Alfa Laval is calling on power generators and process operators to reassess how they manage ageing gasketed plate heat exchangers (GPHEs), warning that continuing to repair or retrofit obsolete equipment may create hidden costs and operational risks over time.

GPHEs play an important role in cooling and heat transfer systems across the power industry. As equipment ages, its performance can gradually decline, while the risk of leakage, fouling, corrosion, unplanned maintenance and insufficient thermal capacity can increase.

Although repair or retrofit may appear to be the lower cost option, the total impact can be significantly greater when higher energy and water consumption, more frequent maintenance, reduced availability and the risk of disruption are considered.

By contrast, replacing an ageing GPHE with modern, high-efficiency equipment can help operators improve heat-transfer performance, reduce resource consumption and maintenance requirements and increase the reliability and resilience of critical cooling systems.

Valeska Villablanca, Business Unit Manager for Energy Process at Alfa Laval, said: “When it comes to equipment in a process line, it is easy to assume that the old saying ‘if it isn’t broke, don’t fix it’ applies. However, an ageing heat exchanger may still be operating while quietly creating higher costs and greater operational risk in the background.

“Declining thermal performance, increased maintenance requirements and reduced availability can all affect the overall efficiency of a power-generation site. This is why operators should assess the replace-versus-repair decision based on whole-life cost, operational risk and future performance, not just the immediate cost of the intervention.”

For power operators, the decision can be particularly complex. Equipment may be integrated into established systems and replacement projects may need to be co-ordinated with planned outages, site access restrictions, engineering approvals and wider reliability requirements.

However, modernising an ageing GPHE does not necessarily require a complete redesign of the installation. In many cases, a replacement can be selected to match the existing footprint and connections, minimising disruption while improving capacity and efficiency. Alfa Laval can provide guidance and support for any required pipework modifications, including connection drawings and related documentation.

One Alfa Laval customer, a Saudi Arabian oil refinery, faced a similar challenge when the GPHEs in its closed-loop cooling system could no longer cope with the thermal load created by rising water temperatures.

Replacing 21 ageing GPHEs with Alfa Laval T-Series units increased heat removal by 41%. The project also helped reduce operating costs and increase production capacity without expanding the original installation footprint.

The example demonstrates how replacing ageing heat-transfer equipment can deliver benefits beyond the equipment itself, supporting improved plant performance while helping operators respond to changing operating conditions.

Alfa Laval is also encouraging businesses to consider their choice of partner when investing in replacement equipment. Sector expertise, a global installed base and the availability of lifecycle service support can all contribute to reliable long-term performance.

Valeska continued: “When you purchase a new GPHE, you are investing in more than a piece of equipment. You are also choosing the expertise, technology and service capability that will support its performance over the long term.

“A partner with experience in the power and energy sectors can help operators assess the most appropriate solution, understand the whole-life value of replacement and plan the work around operational requirements. Continued service and support after installation can then help keep the equipment performing efficiently for years to come.”

Alfa Laval will discuss the replace-versus-repair equation in more detail during the EIC Connect UK & Ireland 2026 event, taking place in Manchester on 17-18 November.

The topic will also be explored when Alfa Laval hosts the EIC 7th Regional Committee meeting at its UK & Ireland head office and service centre in Camberley on 24-25 November.

Find out more about replacing ageing heat exchangers: Alfa Laval's Gasketed plate-and-frame heat exchangers

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