, cracking and corrosion/erosion, our fully automated weld technology and weld overlay solutions offer an onsite solution to address corrosion issues in nozzles from 2 to 24 inches in diameter. Patented Unifuse® processes enable us to build up wall thickness to restore the pressure boundary and to apply an improved metallurgy to reduce the effects of corrosion or the combined corrosion/erosion process, delivering the same high-quality deposit, thus avoiding expensive replacement costs.

Turn to WSI for machine orbital welding services during planned or emergent outages

As operational requirements increase, the use of advanced materials in piping systems has become the norm. Weight reduction, corrosion performance and mechanical failure mitigation in aggressive operating environments facilitated by improvements in materials and construction practices increase profitability and safety. 

WSI is the largest provider of machine orbital welding services for refineries, nuclear plants, and fossil plants. Our revolutionary HotPulse^® enabled orbital welding equipment provides both mechanical properties and volumetric quality better than conventional field welding processes, and with deposition rates competitive with SMAW and FCAW. This recent technology has been implemented on several major piping replacement projects to date, and has exceeded quality and schedule expectations, while being completed safely. That is why more plant operators turn to WSI for machine orbital pipe welding services during planned or emergent outage.

Permanent repair solutions that extend operational lifespan

Pressure vessel integrity is one of the most critical issues faced within process industries. Changes in feedstock chemistry and increased production demands on the units create corrosion damage mechanisms that were not anticipated in the original designs. WSI pioneered the weld metal overlay process for boiler corrosion in the 1980’s, and continues to provide cutting-edge structural weld overlay, weld cladding and specialty welding solutions today.

Our patented Unifuse^® technology was introduced to the process industries and soon became one of the most commonly used techniques for process vessel corrosion mitigation. The Unifuse product is a fully fused weld metal deposit using corrosion-resistant alloys that are applied to the vessel using proprietary automated welding systems. These automated welding systems are designed to provide an exceptional quality weld deposit with a minimum of heat input to the base material. Because it is a true weld deposit, the applied thickness can be included in calculations for the restoration of pressure boundary thickness. That is why thousands of applications exist in the industry and major refiners consider Unifuse the best return on investment choice that they have.