Inspection and repair of an industrial separator in Austria – Alloy 625 weld overlay
PROJECT COMPLETED – Comprehensive inspection and repair of an industrial separator (with rotor assembly) in Austria. Alloy 625 weld overlay, diagnostics, and servicing. Project completed in accordance with the schedule.
Inspection and repair of an industrial separator with rotor assembly in Austria
At one of the industrial facilities in Austria, we carried out a comprehensive project involving the inspection and repair of a process separator.
The works were completed in accordance with the planned schedule, and the unit was restored to full operational capability.
The project was executed by a team of 12 PRO-Welding Industry Services specialists, including fitters and welders, responsible for the full scope of servicing and repair works.
Scope of work – PRO-Welding Industry Services specialists
1. Diagnostics and technical condition assessment
The first stage of the project involved thorough preparation of the unit for inspection.
The scope included:
- removal of process dust,
- detailed visual assessment of internal components,
- identification of wear areas.
Based on this, the following were identified:
- corrosion spots,
- surface wear caused by erosion,
- local material loss.
This allowed for precise determination of the required repair scope.
2. Weld overlay – Alloy 625 (Thermanit 625)
Worn surfaces were rebuilt using weld overlay with a nickel-based material – Alloy 625 (Thermanit 625).
The weld overlay process enabled, among others, restoration of component geometry and protection of surfaces against further wear.
The material used is characterized by high resistance to aggressive operating environments, resulting in increased durability of the regenerated components.
3. Machining and finishing
After completion of the weld overlay, the surfaces were subjected to machining.
The scope included:
- restoration of the original geometry,
- smoothing of working surfaces.
The objective was to ensure proper operating conditions of the unit and to reduce the re-accumulation of process dust.
4. Servicing of installation components
The scope of work also included auxiliary installation components:
- replacement of complete sealing assemblies,
- inspection and replacement of control and shut-off valves,
- modernization and replacement of air supply pipelines (including blow-off/regeneration systems), with verification of their flow capacity and tightness.
Project outcome
As a result of the performed works, the following was achieved:
- restoration of full operational capability of the separator,
- increased service life of the unit,
- improved efficiency of the installation,
- reduced risk of unplanned downtime.
Repair of critical industrial equipment components – importance for maintaining operational continuity of the installation
The executed project involving the inspection and repair of an industrial separator equipped with a rotor assembly represents a typical scenario encountered in industrial installations.
In many cases, it is not the entire unit, but its critical working components that determine the reliability and operational continuity of the installation.
Such components include in particular:
- surfaces exposed to erosion and abrasion,
- elements in direct contact with the process medium,
- components operating under continuous mechanical load (e.g. rotating parts).
Industrial equipment repair – inspection, welding and mechanical installation works
In many industrial applications, replacement of the entire unit is not necessary. An alternative is the repair of critical industrial equipment components, which includes:
- diagnostics of the actual degree of wear,
- identification of critical areas,
- selection of the appropriate repair technology,
- machining of working surfaces.
In the described project, weld overlay using a nickel-based material (Alloy 625) was applied, enabling the restoration of surfaces in the areas most exposed to wear.
Impact of repairs on operational continuity of the installation
From a maintenance perspective, the impact of repairs on the operational continuity of the installation is of key importance.
Properly planned service activities can:
- reduce the risk of failures,
- extend intervals between inspections,
- stabilize equipment operation,
- enable planning of maintenance shutdowns.
In practice, this means a transition from a reactive model (failure → repair) to a more predictable approach based on diagnostics and work planning.
Summary
Repair of critical industrial equipment components is an important element of maintenance strategy in industry.
Based on the example of the inspection of an industrial separator in Austria, it can be observed that properly planned activities enable:
- restoration of equipment functionality,
- increased service life,
- maintenance of operational continuity of the installation.
PRO-Welding Industry Services – industrial welding services and mechanical installation works
We specialize in executing projects for heavy industry across Europe, including:
- industrial welding,
- piping installations,
- service works and maintenance support,
- shutdown support.
We have a team of several hundred qualified specialists – welders and fitters – with experience in delivering international projects on active industrial sites.
Our personnel hold the required welding qualifications and certifications and have experience working in accordance with applicable standards and quality procedures.
We ensure rapid mobilization of teams – also on short notice.