2

FLOATING HEAD Heat Exchanger

General Assembly view

Shell side Inlet

Shell side Outlet

Tube side Inlet

Tube side Outlet

Shell

Back Cover

Distributor

Tube Sheet

Gaskets

Gasket

Saddle

Floating HeadBundle

3

Floating Head Heat Exchanger

Cross Sectional View

BaffleShell

Distributor Back cover

Tube Bundle

Floating Head

4

Split ring

FLOATING HEAD Heat Exchanger

Split View of Parts

Distributor Back CoverFloating

Head

Gasket

SpacerGasket GasketGasket

Shell

Floating Head Detail

Tube Bundle

Tube sheet Tube sheet

5

Do Not Start The Job Without A Safety Plan

6

Bundle Puller

FLOATING HEAD Heat ExchangerMaintenance Activity Description

Blind Inlets-Outlets at plant area

Disconnect and remove Distributor with gasket

Disconnect and remove Back cover with gasket

Disconnect and remove Floating Head with gasket

Install the bundle puller

Pull the bundle out

Ground level

7

Bundle Puller

FLOATING HEAD Heat ExchangerMaintenance Activity Description…..Continuation

Clean Shell and covers

Lift the bundle puller with clean bundle and new gasket, ready for reinstallation

Lower the bundle and take to hydro-jetting area

Ground level

8

Bundle Puller

FLOATING HEAD Heat ExchangerMaintenance Activity Description…..Continuation

Reinsert the bundle by bundle puller

Lower the bundle puller to the ground and take it away

Ground level

9

FLOATING HEAD Heat ExchangerMaintenance Activity Description…..Continuation

Install front Test Ring with gasket

Install back Test Ring with gasket Fill the shell by water

Install Pressure Gauge

Ground level

Shell Side Hydro-test

PG

Install Blinds in shell

Water Pump

Connect water pump Check leakages from tubes

Raise the pressure up to value given by Inspection

10

Water

Water

FLOATING HEAD Heat Exchanger

Shell Side Hydro-test …Check leakages from tubes continuation

PG

“A” “B”

View “B”

View “A”

11

Tube leak elimination Details

Detail “B”

[By Plug both sides]

Detail “A”

[By Expansion both sides]

Leak

Leak

FLOATING HEAD Heat Exchanger Shell Side Hydro-test ….Continuation Details

Tube Expander Tool

PG

“A” “B”Shell under pressure

12

FLOATING HEAD Heat ExchangerFLOATING HEAD Heat ExchangerMaintenance Activity Description…..Continuation

PG

Remove Test Ring & gasket [distributor side]

Reinstall distributor with new gasket & tight bolts

Remove Test Ring & gasket [floating head side]Reinstall Floating Head with split flange, new gasket & tight bolts

Blind Distributor in & out

Discharge water from shell drain

Drain

13

FLOATING HEAD Heat Exchanger

PG

Check distributor gasket sealing

Check floating head gasket sealing

PG

Fill tube side by water

Drain

Install PG in distributor top nozzle

FLOATING HEAD Heat Exchanger Tube Side Hydro-test ….Continuation Details

Connect water pump

Water Pump

Raise the pressure up to value given by Inspection

Discharge the water, remove PG and water pump

Remove blinds form distributor nozzle and tight bolts

14

FLOATING HEAD Heat Exchanger

PG

Check bundle to shell gasket sealing

Check Back cover gasket sealing

Fill Shell side by water

Drain

FLOATING HEAD Heat Exchanger Shell Side Final Hydro-test ….Continuation Details

Install Back cover with Gasket

Water Pump

Raise the pressure up to value given by Inspection

Discharge the water, remove PG and water pump

Remove blinds form shell nozzles and tight bolts

Connect water pump

15

FLOATING HEAD Heat ExchangerFLOATING HEAD Heat Exchanger

Handover & Final House Keeping Close Work permit Remove tools and equipment

Clean and wash the area Remove scaffold after unit start-up

By Maintenance