THERMAL COATING TECHNOLOGIES
FOR
BOILER EROSION/CORROSION PREVENTION
WHERTEC TECHNOLOGIES
INC.
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By utilizing inspection services, specialized coatings
and weld overlay, Whertec provides products and
services that protect metal substrates against erosion
and corrosion
Our goal is to provide superior comprehensive
services and resources to assure that our clients
achieve maximum operational utilization of their
equipment
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WHERTEC PRODUCTS
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Thermal sprayed
coatings
Ceramics
Weld overlay and weld
repairs
Inspection Services
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Boiler Inspection Services (BIS)
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Visual Inspection
Boiler Mapping
U.T. readings / Trend
Analysis
Coating thickness
readings / Trend
Analysis
Recommendations
Reports and
documentation
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BOILER INSPECTION SERVICES
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Continuous Inspections
during a Coating Project
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Tailored project QCP
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Technician accountability
results in quality
workmanship
BENEFIT:
Experienced boiler inspectors actively monitoring
coating work to guarantee quality and customer
satisfaction.
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BOILER TUBE WASTAGE RATES
CAN BE AFFECTED BY:
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Fuel type
Bed material composition
Particle size and shape
Particle impact velocity
Particle angle of attack
Operating pressure and temperature
Operating procedures
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Typical areas of tube wastage
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1- Refractory Interface
2- Corners
3- Cyclone inlet
4- Roof tubes
5- Wingwall tubes
6- Openings and ports
7- Water wall tubes/membrane
WB
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Thermal Spray Process
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Thermal spray coating adhesion
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After impact the molten
particles cool and shrink
to mechanically lock
onto the asperities (peaks
and valleys) of the
profiled substrate.
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Thermal spray performance
30 mil of cored wire arc
sprayed coating after 4
months in service
9 mils of W-915 HVOF coating
after 2 years in service
Gouging / erosion due to
unpredictable eddy currents
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Cored wires
Thicker sacrificial arc sprayed coatings
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ARC SPRAY
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MATERIALS
Pre alloyed wires and powders
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THERMAL SPRAY SYSTEMS
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HVOF
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HVOF MATERIALS
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Blended
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Agglomerated
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HVOF Powder
Pre Alloyed
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W-915 COMPONENTS
PRE-ALLOYED
MATERILS
 NOMINAL
CHEMISTRY
-Chromium
-Titanium
-Nickel
-Carbon
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Application Procedures
Lead Edge Erosion
Taper Design
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Tube Replacement
Severe SH tube erosion
Erosion resistant HVOF
coating application
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CASE HISTORY
ADM Decatur #3
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Inspection and W-915 thermal Spray reduced
Repair Time from 14 days to 2 days
2001 – 9 Forced Outage
2002 – 4 Forced Outages
2003 – 1 Planned 2 Forced Outages
2004 – 1 Planned Outage
2005 – 2 Planned – 0 Forced Outages
2006 – 1 Planned – 0 Forced Outages
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W-915 performance
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AUTOMATION
Automated Systems for vertical
waterwall applications:
• Quality & consistency
• Repeatability
• Cost savings
• Improved production rates
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Automation
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THERMAL COATING
(SPRAY & FUSE)
• Metallurgical bond
• High temperature erosion
and corrosion resistance
• No interconnected porosity,
high density
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Arc Spray
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Cold Spray
(W-750 CERAMIC COATING)
• Visual ID of high wear areas -
minimize your NDE time &
expense
• Quickly applied - 150 ft2/hour
application rates
• Low Cost
• Coating thickness can be easily
monitored & touched up
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W-750 Ceramic
New Application
After Two years service
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Whertec Mechanical, LLC
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Qualified and experienced
personnel
State of the art automation
and equipment
Proven industrial field
performance
R Stamp for repair of ASME
vessels
High quality materials
Qualified technical support
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Whertec Mechanical, LLC
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WELD OVERLAY PROTECTION
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On-Site Automated Welding Systems
Surface Prep Equipment
Operational and Safety Systems
Over 400 combined years of Field Industrial Experience
Proven Track Record for completing projects ON-TIME and
within SPECS working in various types of boilers and pressure
vessels
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WHERTEC MECHANICAL
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Have completed projects with as
many as <23> automation systems
and <60> employees
Use highly skilled employees with
certifications in carbon steel,
stainless steels and nickel alloy,
overlay processes
Shop and field capabilities
State of the art automation
Dedicated QA/QC Manager on
every project
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Proven Maintenance Solutions
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