Industry boiler services to protect components against high-temperature erosion and corrosion

WSI is the largest global automated repair provider, offering comprehensive boiler services, including corrosion and erosion-resistant weld metal overlays. Our industrial boiler repair solutions are applied to boilers worldwide, ensuring optimal surface protection in the most demanding environments.

With over 30 years of experience in boiler repair and protection, WSI’s Unifuse® technology provides superior surface protection for waste-to-energy boilers, biomass boilers, coal-fired boilers, black liquor recovery boilers, and furnaces and hoods in steel manufacturing. Our Unifuse weld overlay, both shop and field-applied, is the leading method for preventing boiler erosion and corrosion.

Unifuse 360 technology for proven boiler tube protection

WSI’s Unifuse 360 technology extends boiler tube life and reduces maintenance costs, inspections, and fabrication problems. Unifuse 360 provides comprehensive 360° protection against corrosion and erosion for boiler tubes. Our facilities can apply overlay thicknesses of 1.2-3.0 mm (or more with multilayer overlay) to tubes and headers up to 15 meters long and with diameters between 21–273 mm.

• Replace high-maintenance mechanical tube shielding
• Customize erosion resistance in soot-blower lanes
• Provide 360° protection from corrosion and erosion

Our superior boiler repair technology, engineering resources, and automated processes offer a world-class boiler service solution, delivering consistency, quality, and value. Manufactured according to PED and ASME regulations, Unifuse 360 tubes provide excellent heat transfer with the longest reliable working life.

Unifuse 180 technology for boiler panel life extension

The Unifuse 180 technology integrates multiple elements to deliver the best-performing weld overlay panel protection in the field or shop. Unifuse 180 provides high-quality surface protection for boiler panels. Our facilities include GMAW technology and panel mounting systems capable of overlaying flat panels up to 18 meters long and 2 meters wide.

• Sophisticated engineering analysis to address predicted welding stresses
• Metallurgical support for optimized alloy selection
• Precision application equipment for consistent deposition control
• Minimization of heat input for optimal chemistry and minimal distortion stress
• Experienced application specialists

WSI has the longest track record and extensive experience delivering boiler overlay services for pressure boundary restoration or preservation. As a leader in developing engineered solutions and applying specialty welded metal overlays, WSI is unequaled in its ability to deliver an optimal solution for boiler panel protection.

Coke drum services address coker-specific challenges with advanced weld automation

For decades, WSI has provided advanced coke drum services and repair options to address prevalent coke drum failures. Our unique process uses highly engineered weld metal overlay to modify the vessel’s structure, mitigating bulging and cracking of the pressure boundary shell, support skirt-to-shell interface weld area, and lower cone cladding damage. As the industry’s largest provider of structural repairs for coke drums, WSI excels in coke drum maintenance and coker drum repair.

Our process involves installing a highly engineered weld metal overlay on existing vessels and modifying their structure to mitigate bulging and cracking caused by low-cycle fatigue.

Precision weld automation for optimal coker drum repair

Our tightly controlled welding parameters, managed by closed-loop automated welding systems, employ controlled deposition techniques (temper bead) to eliminate the need for post-weld heat treatment. This approach has been successfully implemented in over 100 coke drums worldwide, ensuring reliable coke drum automated weld overlay repairs.

For support skirt crack repairs, WSI uses proprietary welding processes to replace critical welds and install new skirt sections without post-weld heat treatment. This method has been proven superior, with dozens of successful skirt repairs across the industry.

WSI engineered solutions for coke drum reliability

Delayed coking, which has been in use since the 1950s, subjects components to significant temperature and pressure fluctuations, causing low cycle fatigue failures in coker drums. These drums are costly to replace and are critical assets, making life extension, shortened turnaround cycles, and improved reliability and safety essential.

As the largest provider of structural repairs for coke drums, WSI extends life, shortens turnaround cycles, and enhances the reliability and safety of these critical assets through our automated coker drum weld overlay.

• Bulge repair and structural shell reinforcement
• Lower cone replacement welds utilizing the HotPulse^® critical weld process
• Shell and support skirt crack repair
• ID cladding damage and defect repair

With our extensive experience and cutting-edge technology, WSI provides industry-leading coker weld overlay repair and coke drum services, ensuring the highest quality and reliability for your critical assets.

Patented duplex stainless welding technology for digester services

WSI’s patented duplex stainless welding technology sets the industry standard for protecting digesters with digester weld overlay. The Unifuse® vessel weld overlay process utilizes a 309 or 312 stainless steel deposit, effectively eliminating solidification cracking typical in conventional 312 welds.

Combatting corrosion in digesters with advanced digester services

Due to increased production demands and environmental process changes, digesters, typically made from carbon steel, face severe corrosion from cooking liquor. Initially developed for field installations, WSI’s Unifuse technology offers fully fused, low-dilution, corrosion-resistant cladding to mitigate this degradation through automated weld metal overlay.

Continuous digesters: targeted protection with digester weld overlay

In continuous digesters, corrosion-prone areas are identified through periodic thickness mapping. The Unifuse® vessel overlay process applies a 309 or 312 stainless steel deposit to critical wastage zones, adhering to tight maintenance schedules crucial for continuous digester operations.

Batch digesters: enhanced corrosion resistance with batch digester weld overlay

312 stainless steel is used for enhanced protection for batch digesters exposed to more aggressive corrosion. WSI’s Unifuse process, distinguished by its patented duplex stainless welding technology, eliminates solidification cracking seen in conventional 312 welds, setting it apart in the industry.

 Unmatched industry experience and reliability in digester repair

WSI has the largest installed base of digester weld metal overlay in the industry and a solid reputation for safety, quality, and exceptional value.

• Advanced Duplex Stainless Welding Technology: Eliminates solidification cracking and offers superior protection.
• Corrosion-Resistant Cladding: Fully fused, low-dilution stainless steel cladding for carbon steel digesters.
• Targeted Application: Applies 309 or 312 stainless steel deposits to critical areas identified through thickness mapping.
• Proven Performance: The industry’s largest installed base of digester weld overlay, backed by a reputation for safety and quality.

WSI’s industry-leading solutions ensure the longevity and reliability of your digesters. Our commitment to innovation and excellence makes us the preferred provider for digester service and digester repair.