FLOATING HEAD Heat Exchanger

General Assembly view

Gaskets Tube side Inlet Shell side Inlet Gasket Bundle

Shell

Floating Head

Back Cover

Distributor Saddle

Tube side Outlet Tube Sheet

Shell side Outlet

Floating Head Heat Exchanger Cross Sectional View

Floating Head

Shell
Tube Bundle Baffle

Distributor

Back cover

FLOATING HEAD Heat Exchanger

Split View of Parts
Gasket Gasket Split ring Spacer Gasket Gasket

Tube Bundle

Tube sheet

Tube sheet

Distributor

Floating Head

Back Cover

Shell

Floating Head Detail

Do Not Start The Job Without A Safety Plan

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FLOATING HEAD Heat Exchanger

Maintenance Activity Description
Blind Inlets-Outlets at
plant area

Disconnect and remove

Floating Head with gasket

Disconnect and remove

Distributor with gasket

Install the bundle puller Pull the bundle out

Disconnect and remove

Back cover with gasket

Bundle Puller

Ground level

FLOATING HEAD Heat Exchanger

Maintenance Activity Description..Continuation
Lower the bundle and
take to hydro-jetting area Clean Shell and covers

Lift the bundle puller with

clean bundle and new gasket, ready for reinstallation

Bundle Puller

Ground level

FLOATING HEAD Heat Exchanger Maintenance Activity Description..Continuation

Reinsert the bundle by
bundle puller

Lower the bundle puller to

the ground and take it away

Bundle Puller

Ground level

FLOATING HEAD Heat Exchanger

Maintenance Activity Description..Continuation

Shell Side Hydro-test

Install front Test Ring with
gasket

Install Pressure Gauge Connect water pump Fill the shell by water

Raise the pressure up to

value given by Inspection

Install back Test Ring

with gasket

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

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
Leak

[By Plug both sides]

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

PG

Drain

12

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

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

Check floating head gasket sealing Check distributor gasket sealing

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

PG

PG

Drain Water Pump

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FLOATING HEAD Heat Exchanger Shell Side Final Hydro-test .Continuation Details
Install Back cover with Gasket Connect water pump Fill Shell side by water Raise the pressure up to
value given by Inspection

Check Back cover gasket sealing Check bundle to shell gasket sealing

Discharge the water, remove PG and water pump Remove blinds form shell nozzles and tight bolts

PG

Drain Water Pump

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FLOATING HEAD Heat Exchanger

Handover & Final House Keeping

Remove tools and equipment Clean and wash the area Close Work permit

By Maintenance

Remove scaffold after unit start-up

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