Alfa Laval CB200 Series
Alfa Laval Alfa Laval CB200 Series — Alfa Laval Brazed & Fusion-Bonded Plate Heat Exchanger (CB / AlfaNova). Alfa Laval's brazed and fusion-bonded plate heat exchangers are compact, high-efficiency units for demanding marine and industrial applications. CB models employ stainless steel plates brazed with 100% copper in vacuum furnaces, while AlfaNova uses patented AlfaFusion technology combining all-stainless-steel construction (316) with stainless steel
Inspector Detail
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Common issues
- Selecting a copper-brazed CB-series unit for a raw seawater duty when a fusion-bonded AlfaNova core is needed for that corrosion environment
- Progressive fouling on either circuit narrowing the approach temperature over time
- Brazed joint fatigue leakage after long service, especially where thermal cycling is frequent (start/stop duties)
- Plate pack blockage from particulate ingress when upstream strainers are undersized or poorly maintained
- External corrosion at carbon steel piping/flange connections if coatings are not kept up
- Reduced performance from incorrect flow direction or an undersized unit for the actual duty load
Inspection checklist
- Confirm which core material (copper-brazed CB vs 100% stainless AlfaNova) is actually fitted before assuming duty suitability
- Trend the approach temperature and pressure drop against commissioning figures
- Inspect brazed seams for weeping, staining or corrosion
- Check upstream strainers for condition and cleaning frequency
- Verify the nameplate pressure rating matches the system's operating pressure
- Sample both circuits periodically for cross-contamination
- Inspect supports and connections for vibration fatigue
Service intervals
| Performance trend review (approach temp / pressure drop) | monthly to quarterly depending on service criticality |
| Strainer cleaning upstream | monthly to quarterly depending on water source |
| CIP chemical cleaning | condition-based, commonly every 6-24 months |
| Nameplate/material data verification against duty | at each major maintenance or whenever the unit's service is changed |
Typical wear limits
| Pressure drop rise vs commissioning baseline | commonly used as a cleaning trigger around 20-40% above baseline - unit-specific, not a fixed figure |
| Approach temperature rise vs design | a sustained few-degree C rise above design is a typical fouling indicator |
| Core material corrosion evidence | any visible copper braze corrosion on a unit meant for raw seawater duty indicates the wrong core material was fitted, which is a limit in itself, not a numeric one |
Ranges are typical for this design class. Always confirm against the manufacturer documentation for your serial number.
Critical spares
- Isolation valves for both circuits
- Strainer elements
- Flange gasket sets
- Monitoring instrumentation (pressure/temperature)
- A like-for-like replacement core, since neither CB nor AlfaNova units are field-repairable internally
Safety
- Never exceed the nameplate design pressure when pressure testing
- Isolate and vent before breaking connections - trapped pressure and thermal expansion
- Confirm the fitted core material is corrosion-appropriate for the duty before use - the wrong material choice is a corrosion failure risk, not just a performance one
Class survey
As a family of pressure-retaining heat exchangers, class attention is on correct material certification for the actual duty (especially seawater contact), pressure test records, and general piping/machinery survey coverage rather than a dedicated survey item, unless the unit serves a class-essential system.
Components & Design
Component data being added…
Technical Data
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Common failures & inspection points
Visual inspection inside heat exchanger after opening plate package; UV light detection—white spots indicate water-soluble scaling, black spots indicate oil-soluble deposits. Monitor pressure drop across unit during operation as early fouling indicator. If fouling detected, perform optimized CIP (Cleaning-in-Place) with custom-formulated cleaning agents (2–4 hours typical duration). Backflushing (3× daily, 30-second pulses) may prevent accumulation.
During operation: inspect for any liquid weeping from gasket glands or plate boundaries—must be zero. Perform periodic integrity testing (recommended every 2 years per Alfa Laval): place donor fluid in primary path, recipient fluid in secondary path, apply positive pressure differential, monitor electronically for donor fluid leakage into secondary circuit. On brazed/fusion-bonded units (CB, AlfaNova), inspect solder/bond lines for microcracks using visual inspection and dye-penetrant testing if available.
Monitor inlet and outlet temperature differentials during operation. Document frequency and magnitude of temperature swings. For brazed CB units, be especially cautious—Alfa Laval notes brazed units are sensitive to large, sudden, frequent temperature changes. Inspect solder-joint interfaces during maintenance outages for hairline cracks. Check tightening torque of frame bolts according to Alfa Laval specifications; incorrect bolt load accelerates fatigue. Request Alfa Laval assessment if temperature cycling frequency exceeds design envelope.
Visually inspect all gasket grooves when plate package is opened—look for cracks, discoloration, swelling, or hardening. Confirm gasket material compatibility with both heat transfer media (check Alfa Laval compatibility matrix). If cracks detected or if unit has been in service >5–7 years, replace gaskets with certified Alfa Laval equivalents using correct groove placement procedure. After replacement, perform torque-down sequence per manual and conduct integrity test before restart.
After opening plate package, inspect plate surfaces under good lighting for pitting, discoloration, or rust staining—prioritize gland/seal areas and plate corners where stagnation may occur. In marine service, perform visual assessment annually or after seasonal lay-ups. For high-corrosion marine duty, verify AlfaNovaM (all-stainless-steel) is in use rather than standard CB (which may have dissimilar metals). Confirm flush/circulation program is followed to prevent salt/sediment accumulation. If pitting observed, consult Alfa Laval on material upgrade or replacement.
Monitor differential temperature across inlet and outlet on each circuit. Uneven temperatures indicate distribution maldistribution or internal blockage. Inspect plate inlet and outlet ports visually for debris or sediment before opening. Compare actual thermal performance (capacity, outlet temperature) against design baseline—significant drop indicates fouling or flow restriction. If blockage suspected in narrow channels, perform flushing with appropriate solvents (per CIP protocol) or request Alfa Laval chemical cleaning. Verify inlet filtration is active to prevent future particulate ingress.
Type-general inspection and maintenance points for this equipment category — not model-specific.
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