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
www.alfalaval.com
Alfa Laval Condition Audit Gasketed Plate Heat Exchangers
• 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
Why should an Alfa Laval Condition Audit be performed?
*Only possible when PHE is not in operation
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Description Alfa Laval Condition Audit Gasketed Plate Heat Exchangers
How is an Alfa Laval Condition Audit performed?
Analysis of customer data
Onsite inspection visit using standardized procedures
Delivery of Condition Audit report including feedback and discussion on
actual state and future needs
Perform actions to improve/optimize
the plate heat exchanger
In operation
PHE connected to
process
Not in operation
PHE not connected to
process
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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
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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
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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
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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
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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
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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
identified. The unit could then have been
reconditioned during a scheduled
shutdown and the production losses
prevented.
Results
• Minimized risk for unscheduled downtime and
production loss
• Improved control of maintenance budget
* 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
POTENTIAL
SAVINGS
VALUE HOW
Potential
production
savings*
€ 150,000 Gasket lifetime
prediction
Total savings € 150,000 Alfa Laval
Condition Audit
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:
• Secured factory output
• Reduced maintenance cost
• Prolonged equipment lifetime
• Increased plant safety
• Improved control of maintenance budget
PEACE OF
MIND
PEACE
OF
MIND
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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
Remaining gasket lifetime depends on:
• Gasket material properties (from
Alfa Laval material reference
database)
• Gasket compression set
• Operating temperature
Gasket compression set > 80%
‒ High risk for leakage. Plan for
immediate change of gaskets.
Gasket compression
set*
*Permanent gasket
deformation, which reduces
the sealing force
Gasket
compression
set (%)
Time
Limit: 80%
Actual value
Date of audit
Remaining
lifetime
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Deformed gasket groove
Reduced gasket compression
Reduced sealing force
Increased risk for leakage
Facts & figures Alfa Laval Condition Audit Gasketed Plate Heat Exchangers
Plate deformation test
Deformed
gasket groove
Fully compressed gasket
Less compressed gasket due
to deformed gasket groove
Gasket compression > 25%
‒ Gasket compression is OK.
Gasket compression 20% - 25%
‒ Gasket compression is reduced.
Gasket compression < 20%
‒ Gasket compression is too low. Action should be taken.
