1. Floating Head Heat Exchanger
MAINTENANCE
Floating Head Heat Exchanger
Peyman Ranjbar

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 Head
Bundle

3. Floating Head Heat Exchanger
Cross Sectional View
Baffle
Shell
Distributor
Back cover
Tube Bundle
Floating Head

4. FLOATING HEAD Heat Exchanger
Split View of Parts
Gasket
Gasket
Split ring
Spacer
Gasket
Gasket
Tube Bundle
Tube sheet
Distributor
Back Cover
Floating Head
Shell
Floating Head Detail

5. Do Not Start The Job Without A Safety Plan
MAINTENANCE
Floating Head Heat Exchanger
Safety
First
Plan
Do Not Start The Job Without A Safety Plan

6. 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

7. FLOATING HEAD Heat Exchanger
Maintenance Activity Description…..Continuation
Lower the bundle and take to hydro-jetting area
Lift the bundle puller with clean bundle and new gasket, ready for reinstallation
Clean Shell and covers
Bundle Puller
Ground level

8. 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

9. FLOATING HEAD Heat Exchanger
Maintenance Activity Description…..Continuation
Shell Side Hydro-test
Install front Test Ring with gasket
Install Pressure Gauge
Raise the pressure up to value given by Inspection
Connect water pump
Install back Test Ring with gasket
Check leakages from tubes
Fill the shell by water
Install Blinds in shell PG
Water Pump
Ground level

10. FLOATING HEAD Heat Exchanger
Shell Side Hydro-test …Check leakages from tubes continuation PG
“A”
“B”
Water
View “A”
Water
View “B”

11. FLOATING HEAD Heat Exchanger
Shell Side Hydro-test ….Continuation Details PG
“A”
“B”
Shell under pressure
Tube leak elimination Details
Detail “A”
[By Expansion both sides]
Detail “B”
[By Plug both sides]
Leak
Tube Expander Tool
Leak

12. FLOATING HEAD Heat Exchanger
Maintenance Activity Description…..Continuation
Discharge water from shell drain
Reinstall distributor with new gasket & tight bolts
Remove Test Ring & gasket [floating head side]
Remove Test Ring & gasket [distributor side]
Blind Distributor in & out
Reinstall Floating Head with split flange, new gasket & tight bolts PG
Drain

13. FLOATING HEAD Heat Exchanger
Tube Side Hydro-test ….Continuation Details
FLOATING HEAD Heat Exchanger
Install PG in distributor top nozzle
Check floating head gasket sealing
Discharge the water, remove PG and water pump
Connect water pump
Check distributor gasket sealing
Fill tube side by water
Remove blinds form distributor nozzle and tight bolts
Raise the pressure up to value given by Inspection PG PG
Water Pump
Drain

14. FLOATING HEAD Heat Exchanger FLOATING HEAD Heat Exchanger
Shell Side Final Hydro-test ….Continuation Details
Install Back cover with Gasket
Check Back cover gasket sealing
Discharge the water, remove PG and water pump
Connect water pump
Check bundle to shell gasket sealing
Fill Shell side by water
Remove blinds form shell nozzles and tight bolts
Raise the pressure up to value given by Inspection PG
Drain
Water Pump

15. FLOATING HEAD Heat Exchanger 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