Alfa Laval Condition Audit

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1 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

2 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

3 Description How is an Alfa Laval Condition Audit performed? Analysis of customer data Onsite inspection visit using standardized procedures In operation PHE connected to process Not in operation PHE not connected to process Delivery of Condition Audit report including feedback and discussion on actual state and future needs Perform actions to improve/optimize the plate heat exchanger

4 Description 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

5 Description 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

6 Benefits 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

7 When to use 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

8 Related services 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

9 Customer case 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. POTENTIAL SAVINGS Potential production savings* VALUE HOW 150,000 Gasket lifetime prediction Results Minimized risk for unscheduled downtime and production loss Improved control of maintenance budget Total savings 150,000 Alfa Laval Condition Audit * 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

10 Frequently asked questions 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

11 Summary 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 PEACE MIND OF MIND

12 References Shipbuilder in South Korea Copper smelter in Sweden Mining company in Chile Brewery in Japan

13 Facts & figures Remaining gasket lifetime prediction Gasket compression set (%) Limit: 80% Actual value Remaining lifetime Remaining gasket lifetime depends on: Gasket material properties (from Alfa Laval material reference database) Gasket compression set Operating temperature Date of audit Time Gasket compression set* *Permanent gasket deformation, which reduces the sealing force Gasket compression set > 80% High risk for leakage. Plan for immediate change of gaskets.

14 Facts & figures Plate deformation test Deformed gasket groove Reduced gasket compression Reduced sealing force Increased risk for leakage Deformed gasket groove Less compressed gasket due to deformed gasket groove Fully compressed gasket 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.

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