Floating Head Heat Exchanger Maintenance

FLOATING HEAD Heat Exchanger General Assembly view Gaskets Tube side Inlet

Shell side Inlet

Shell

Gasket Bundle

Floating Head

Back Cover

Distributor Saddle

Tube side Outlet Tube Sheet

2

Shell side Outlet

Floating Head Heat Exchanger Cross Sectional View Floating Head

Shell Tube Bundle

Distributor

3

Baffle

Back cover

FLOATING HEAD Heat Exchanger Split View of Parts Gasket

Split ring

Gasket

Tube sheet

Distributor

Floating Head

Shell

Floating Head Detail

4

Gasket

Gasket

Tube Bundle

Tube sheet

Spacer

Back Cover

Do Not Start The Job Without A Safety Plan 5

FLOATING HEAD Heat Exchanger Maintenance Activity Description Blind Inlets-Outlets at

Disconnect and remove

plant area

Floating Head with gasket

Disconnect and remove

Install the bundle puller

Distributor with gasket

Disconnect and remove

Pull the bundle out

Back cover with gasket

Bundle Puller

Ground level

6

FLOATING HEAD Heat Exchanger Maintenance Activity Description…..Continuation Lower the bundle and

Lift the bundle puller with

take to hydro-jetting area Clean Shell and covers

clean bundle and new gasket, ready for reinstallation

Bundle Puller

7

Ground level

FLOATING HEAD Heat Exchanger Maintenance Activity Description…..Continuation Reinsert the bundle by

Lower the bundle puller to

bundle puller

the ground and take it away

Bundle Puller

8

Ground level

FLOATING HEAD Heat Exchanger Maintenance Activity Description…..Continuation

 Shell Side Hydro-test Install front Test Ring with gasket

Install back Test Ring with gasket

Install Pressure Gauge

Raise the pressure up to value given by Inspection

Connect water pump Fill the shell by water

Check leakages from tubes

Install Blinds in shell PG

Ground level 9

Water Pump

FLOATING HEAD Heat Exchanger

 Shell Side Hydro-test …Check leakages from tubes continuation PG

“B”

“A” Water

View “A”

Water

View “B” 10

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

Tube leak elimination Details “A”

Shell under pressure

“B”

Detail “A” [By Expansion both sides]

Detail “B” [By Plug both sides]

Leak

Leak

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Tube Expander Tool

FLOATING HEAD Heat Exchanger Maintenance Activity Description…..Continuation Discharge water from shell drain Remove Test Ring & gasket [distributor side]

Reinstall distributor with new gasket & tight bolts Blind Distributor in & out

PG

Drain

12

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

FLOATING HEAD Heat Exchanger  Tube Side Hydro-test ….Continuation Details Check floating head gasket sealing Check distributor gasket sealing

Install PG in distributor top nozzle Connect water pump Fill tube side by water Raise the pressure up to value given by Inspection

PG

PG

Drain Water Pump

13

Discharge the water, remove PG and water pump Remove blinds form distributor nozzle and tight bolts

FLOATING HEAD Heat Exchanger  Shell Side Final Hydro-test ….Continuation Details Check Back cover gasket sealing

Install Back cover with Gasket Connect water pump

Check bundle to shell gasket sealing

Fill Shell side by water 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

PG

Drain Water Pump

14

FLOATING HEAD Heat Exchanger

Handover & Final House Keeping

By Maintenance

 Remove tools and equipment

 Close Work permit

 Clean and wash the area

 Remove scaffold after unit start-up

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