Time-critical repairs during dry dock can make the difference between sailing on schedule or facing costly delays. Premier Separator Services was recently called upon to carry out an Alfa Laval plate heat exchanger repair for a major cruise ship operator during the final stages of a dry docking and refurbishment programme.
The issue related to a leaking main engine central cooler, identified just as the vessel was preparing to return to service.
The Problem
Initial inspection revealed that the end frame plate of the plate heat exchanger had suffered severe corrosion and pitting. Under normal circumstances, this type of damage would require:
- Cutting an opening in the vessel’s structure
- Removing the frame plate from the engine room
- Grit blasting and assessment
- Weld repair and/or machining
This traditional approach would have involved significant time, cost, and disruption to the dry dock schedule.
The Solution: In Situ Alfa Laval Plate Heat Exchanger Repair
Premier Separator Services proposed an alternative repair method that avoided structural modifications to the vessel and dramatically reduced downtime.
Using a Belzona marine-grade repair system, specifically designed to bond to heavily corroded (“gingered”) surfaces, our service engineers carried out a full in-situ repair within two days.
The repair process included:
- Mechanical removal of corrosion using angle grinders and needle guns
- Fresh water washing to eliminate salt contamination
- Final surface preparation for optimal adhesion
- Application of Belzona marine metal using a scrubbing action to ensure full surface contact
- Building up the repair material to the required thickness
- Dressing the surface back to achieve a near-flat finish
- Application of two protective coats of Belzona 1341 fluid coating system
This method restored the integrity of the end frame plate while providing long-term corrosion protection.
Addressing the Cracked End Plate
In addition to corrosion damage, a crack was identified in the end plate. Rather than replacing the plate and altering tightening dimensions, the issue was resolved by:
- Installing two end plate gaskets on the first two plates
- Effectively isolating the damaged plate
- Maintaining the original tightening length of the heat exchanger
This approach allowed the Alfa Laval plate heat exchanger repair to be completed without compromising system geometry or performance.
The Result
After a 24-hour curing period, the plate pack was re-tightened and the heat exchanger returned to service. The vessel avoided major structural work, costly delays, and extended dry dock time.
The Alfa Laval plate heat exchanger repair was completed efficiently, safely, and well within the vessel’s operational schedule, allowing the cruise ship to sail on time.
The Expert Heat Exchanger Repair Support
Premier Separator Services provides specialist Alfa Laval plate heat exchanger repair, servicing, and refurbishment for marine and offshore vessels worldwide. From emergency in-situ repairs to full workshop overhauls, our engineers deliver practical solutions that minimise downtime and cost.
If you’d like to learn more, explore our other case studies and technical blogs or contact our team to discuss your plate heat exchanger requirements.