Alfa Laval AXP27-MAX
Alfa Laval AXP27-MAX fusion-bonded all-stainless plate heat exchanger (fusion-bonded all-stainless). Plate count 16-200, max flow rate 110.0 m3/h, design pressure 48 bar. AlfaFusion technology — no copper or nickel; ideal for ammonia, freshwater and CO2 applications.
Inspector Detail
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Common issues
- Fouling/scaling on the seawater side reducing heat transfer efficiency
- Marine growth/biofouling in the seawater circuit
- Erosion-corrosion at high-velocity inlet areas on the seawater side
- Reduced flow from partial blockage, since the fusion-bonded plate pack cannot be mechanically opened for cleaning
- External flange/connection leakage at pipe interfaces
- Freshwater/glycol chemistry degradation affecting corrosion protection on the fresh water side
Inspection checklist
- Monitor approach temperature and pressure drop trend on both circuits against the commissioning baseline
- Inspect strainers/filters upstream on the seawater side
- Check external flange connections and gaskets for leakage
- Review seawater treatment/anti-fouling dosing operation, where fitted
- Check freshwater circuit chemistry/inhibitor concentration
- Inspect support/mounting structure for vibration wear
- Verify pressure relief/safety devices on the circuit are functional and within test date
- Check insulation condition where fitted
Service intervals
| Strainer cleaning | monthly or per observed fouling rate |
| Performance trend review (pressure drop/approach temp) | quarterly |
| CIP chemical cleaning of the plate pack | condition-based, when performance degrades - per Alfa Laval CIP guidance for AlfaFusion units |
| Freshwater treatment/inhibitor check | monthly |
| External leak/visual inspection | at each engine room round |
Critical spares
- Complete replacement unit or plate pack cartridge - fusion-bonded packs are not field-rebuildable like gasketed units; confirm the specific service concept with Alfa Laval
- External flange gaskets/O-rings
- Strainer elements
- CIP cleaning chemicals
- Pressure relief valve, where fitted to protect the 48 bar rated circuit
Safety
- High design pressure (48 bar) - strict isolation/depressurization procedure required before any work on connections
- Pressure testing hazards
- Chemical handling during CIP cleaning
- Ammonia handling precautions apply if the unit serves an ammonia-adjacent circuit
Class survey
Central coolers serving essential systems are surveyed as part of Continuous Machinery Survey. Surveyors check pressure test/relief valve certification given the 48 bar design pressure, external condition, absence of leakage, and that the installation matches the approved cooling system diagram, including the duty/standby arrangement if fitted.
Components & Design
Component data being added…
Technical Data
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Common failures & inspection points
Inspect seals visually for cracks, hardening, swelling and discoloration; verify material compatibility with process fluids; check ClipGrip™ fastening. Aging symptoms and loss of elasticity are replacement indicators.
Verify A-dimension per manufacturer specifications with caliper (metallic contact required). Keep bolts clean and lubricated. Avoid over-tightening. Perform regular re-tightening after operating hours. At too low A-dimension, pressure loss and leakage are to be expected.
Monitor pressure differential across heat exchanger (increase indicates deposits). Check heat duty versus design value. Optimize CIP intervals after performance audits. Deposits generate higher pump load (energy waste up to 8,000 kWh/year possible).
After disassembly, inspect plate surfaces for local measurements (pitting), cracks and perforation corrosion. Verify material compatibility with process fluid. Observe fatigue cracks especially at corners and transitions. When perforation occurs, plate is unrecoverable and must be replaced.
After disassembly and cleaning, perform hydrostatic test per data sheet. Test pressure typically 1.5× operating pressure. Check external and internal leakage at all connections and plate edges. Document findings.
After opening, verify plate sequence and honeycomb pattern (corrected chevron patterns must alternate). Activate/validate 5-point alignment system for larger units. Offset or misplacement leads to short-circuiting and reduced heat duty.
Type-general inspection and maintenance points for this equipment category — not model-specific.
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