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

Shell side Outlet

Floating Head Heat Exchanger

Cross Sectional View
Floating Head
Tube Bundle

Distributor

Baffle

Shell

Back cover

FLOATING HEAD Heat Exchanger

Split View of Parts
Gasket

Split ring

Gasket

Tube sheet

Distributor

Floating
Head

Shell

Floating
Head Detail

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

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

Lower the bundle puller to

bundle puller

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 back Test Ring

with gasket

Install Pressure Gauge

Connect water pump
Fill the shell by water

Raise the pressure up to

value given by Inspection

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

 Shell Side

FLOATING HEAD Heat Exchanger

Hydro-test .Continuation Details
PG

Tube leak elimination Details

A

Shell under pressure

Detail A
[By Expansion both sides]

Detail B
[By Plug both sides]

Leak

Leak

11

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

 Tube Side

FLOATING HEAD Heat Exchanger

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

 Shell Side

FLOATING HEAD Heat Exchanger

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

15