Top Solutions When Spare Parts Cannot Be Replaced or Acquired
Rosengarten, May 10th, 2021
Ensuring Maximum Machine Uptime with Reliable Service
In industrial production, machine uptime is a crucial factor for profitability, especially when it comes to industrial compressors and blowers. These machines play a critical role in maintaining production flow. However, over time, wear and tear inevitably occur, affecting even the best-maintained equipment. While preventive maintenance can help reduce wear, it’s often unavoidable that some parts will eventually need repairs or replacement. So, what should you do if essential components—like an impeller—suddenly fail and can’t be quickly replaced or acquired?
A Dependable Service Partner for Urgent Repairs
“In situations like these, we are here as your reliable service partner, ready to support you with any challenge,” says Manuel Hilpert, Deputy Managing Director of Serafima GmbH & Co. KG. As an independent service provider, Serafima offers expert advice, full support, high-quality repairs, and a wide range of replacement parts for both flow and process technology systems.
Case Study: Emergency Repair for a Damaged Axial Fan Impeller
Recently, Serafima was called upon by a German client facing a critical issue with an aging axial fan. The client discovered severe damage to the fan’s impeller and urgently needed a replacement to avoid costly downtime. However, because the fan system was old, replacing the entire system wasn’t financially viable. To make matters more challenging, the original manufacturer was no longer in business, meaning that no design documents were available. Thus, a quick change of strategy was essential.
From Inspection to Solution: Our Step-by-Step Approach
To start, the damaged impeller was sent to Serafima’s service center, where it underwent a thorough inspection. The results confirmed the client’s suspicion: the impeller was beyond repair. Almost every blade had missing fragments, and from a safety perspective, a repair wasn’t advisable. A new impeller was urgently required. To move forward, two relatively intact blades were selected, and their original shape and surface were restored using TIG welding, allowing work to continue the very same day.
Advanced 3D Scanning and CAD Modeling
Next, after the initial repair, the impeller’s geometry was captured using a handheld MMDX 3D laser scanner. This data was then transferred to CAD software, which enabled Serafima to quickly create a new 3D model of the impeller. Furthermore, using Finite Element Analysis (FEA), the strength of the new design was tested, allowing for adjustments that not only improved the impeller’s durability but also significantly extended its expected lifespan.
Manufacturing and Quality Assurance for the New Impeller
After finalizing the 3D model, a new casting mold was created specifically for the impeller blades. New aluminum blades were cast, and a new hub with an embedded steel core was manufactured. With the help of TIG welding, a new impeller was assembled. To ensure the quality of the surface, dye penetrant inspection (PT) was conducted, and the impeller was carefully balanced for optimal performance. Finally, one of our service technicians installed the impeller on-site, allowing the client to resume operations almost immediately.
Why Choose Serafima for Aging Machinery?
When machines reach a certain age and certain components become hard or even impossible to replace—or when replacing the entire machine is simply too costly—it’s vital to have a competent service partner by your side. At Serafima GmbH & Co. KG, we are committed to offering fast, customized solutions that meet your unique needs, ensuring that your equipment stays operational and efficient for as long as possible.
Interested in Learning More?
If you’re curious about how we can help, we would be more than happy to discuss our reverse engineering capabilities with you. Supported by modern simulation and manufacturing technology, we can bring new life to old equipment. Simply send us a brief email with your contact details and the subject line “Reverse Engineering,” and we’ll get in touch with you promptly.
For more information, visit: https://www.serafimaint.com/leistungen/ersatzteile
Keywords: Serafima, axial impeller, compressors, fans, spare parts, independent service provider, full-service
About Serafima GmbH & Co. KG
Serafima GmbH & Co. KG, part of the Schwäbisch Haller Schaeff Group, has been providing smart and efficient solutions for process technology and flow machinery in the process gas industry for over 20 years. This includes sectors like oil & gas, chemical, petrochemical, food, and steel. Since separating from its former parent company, FIMA Maschinenbau GmbH, after its insolvency in 2019, Serafima has operated as an independent full-service provider for all types of turbomachinery and rotating equipment. This independence allows us to offer maximum flexibility and sustainable success for our clients.
Contact for Reader Inquiries:
Serafima GmbH & Co. KG
Stephan Jakob, Managing Director
Karl-Kurz-Straße 2
74538 Rosengarten-Uttenhofen
Phone: +49 791 94600-0
Fax: +49 791 94600-169
Email: info@serafimaint.com
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KOKON – Marketing Profiling PR
Marion Oberparleiter
Lindenstr. 6
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