Project Timeline
- 6 Weeks from Start Date:
- WSI proposed proprietary patented HF 40™ material for application
- Novo Power submitted recommendation request to boiler manufacturer.
- 4 Weeks from Start Date:
- Boiler manufacturer tested WSI HF 40™ material.
- 3 Weeks from Start Date:
- Boiler manufacturer recommended that HF 40™ would be the most durable weld overlay application for this unique issue.
- Setup Time: 8 hours
- Sandblast Time: 8 hours
- First Arc: 20 hours from site arrival
- Project completed, inspected, and loaded out in less than 6 days:
- 4 Boilermakers per shift
- 202 ft2 of HF 40™ overlayed in 9 shifts
- Pinhole repair time under 2 hours
- Replacement of 30 ft of membrane
- Zero tube leaks on severely damaged material
Challenges
- Advanced Deterioration: Tubes across the 6’ x 2’ areas of air ports feeding fuel showed significant wear.
- Previous Repairs: The customer originally applied a form of thermal spray in two applications, but that coating had worn off in less than six months.
- Frequent Replacement: Tubes were being replaced every two years due to severe erosion. The customer needed to upgrade tube protection to avoid the costly replacement process.
- Tight Schedule: The customer required this project to be executed in ten (10) days or less, due to other work being performed inside the boiler.
- Tight Budget: The customer had a very limited amount of funds to direct toward this project, and required careful planning and control over expenditures.
- Remote Location: The customer was in a remote area and did not have many support options available.
- Inadequate Capacity: The immediate area could not support onsite power requirements for such a project, as the location did not have enough total amps/wattage to handle new loads in addition to existing equipment.
The WSI Difference – Hardfacing Alloy Application
- Proprietary HF 40™ Alloy: WSI’s hardfacing overlay can be applied to carbon steels, alloy steels, and stainless steels by Gas Metal Arc Welding (GMAW) and Gas Tungsten Arc Welding (GTAW) processes. It is widely used on corrosion resistant alloys that cannot provide good erosion protection for a desired performance lifetime.
- WSI Patented Alloy
- Iron (Fe) based alloy
- Prevents erosion in high temperature environments
- Only one layer is required for chemistry and corrosion-erosion resistant properties
- Shop and field application capabilities
- Industry Elite Field Craft
- Superior HF 40™ properties applied by skilled craftsmen (automated and manual)
- WSI Boilermakers are the only craft to field/shop apply HF 40™ Alloy
- Unmatched industry experience with proven results
- Why HF 40™ Alloy
- Field tested and proven by WSI Quality Program
- Industry tested and verified by industry leaders
- Applied directly to waterwalls, Vortex Finders in cyclones, and other erosion-vulnerable components
Results
- Organizational Readiness for Unique Issues: WSI’s collective capability to prepare for, address, and adapt to unexpected, non-routine challenges and disruptions drove a successful project and backed up our reputation as a leader in the field.
- Expedited HF 40™ Approval: Hardfacing overlays from WSI were expertly applied using advanced GMAW and GTAW techniques. This proven solution enhanced erosion resistance, and will significantly extend the service life of equipment exposed to harsh conditions.
- Optimized Schedule Due to Auxiliary Work: With other work also being performed inside the boiler, WSI created the most effective and efficient work schedule possible to balance customer demand with operational constraints.
- Right First Time: First time quality with no repairs, rework, or corrections necessary.
- Goal Zero: WSI’s safe work practices resulted in ZERO injuries, lost time, and downtime.
“After understanding the WSI overlay process, we were confident in the application but we weren’t convinced the upgraded alloy would hold up. After approval and testing on the HF 40 alloy, we had no doubt.” – General Manager