Alfa Laval Condition Audit Gain insights about the actual condition of your Alfa Laval gasketed plate heat exchanger and optimize it for the future. A service from Alfa Laval 360 ° Service Portfolio
Alfa Laval Condition Audit Gasketed Plate Heat Exchangers Why should an Alfa Laval Condition Audit be performed? • Gain insight about the state of equipment – Detailed mechanical condition – Need of repair – Remaining gasket lifetime prediction* • Discuss possible optimization – Maintenance plan – Strategic spare parts – Cleaning services • Receive feedback on actions to be taken *Only possible when PHE is not in operation www.alfalaval.com
Description Alfa Laval Condition Audit Gasketed Plate Heat Exchangers How is an Alfa Laval Condition Audit performed? Onsite inspection visit using standardized procedures Delivery of Condition Audit Perform actions report including Not in to improve/optimize Analysis of In operation feedback and operation the plate heat customer data discussion on PHE exchanger PHE not actual state and connected to connected to future needs process process www.alfalaval.com
Description Alfa Laval Condition Audit Gasketed Plate Heat Exchangers • All Condition Audits include checking: – Frame and bolt condition – General plate condition – General gasket condition – Spare parts inventory • All not-in-operation audit also includes checking: – Gasket lifetime prediction – Detailed plate condition including plate deformation test – Detailed frame condition including connection linings – Fouling evaluation www.alfalaval.com
Description Alfa Laval Condition Audit Gasketed Plate Heat Exchangers Serving non-Alfa Laval equipment • Service for all major OEMs • A one-stop shop • Vast knowledge of all brands, more than 30 years of experience • Covering more than 400 different GPHE models • Possible combination with other services such as Alfa Laval Cleaning Services GPHE and Alfa Laval Performance Audit GPHE www.alfalaval.com
Benefits Alfa Laval Condition Audit Gasketed Plate Heat Exchangers Knowing the condition of an Alfa Laval gasketed plate heat exchanger allows customers to: – Optimize maintenance plans – Secure production – Prevent safety issues – Improve control of maintenance budget – Increase equipment lifetime www.alfalaval.com
When to use Alfa Laval Condition Audit Gasketed Plate Heat Exchangers An Alfa Laval Condition Audit should be considered when any of the following circumstances exist: • Process critical equipment • Change in process conditions • Valuable equipment (large, exotic materials) • Older installations www.alfalaval.com
Related services Alfa Laval Condition Audit Gasketed Plate Heat Exchangers • Alfa Laval Performance Audit Plate Heat Exchangers • Alfa Laval Redesign Gasketed Plate Heat Exchangers • Alfa Laval Cleaning Services Gasketed Plate Heat Exchangers • Alfa Laval Reconditioning Gasketed Plate Heat Exchangers • Alfa Laval Performance Agreements Gasketed Plate Heat Exchangers www.alfalaval.com
Customer case Alfa Laval Condition Audit Gasketed Plate Heat Exchangers One out of four big Alfa Laval units installed in a sulphuric acid plant in South America started to leak, due to worn-out gaskets, a few months after a scheduled shutdown. The unit was out of operation for four weeks due to gasket replacement. If an Alfa Laval Condition Audit had been performed at an earlier stage, the poor condition of the gaskets would have been POTENTIAL VALUE HOW identified. The unit could then have been SAVINGS reconditioned during a scheduled € 150,000 Potential Gasket lifetime shutdown and the production losses production prediction prevented. savings* Results € 150,000 Total savings Alfa Laval Condition Audit • Minimized risk for unscheduled downtime and production loss * Production loss calculation: One unit out of operation => 25% production loss = 250 tons/week • Total loss: 250 tons x 4 weeks x 150 € /ton = € 150,000 Improved control of maintenance budget www.alfalaval.com
Frequently asked questions Alfa Laval Condition Audit Gasketed Plate Heat Exchangers • Who performs an Alfa Laval Condition Audit? – Alfa Laval Condition Audits are performed by highly qualified Alfa Laval service engineers with extensive gasketed plate heat exchanger and process knowledge • How are results delivered? – Audit results, together with service and upgrade recommendations, are delivered to the customer in a detailed audit report www.alfalaval.com
Summary Alfa Laval Condition Audit Gasketed Plate Heat Exchangers Knowing the condition of an Alfa Laval gasketed plate heat exchanger can lead to: PEACE • Secured factory output OF • Reduced maintenance cost • PEACE OF Prolonged equipment lifetime MIND • MIND Increased plant safety • Improved control of maintenance budget www.alfalaval.com
References Alfa Laval Condition Audit Gasketed Plate Heat Exchangers • Shipbuilder in South Korea • Copper smelter in Sweden • Mining company in Chile • Brewery in Japan www.alfalaval.com
Facts & figures Alfa Laval Condition Audit Gasketed Plate Heat Exchangers Remaining gasket lifetime prediction Gasket Remaining gasket lifetime depends on: compression • set (%) Gasket material properties (from Alfa Laval material reference Limit: 80% database) • Gasket compression set Actual value • Remaining Operating temperature lifetime Date of audit Time Gasket compression set > 80% Gasket compression set* ‒ High risk for leakage. Plan for immediate change of gaskets. *Permanent gasket deformation, which reduces the sealing force www.alfalaval.com
Facts & figures Alfa Laval Condition Audit Gasketed Plate Heat Exchangers Plate deformation test Increased risk for leakage Deformed gasket groove Reduced sealing Reduced force gasket compression Deformed gasket groove Gasket compression > 25% ‒ Gasket compression is OK. Gasket compression 20% - 25% ‒ Gasket compression is reduced. Less compressed gasket due Gasket compression < 20% to deformed gasket groove ‒ Gasket compression is too low. Action should be taken. Fully compressed gasket www.alfalaval.com
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