HERE ARE THE BENEFITS
MASSIVE REDUCTION IN FORCED OUTAGE TIME
Zero Wait Time
You don’t have to wait 24–48 hours for a specialized contractor to arrive on-site.
Rapid Extraction
Removing a seized M100 turbine stud with standard drilling techniques can take several shifts; ARES-500 can core it out in a fraction of time, keeping your outage schedule on track.
SAFEGUARDING MULTI-MILLION DOLLAR ASSETS
Components like turbine casings or high-pressure valve bodies are irreplaceable in the short term.
Thread Integrity
Standard drilling often ruins the hole threads of the casing. Spark erosion is a precise non-contact process that protects the original threads, allowing you to simply screw in a new bolt without needing oversized inserts or welding repairs.
Stress-Free Removal
Since there is no torque or physical force, there is zero risk of cracks — a common danger with heavy drilling.
MASTERY OVER SUPERALLOYS
Hardness Independent
Whether it’s a broken carbide drill, a Stellite-faced valve seat, or an Inconel stud, the electrical arc melts through them all with the same ease.
Precision in Tight Spaces
Portable units can be clamped directly onto the component, working in positions where a standard radial drill could never fit.
HIGH ROI (RETURN ON INVESTMENT)
The cost of the machine is often recovered in a single successful intervention.
If the machine prevents a 12-hour delay in restarting a generator, the saved revenue alone covers the purchase price of the equipment several times over.
INCREASED IN-HOUSE CAPABILITY
Autonomy
Your maintenance team gains the ability to handle “worst-case scenarios” without external help, ensuring total control over the outage timeline.
On-Demand Expertise
For plants without a dedicated internal team, Nuova Simat provides rapid-response on-site services. Our specialist technicians can be deployed immediately, guaranteeing the same precision and restart date certainty as an in-house solution.
Safety
Portable metal disintegration guarantees safety by eliminating the risk of drill bit breakage and thermal damage, protecting both the operator and the component’s integrity.
ON-SITE AUTONOMY VS. EXTERNAL OUTSOURCE
Feature | On-Site Unit (Owned) | Off-Site Unit |
RESPONSE TIME | Instant. Your maintenance team starts the repair as soon as the problem is identified. | Delayed. Requires the unit to be shipped |
DOWNTIME COST | Minimal. Keeps the “critical path” of the outage moving. | Extremely High. Every hour waiting for the machine (and team) arrival on-site is lost revenue. |
LOGISTICS | None. The machine goes to the component. No cranes or trucks are needed for the part. | High Risk & Cost. Massive parts must be dismounted, lifted, and shipped to a workshop if drilling fails or cannot be performed safely in-situ. |
RISK OF DAMAGE | Low. The electrode never touches the threads. It preserves the original hole alignment and diameter. | High. Drill bits often “walk” or vibrate, causing oversized holes, ovalization, or irreversible damage to the internal threads. |
MATERIAL CAPABILITY | Full. Handles Inconel, Stainless, and Carbide on-site. | Limited. Extremely difficult and risky to drill through broken carbide or hardened taps without specialized equipment. |
FINANCIAL IMPACT | High Initial Investment but pays for itself in few uses. | Low Initial Cost but high “per-incident” fees and massive indirect outage costs. |
EMERGENCY READINESS:COST-BENEFIT ANALYSIS
During a scheduled shutdown, finding a broken bolt is a common emergency.
Having the EDM unit ready in your plant prevents a small mechanical failure from turning into a week-long delay. Imagine a seized M100 turbine stud discovered during a scheduled outage:
The “Drilling Failure” Delay:
Before calling for help, the maintenance team spends 12 hours attempting to drill the stud.
The bit damages the first two threads, and eventually snaps inside the stud. Now you have a hardened tool stuck inside a seized bolt.
External Outsource Delay:
It would take at least 24 hours for the rental unit to arrive on-site and set up.
Average Lost Revenue:
Let’s estimate $ 25,000 per hour (varies by plant size).
Total Downtime Added:
36 hours of delay.
TOTAL $ 900,000 loss in a single incident.
Cost of Repair:
Additional fees for thread repair or oversized bushing due to drilling damage.
The "On-Site Insurance" Result
By using ARES-500 immediately, the stud would be removed in about 4 hours.
NET SAVINGS: Over $800,000 and a guaranteed restart date.
Equipment Payback:
The machine pays for itself over a single critical failure.
Outage Autonomy:
During “peak season” (Spring/Autumn), external contractors are often overbooked. Owning the machine removes the risk of being “next on the list”.
You buy it to buy back time.
It is the only tool that turns a ‘catastrophic delay’ into a ‘minor scheduled task’.
CONTACTS
- Via Spagna, 32-34, Polo Industriale di Guasticce, 57017 Guasticce, Collesalvetti (LI) - Italia
- info@nuovasimat.com
- +39 0586 983108
- +39 338 6996109
Nuova Simat S.r.l. Società Benefit| Cod. Fiscale e P. IVA 01591210495 | capitale sociale € 100.000,00 i.v. | codice SDI M5UXCR1