Industrial Maintenance Services

Industrial Maintenance Services

WSI

Industrial Maintenance Services

As a global leader in specialized installation and maintenance solutions, WSI leverages innovative welding technologies and techniques to extend life and maximize the value of assets in challenging energy and industrial environments. With extensive industry experience, a global presence, and best-in-class execution, we ensure improved plant reliability safely and effectively.

Renowned worldwide for delivering substantial ROI, we apply specialized industrial maintenance services to meet and exceed client expectations in industrial welding services, energy industry welding services, and oil and gas welding services across various sectors.

WSI – The world leader in pressure equipment welding services for life extension

Whether it’s pressure equipment welding maintenance, emergency repair, or planned turnaround services, we lead the industry with innovative solutions and proven results. With the world’s most extensive portfolio of life extension projects and qualified procedures, WSI handles any unit-specific challenges with unmatched expertise and reliability. Our production facilities in the USA and Europe allow us to manage projects of any size, delivering exceptional results worldwide.

Specialized industrial maintenance services for enhanced performance

WSI integrates specialty welding technologies and techniques to provide customized solutions, ensuring enhanced performance, durability, and reliability of industrial equipment in demanding environments.

Each service area employs tailored technologies and techniques to optimize asset performance and lifecycle management. Our industrial maintenance services range from automated weld repairs to advanced engineering solutions, addressing the most challenging mechanical integrity issues. Whether upgrading a coke drum, heater, or waterwall, or repairing a boiler, furnace tube, nozzle, piping, or pressure vessel, we are committed to delivering effective solutions.

On-site field machining services for critical systems and equipment

WSI Field Machining Services specializes in high-quality machining and tooling solutions, both planned and emergent, to extend the operating life of critical systems, equipment, and components. Our extensive expertise and rapid response times ensure on-site repair demands are met promptly. Our field machining services include:

  • Large-scale flange facing
  • Line boring
  • Pipe severing and beveling
  • Insitu drilling and tapping

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Nozzle Repair

Nozzle Repair

Industrial Maintenance Services

Nozzle Repair

Reliable and cost-effective weld overlay nozzle repair with automated technology and precision

To address challenges such as wall thinning, pitting, cracking, and corrosion/erosion in vessel nozzles, our fully automated weld process and Nozzlefuse™ overlay provide an effective onsite solution. Nozzlefuse ensures consistent quality with the lowest dilution rates and the highest standards, handling nozzles from 2 to 24 inches in diameter.

Nozzlefuse 26: For nozzles 2 to 6 inches in diameter, using the Unifuse® GTAW process for ID weld overlay up to 750 mm in length.

Nozzlefuse 624: For nozzles 6 to 24 inches in diameter, using hot wire Unifuse GTAW for ID weld overlay up to 750 mm in length.

Nozzles in pressure vessels can be susceptible to localized thinning due of the effects of corrosion and erosion

Advanced Unifuse processes with hot wire TIG technology

Our patented Unifuse processes restore wall thickness and improve the metallurgy of nozzle surfaces, combating corrosion and erosion. By integrating hot wire TIG technology, we leverage efficient automatic welding equipment operated by skilled welders and technicians, ensuring consistent quality and timely, reliable repairs. These processes are ideal for pressure vessel nozzle repair and other critical nozzle services.

Unifuse technology delivers high-quality weld deposits, meeting stringent industry standards and avoiding the high costs of nozzle replacement. This method effectively prolongs the service life of nozzles, making it a highly economical solution for weld overlay nozzle repair.

Ensuring a smooth and efficient liquor recovery process

WSI Black Liquor Nozzles are specialized components designed for liquor recovery boilers in the Pulp and Paper industry. Integrated into OEM designs, these nozzles ensure the correct, laminar distribution of black liquor within the boiler, which is crucial for optimal performance and operational effectiveness.

Aligned with boiler manufacturers’ specifications, WSI Black Liquor Nozzles undergo a unique overlay process using our patented Unifuse 360 automated welding. This process creates a smooth, highly resistant surface, significantly extending its service life and ensuring peak performance and safety.

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Downloads

Brochure - English

Brochure - French

Brochure - German

Brochure - Italian

Brochure - Spanish

Brochure - Brazil Spanish

Brochure - Brazil Portuguese

Data Sheet - EN (Black Liquor Nozzles)

Data Sheet - PT BR (Black Liquor Nozzles)

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Nuclear Services

Nuclear Services

Nuclear Services

Nuclear Services

Engineered Nuclear Welding Solutions You Can Trust

WSI delivers industry-leading nuclear welding maintenance, repair, and overlay solutions whether planned or emergent that protect critical assets and extend the life of your plant. With nearly 50 years of nuclear expertise, WSI’s Nuclear QA Program meets the requirements of 10 CFR 50 Appendix B and NQA-1. Our teams bring the specialized skills, tooling, and engineering rigor required for projects that are critical to safety, critical to schedule, and critical to quality.

