Condition Audit Gain insights about the actual condition of your - - PowerPoint PPT Presentation

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

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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

• peration

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

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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

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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

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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.