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.
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.
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.
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.
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.
Raizen announced WSI as one of the recipients of its annual supplier recognition awards, selected for outstanding performance in alignment with Raizen's culture and values.
Supporting customers with responsive service, trusted guidance, and dependable warranty protection for over 85 years
Committed to compliance with the Buy American Act (BAA)
Proudly compliant with the Build America, Buy America (BABA) Act
Class 1 division 1 explosion proof lighting prevents ignition in areas with constant flammable gases or vapors
Class 1 Div 2 hazardous-rated lighting provides protection where flammable gases or vapors are unlikely but possible
C2D1 explosion proof lighting prevents combustible dust ignition where hazardous conditions are always present
Class 2 division 2 hazardous-rated lighting (C2D2) minimizes the risk in areas where combustible dust may occur
Class III explosion proof lighting prevents ignition in environments with ignitable fibers or flyings
IEC 60079 zone classification for hazardous areas
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.
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.
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.
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.
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Supporting customers with responsive service, trusted guidance, and dependable warranty protection for over 85 years
Committed to compliance with the Buy American Act (BAA)
Proudly compliant with the Build America, Buy America (BABA) Act
Class 1 division 1 explosion proof lighting prevents ignition in areas with constant flammable gases or vapors
Class 1 Div 2 hazardous-rated lighting provides protection where flammable gases or vapors are unlikely but possible
C2D1 explosion proof lighting prevents combustible dust ignition where hazardous conditions are always present
Class 2 division 2 hazardous-rated lighting (C2D2) minimizes the risk in areas where combustible dust may occur
Class III explosion proof lighting prevents ignition in environments with ignitable fibers or flyings
IEC 60079 zone classification for hazardous areas
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.
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.
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.
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.
WSI has the largest installed base of digester weld metal overlay in the industry and a solid reputation for safety, quality, and exceptional value.
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.
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Supporting customers with responsive service, trusted guidance, and dependable warranty protection for over 85 years
Committed to compliance with the Buy American Act (BAA)
Proudly compliant with the Build America, Buy America (BABA) Act
Class 1 division 1 explosion proof lighting prevents ignition in areas with constant flammable gases or vapors
Class 1 Div 2 hazardous-rated lighting provides protection where flammable gases or vapors are unlikely but possible
C2D1 explosion proof lighting prevents combustible dust ignition where hazardous conditions are always present
Class 2 division 2 hazardous-rated lighting (C2D2) minimizes the risk in areas where combustible dust may occur
Class III explosion proof lighting prevents ignition in environments with ignitable fibers or flyings
IEC 60079 zone classification for hazardous areas
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.
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.
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.
Related Feature Stories
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Supporting customers with responsive service, trusted guidance, and dependable warranty protection for over 85 years
Committed to compliance with the Buy American Act (BAA)
Proudly compliant with the Build America, Buy America (BABA) Act
Class 1 division 1 explosion proof lighting prevents ignition in areas with constant flammable gases or vapors
Class 1 Div 2 hazardous-rated lighting provides protection where flammable gases or vapors are unlikely but possible
C2D1 explosion proof lighting prevents combustible dust ignition where hazardous conditions are always present
Class 2 division 2 hazardous-rated lighting (C2D2) minimizes the risk in areas where combustible dust may occur
Class III explosion proof lighting prevents ignition in environments with ignitable fibers or flyings
IEC 60079 zone classification for hazardous areas
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.
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.
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.
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:
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Explore Industrial Maintenance Services
Industry leading life extension and repair processes to address low cycle fatigue failure
Advanced furnace tube welding technology for challenging u-bend welds in heaters and furnaces
Piping services with revolutionary machine orbital welding for planned or emergent outages
Over 30 years of experience in superheater, reheater, and economizer services
World’s largest installed base for the mitigation of fireside corrosion