Innovative furnace tube welding improves u-bend weld mechanical and chemical properties

WSI’s specialty welding solutions are designed to overcome the specific challenges of U-bend welds in heaters and furnaces, providing refineries with reliable, high-quality welds that support their maintenance and upgrade goals. By utilizing our revolutionary HotPulse^®-enabled orbital welding equipment, we deliver exceptionally high-quality GTAW (Gas Tungsten Arc Welding) welds that withstand the rigorous demands of refinery operations.

HotPulse-enabled welding technology for superior furnace tube welding results

Product heaters and furnaces are crucial in refineries, and many refiners upgrade their metallurgy to reduce degradation and maintenance costs. These upgrades often require numerous insitu orbital welds, which are challenging due to high preheat requirements and complex geometries, leading to significant weld failures.

To address these challenges, WSI developed HotPulse orbital welding technology, or HP GTAW™ welding, specifically for difficult U-bend welds. The equipment positions the operator safely away from high preheat discomfort, while HotPulse technology delivers exceptionally high-quality GTAW (Gas Tungsten Arc Welding) welds at high production rates. This makes it ideal for various applications, including reformer furnace tube replacement, reformer furnace repair and maintenance, and general furnace tube replacement.

Enhanced welding with advanced materials for critical refinery components

Using advanced materials like 9CrV (Chromium-Vanadium Steel), our HotPulse technology significantly enhances the mechanical and chemical properties of welds compared to conventional methods. This improves the integrity and longevity of the welds and ensures the welding process meets stringent quality standards and adheres to tight schedules.

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.

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.

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.