Comprehensive Nuclear Service Capabilities

Comprehensive Nuclear Service Capabilities

Dry Fuel Storage Closure Services

WSI is a leader in remote GTAW canister sealing for dry fuel storage. Our proven system improves ALARA performance, reduces schedule risk, and delivers repeatable weld quality across more than 250 completed canisters with zero defects.

Flow Accelerated Corrosion (FAC) Repair

Using our proprietary Cross Under Piping Unifuse System CUPUS®, WSI applies a remote pulsed spray GMAW overlay to mitigate FAC without costly pipe replacement. CUPUS provides 360-degree coverage inside piping 21 to 60 inches in diameter with minimal heat input and full fusion bonding.

Gate Valve Repair Services

WSI performs remote and automated gate valve repairs using proprietary Seat Repair and Guide Rib Milling tools. Precision machining and hard-facing restore functionality, reduce dose, and improve ALARA results for critical valve systems.

Large and Small Bore Nozzle Weld Overlays

WSI has set industry benchmarks for full structural weld overlays on component and reactor vessel nozzles of varying sizes with complex geometries and tight outage schedule windows. Advanced dual head machine GTAW processes enable high deposition rates while meeting ASME Code requirements.

Large Component Segmentation Services

From steam generator dome separation to heavy wall steel welding, WSI executes complex segmentation projects safely and on schedule. Our field proven processes minimize dose and maintain first time quality supported by some of the largest machining clamshells in the United States.

MSIV Services

WSI’s single setup MSIV Diagnostics and Repair System integrates electronic mapping, machining, and welding to streamline valve repairs and reduce dose. The automated GTAW process delivers consistent weld quality, shorter schedules, and proven results across more than 130 nuclear power plants worldwide.

Outage Support

Augment your outage team with WSI’s nuclear qualified craft professionals and extensive automatic welding tooling. We provide specialty welding maintenance and repair services to keep outages on track and within budget.

Pressurizer Nozzle Weld Overlay (WOL)

To combat primary water stress corrosion cracking PWSCC in Alloy 600 components, WSI applies an engineered structural overlay. Our global track record includes multi location pressurizer nozzle repairs completed safely and efficiently.

Reactor Coolant Pump Nozzle WOL

WSI pioneered First of a Kind weld overlays on reactor coolant pump nozzles delivering optimized WOL (OWOL) solutions and earning NRC approval for breakthrough Alloy 600 mitigation methods.

Structural Weld Overlays

Our code approved structural weld overlays reposition the pressure boundary and place dissimilar metal welds in compression which creates an engineered permanent repair for high energy components in aging power stations.

Engineered and Repair Solutions

Whether it is turnkey weld overlays, pressure vessel nozzle repairs, or unique first of a kind repairs, WSI brings deep expertise in metallurgy custom tooling and ASME Code engineering to every nuclear project. These capabilities demonstrate our leadership in advanced nuclear repair welding for even the most demanding configurations.

Why WSI

WSI provides the expertise and resources to ensure nuclear outage, mitigation, and repair projects are completed safely, efficiently and to the highest quality standards. Our long record of success in nuclear welding gives plant operators confidence that critical systems will remain reliable for years to come and support your plant life extension/uprate plans.

Proven nuclear expertise with nearly 50 years of nuclear industry experience

  • Extensive resources including qualified nuclear craft personnel and more than 250 specialized automatic welding and mechanical systems
  • The Nuclear QA Program meets the requirements of 10 CFR 50 Appendix B and NQA-1
  • Innovation and responsiveness from proprietary overlay technologies to custom tooling, WSI responds quickly to planned and emergent needs

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DOWNLOADS

Dry Fuel Storage Closure Services Data Sheet

Flow Accelerated Corrosion Repair Data Sheet

Gate Valve Repair Services Data Sheet

Large and Small Bore Nozzle Weld Overlays Data Sheet

Large Component Segmentation Services Data Sheet

MSIV Services Data Sheet

Outage Support Data Sheet

Pressurizer Nozzle Weld Overlay Data Sheet

Reactor Coolant Pump Nozzle Data Sheet

Structural Weld Overlays Data Sheet

Engineered and Repair Solutions

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Why WSI

WSI provides the expertise and resources to ensure nuclear outage, mitigation, and repair projects are completed safely, efficiently and to the highest quality standards. Our long record of success in nuclear welding gives plant operators confidence that critical systems will remain reliable for years to come and support your plant life extension/uprate plans.

