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FLOATING HEAD HEAT EXCHANGER

General Assembly view

Gaskets
Tube side inlet Shell side inlet
Gasket

Floating head
Shell Bundle

Back cover

Distributor
Saddle

Tube side outlet Shell side outlet

Tube Sheet

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FLOATING HEAD HEAT EXCHANGER
Cross Sectional View
Tube side inlet Shell side inlet Floating head
Shell
Baffle
Tube Bundle

Distributor
Back cover

Tube side outlet Shell side outlet

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FLOATING HEAD HEAT EXCHANGER
Split View of Parts

Gasket Gasket Split ring Spacer Gasket


Gasket
Tube Bundle

Tube sheet Tube sheet Floating


Distributor head Back cover

Shell

Floating head
Details
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FLOATING HEAD HEAT EXCHANGER

 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 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.

Bundle Puller

Ground level
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FLOATING HEAD HEAT EXCHANGER
Maintenance Activity Description … cont.

• 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

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Ground level
FLOATING HEAD HEAT EXCHANGER
Maintenance Activity Description … Cont.

• Re-insert the bundle by bundle puller.


• Lower the bundle puller to the ground and take it away.

Bundle Puller

Ground level

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FLOATING HEAD HEAT EXCHANGER
Maintenance Activity Description … Cont.
• Shell Side Hydro-test

• Install front TEST RING with gasket.


• Install back TEST RING with gasket.
• Install blinds in shell nozzle.
• Install PG.
• Connect water pump.
• Fill the shell by water.
• Raise the pressure up to value given by Inspection.
• Check leakages from tubes.

PG

Test Ring Test Ring

Ground level Water Pump


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FLOATING HEAD HEAT EXCHANGER
Maintenance Activity Description … Cont.
• Shell Side Hydro-test … Check leakages from tubes
PG

“A” “B”

Water

View “A”

Water

View “B”
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FLOATING HEAD HEAT EXCHANGER
Maintenance Activity Description … Cont.
• Shell Side Hydro-test … Tube leakage elimination details

PG

“A” “B”
Shell under pressure

Detail “A”
[By Expansion both sides]

Detail “B”
[By Plug both sides]
Leak

Leak

Tube Expander Tool 11


FLOATING HEAD HEAT EXCHANGER
Maintenance Activity Description … Cont.
• 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).
• Re-install floating head with split flange, new gasket & tight bolts.

PG

Drain

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FLOATING HEAD HEAT EXCHANGER

• Tube Hydro-test
• 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


• 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
14 Pump
FLOATING HEAD HEAT EXCHANGER

• Handover & Final House Keeping (Maintenance)

• Remove tools and equipment.


• Clean and wash the area.
• Close Work Permit.
• Remove scaffolding after unit start-up.

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