Furnace Tube Welding

Furnace Tube Welding

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

WSI’s specialty furnace tube 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.

WSI’s Solution for an Age Old Problem: Machine U-bend Welding Process

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.

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High Velocity Arc Spray Explained

A fast, durable way to extend the life of critical assets without heat deformation damage or costly downtime

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High Velocity Arc Spray

Specialty Solutions

High Velocity Arc Spray

High Velocity Arc Spray (HVAS) Explained

A fast, durable way to extend the life of critical assets without heat deformation damage or costly downtime

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What it is

High Velocity Twin-Wire Arc Spray technology creates a high-density protective metal coating to enhance the surface of equipment suffering from corrosion, erosion, abrasion, and temperature
The coating composition is often nickel-based, but stainless steels, cobalt alloys, and tungsten carbide composites can also be sprayed, depending on application specifics
The coating thickness generally ranges from 0.3 and 0.6 mm (0.012 to 0.025 mils) and the high velocity nature of the proprietary process gives a porosity level below 2%
No heat-affected zone (HAZ) and no post-weld heat treatment (PWHT) needed. Protects the base metal while delivering superior bond strength (>5000 psi or 35 MPa)
Field-ready system engineered for confined spaces and brown-field conditions, using the latest proprietary thermal spray automation capabilities for maximum consistency

Advantages and Benefits

Rapid Turnaround Life Extension

Quickly protects pressure and process equipment, reducing downtime and maintenance costs

Superior Corrosion and Erosion Resistance

Withstands aggressive processes, high temperature, and high-pressure environments subject to wear problems

Material Flexibility to Match Conditions

Proprietary and commercial Fe-, Ni-, and Co-based alloys carefully selected to match unique operating conditions

Safe and Environmentally Controlled

Industry-approved ventilation systems virtually eliminate hexavalent chromium (Cr VI) exposure to less than one microgram per cubic meter.

Single Source Expertise and Execution

WSI integrates material analysis, application know-how, and field support with complementary services such as Weld Metal Buildup (WMBU), Corrosion Resistant Overlay (CRO), and Structural Weld Overlay (SWOL)

Applications and Sectors

Boilers
Superheaters
Heat Exchangers
Tanks
Reactors
Other: Any process equipment and machine elements subject to corrosion, erosion, high temperature, and high pressure

Oil and Gas Refineries

Power Generation

Pulp and Paper Mills

Steelmaking

Sugar Mills

Minerals Processing

WSI’s High Velocity Arc Spray System combines advanced field technology, skilled craft application, and comprehensive support services

The World Leader in Pressure Equipment Life Extension – WSI has added High Velocity Twin-Wire Arc Spray to our extensive line of corrosion/erosion mitigation services. WSI’s High Velocity Thermal Spray Solution offers our client partners a high-density metal coating designed to freeze the existing surface condition of critical assets suffering from corrosion, erosion, abrasion, impact and wear damage. Through superior permeability and uniformity, this custom life extension application withstands aggressive processes, high temperature, and high-pressure environments while eliminating the potential for Heat Affected Zones (HAZ) and no requirement for Post-Weld Heat Treatment (PWHT).

WSI’s Team of Experienced Professionals is dedicated to protecting and improving the critical components of your operations.

Innovative coating technology for superior erosion/corrosion protection

Market pressures have evolved, and WSI is a diverse partner that continues to evolve in kind. WSI offers engineered solutions that provide the best possible outcome for critical assets within Refineries, Nuclear, Waste-to-Energy, Fossil Fuel Power Plants, Pulp & Paper, Metals & Mineral Processing, and Petrochemical facilities.

Key Benefits of WSI High Velocity Thermal Spray:

WSI High Velocity Thermal Spray is a rapidly applied, low-cost intermediate repair solution that keeps more types of assets online while minimizing downtime.

Versatile Single-Source Contractor Solution: WSI provides a combination of corrosion/erosion mitigation services to extend the life of critical assets in energy facilities. These include Weld Metal Buildup (WMBU) with like material, Corrosion Resistance Overlay (CRO), Structural Weld Overlay (SWOL), and High Velocity Twin-Wire Arc Spray.
Material Analysis & Recommendation: WSI offers proprietary and commercially available corrosion-resistant alloys (CRAs), each with unique benefits. Our modified Fe-based, Ni-based, and Co-based alloys deliver unmatched defense in severely erosive, abrasive, and corrosive environments. WSI’s Materials Science Department will partner with clients’ facilities to select the correct alloy composition for each unique situation and process.
Custom Field-Ready Systems: WSI leverages our extensive machine-welding history to develop rugged brown-field-ready equipment suited for confined space conditions.
Schedule Optimization: WSI mechanically bonded metal coatings are applied efficiently to a wide range of substrate materials, incorporating high velocity and density, reducing the spraying time with outstanding quality.
Prioritizing Safety & Environment: WSI’s industry-approved modular Ventilation Systems are explicitly designed to eliminate Hexavalent Chromium (Cr(VI)) exposure (less than 1 μg/m³) to personnel and the surrounding environment. WSI’s commitment to health and safety ensures production schedules are maintained without concerns of a work stoppage due to safety and environmental interference.

Applications of High Velocity Thermal Spray Coatings:

WSI’s High Velocity Thermal Spray Coating system, with its proprietary protective surface enhancers and specialty alloy materials, is a versatile solution for diverse industrial applications. It offers improved protection against corrosion, oxidation, wear, and dimensional repair and restoration. This adaptability ensures the longevity of critical equipment, providing a high return on investment.

Corrosion & Oxidation: Corrosion and oxidation-resistant coatings are most beneficial for surfaces exposed to extreme high-temperature and high-pressure conditions, such as boilers, superheaters, heat exchangers, digesters, amine units, gas purification units (H2S/CO2), and other process equipment.
Wear: Wear-resistant coatings are applied to industrial process environments where components lose material due to erosion, abrasion, and impact. Some typical applications are CFB boilers, fan blades, coal chutes, mining conveyors, drill bits, pipes, pumps and valves, and turbine components.
Repair & Restoration: WSI’s High Velocity Arc Spray (HVAS) coating system allows for the restoration of worn or damaged components to their original specifications, extending their operational life and significantly reducing replacement costs.
Performance Enhancement: WSI High Velocity Twin-Wire Arc Spray coatings are designed to meet specific operational demands and significantly improve the performance of essential components. Functioning as a thermal barrier, while increasing surface hardness, and protecting against degradation, WSI ensures client’s critical assets run at peak performance and operational efficiency.

Trust WSI to provide the most appropriate solution for your unique problem.