Proven nuclear expertise with nearly 50 years of nuclear industry experience

  • Extensive resources including qualified nuclear craft personnel and more than 250 specialized automatic welding and mechanical systems
  • The Nuclear QA Program meets the requirements of 10 CFR 50 Appendix B and NQA-1
  • Innovation and responsiveness from proprietary overlay technologies to custom tooling, WSI responds quickly to planned and emergent needs

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Orbital Welding

Orbital Welding

Specialty Solutions

Orbital Welding

HotPulse technology delivers consistent results with enhanced safety

WSI is the largest provider of machine orbital welding services for refineries, nuclear, and fossil plants. Our revolutionary HotPulse®-enabled orbital welding equipment provides better mechanical properties and volumetric quality than conventional field welding processes, with deposition rates competitive with SMAW and FCAW.

Our proprietary technology exceeds quality and schedule expectations while being completed safely. It lowers the risks commonly associated with access constraints and high pre-heat temperatures coupled with machine control. More plant operators turn to WSI for machine orbital pipe welding services during planned or emergent outages.

WSI’s Machine Hot Pulse GTAW Technology – Superior Quality at Increased Deposition Rates

Superior orbital weld quality, increased production rates, and reduced risk of failure

HotPulse orbital welding technology, or HP GTAW™ welding, combines unmatched deposition rates with superior arc control. This automated hot pulse orbital welding method delivers excellent weld quality, increased production rates, and reduced failure risks:

  • First-time quality welds
  • Up to 6x higher deposition rate than cold wire TIG
  • Reduced surface tension for better wetting and bead profile
  • Reduced porosity from puddle agitation
  • Grain refinement for better weld metal impact properties
  • Welds with high-alloy or nickel materials
  • Semi-automatic and machine-operated versions provide application flexibility
  • Improved appearance and fit-up tolerance

Enhances the speed, quality, and productivity of orbital pipe and tube welding projects

In an environment with short schedules, tight budgets, and high-quality specifications, there is little tolerance for welding defects and low productivity. Current high-energy systems require heavy wall and higher alloy materials for process reliability, making conventional techniques less viable. WSI’s HP GTAW welding technology significantly enhances the speed, quality, and productivity of orbital pipe and tube welding projects.

HotPulse GTAW Proven Applications

Our innovative orbital welding technology offers advanced solutions for high-quality joints and a wide range of proven applications, ensuring unmatched performance and reliability in industrial settings.

  • Thick wall pressure vessel repairs
  • P91 high-energy lines in coal-fired boilers
  • Head replacement on hydrogen reactors in refineries
  • Heavy wall piping systems in combined-cycle power plants
  • Seam weld repair on heavy wall vessels at chemical plants
  • Furnace U-Bend replacements

By leveraging our advanced automated orbital welding techniques, WSI ensures superior tube welding and tube replacement solutions that meet the highest industry standards for quality and reliability.

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Hot Pulse Technology Data Sheet

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Piping Services

Piping Services

Industrial Maintenance Services

Piping Services

The largest provider of piping services and machine orbital pipe welding

WSI is the largest provider of machine orbital welding and piping services for refineries, nuclear, and fossil plants. Our revolutionary HotPulse®-enabled orbital automated pipe welding equipment delivers superior mechanical properties and volumetric quality compared to conventional field welding processes, with deposition rates competitive with SMAW and FCAW. This advanced technology has been successfully implemented in several major piping replacement projects, consistently exceeding quality and schedule expectations while ensuring safety.

Benefits of choosing WSI for automated pipe welding services

WSI offers unmatched expertise and advanced technology for automated orbital pipe welding services, ensuring superior performance, safety, and reliability. Our proven track record and comprehensive services make us the trusted choice for planned and emergent projects.

  • Expertise in Advanced Materials: Specializing in advanced materials that enhance performance and safety in demanding environments.
  • Revolutionary HotPulse® Technology: Ensures superior weld quality and high deposition rates, ideal for critical applications.
  • Proven Track Record: Successfully implemented in numerous major projects, delivering high-quality results on time and within budget.
  • Safety and Reliability: Processes designed to maintain the highest safety standards, ensuring reliable and long-lasting welds.
  • Comprehensive Services: Expertise and technology to efficiently meet your needs, whether planned maintenance or an emergent repair situation.

For unparalleled machine orbital pipe welding and piping services, plant operators trust WSI to deliver exceptional results during both planned and emergent outages.

WSI’s Machine Hot Pulse GTAW Technology – Superior Quality at Increased Deposition Rates

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Downloads

Hot Pulse Technology Data Sheet

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