Waterwall Services

The world’s largest installed base for waterwall services and fireside corrosion mitigation

Fireside corrosion of waterwall panels is one of the costliest issues for boiler operators, especially in coal-fired units where sulphidation is prevalent. WSI is globally recognized for its Unifuse180^® technology, the industry standard in fireside erosion and corrosion control. This technology has the world’s most extensive installed base for mitigating fireside corrosion in waterwall panels in both critical and sub-critical coal-fired units, offering protection for existing panels and new constructions. Our comprehensive waterwall services ensure the highest level of protection and longevity for your boiler components.

Since 1985, WSI has led the way in fireside corrosion mitigation for Waste to Energy (WTE) boilers with its innovative weld metal overlay using alloy 625. This robust barrier prevents damage from low-melting-point chlorides formed by heavy metal reactions with chlorine. The welded coating ensures a durable bond capable of withstanding thermal cycling and other stressors like soot blowers, effectively protecting against base metal damage. Unifuse 180, initially developed for WTE boilers, remains the most reliable method for mitigating fireside thinning.

State-of-the-art shop production services

WSI operates two state-of-the-art production facilities in the USA and Europe for applying the Unifuse 180 weld metal overlay. Our extensive resources and expertise enable us to handle intricate and large-scale panel configurations for individual plant operators and boiler OEMs. We offer unparalleled fabrication capabilities for waterwall services, accommodating panels up to 18 m long and 2 m wide at a competitive cost per panel. We can apply overlay thicknesses ranging from 1.2 to 3 mm or more, tailored to meet specific requirements.

Field production specialists and waterwall services

WSI’s field application specialists perform on-site waterwall overlay applications. As the largest provider of weld metal overlay globally, WSI has the industry’s largest fleet of equipment and highly trained personnel, capable of easily managing projects of any size.

Industry-leading solution for fireside corrosion mitigation with Unifuse 180 technology

Fireside corrosion presents a significant challenge for boiler operators due to its cost implications. Our Unifuse180 technology offers a highly effective solution, setting the industry standard for managing fireside erosion and corrosion in critical and sub-critical coal-fired units. Unifuse 180 can be applied in the field to protect existing waterwall panels or in the shop for new constructions or replacements of damaged panels. It enhances the longevity of boiler waterwalls and ensures excellent heat transfer efficiency, providing the longest reliable working life.