IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE

Prepared by Carlo Leoni

[Stationary Section Adviser]-20 August 2006
IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
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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IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
Floating Head Heat Exchanger
Cross Sectional View
Floating Head
Shell
Baffle
Tube Bundle

Distributor Back cover

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IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
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 Detail

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IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE

Do Not Start The Job Without A Safety Plan

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IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
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
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IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
FLOATING HEAD Heat Exchanger
Maintenance Activity Description…..Continuation
Lower the bundle and Lift the bundle puller with
take to hydro-jetting area clean bundle and new gasket,
Clean Shell and covers ready for reinstallation

Bundle Puller

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Ground level
IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
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

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

PG

Ground level Water Pump 9

IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
FLOATING HEAD Heat Exchanger
 Shell Side Hydro-test …Check leakages from tubes continuation
PG

“A” “B”
Water

View “A”

Water

View “B”
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IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
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

Tube Expander Tool 11

IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
FLOATING HEAD Heat Exchanger
Maintenance Activity Description…..Continuation

Discharge water from Reinstall distributor Remove Test Ring &

shell drain
Remove Test Ring &
gasket [distributor side]
with new gasket & gasket [floating head
tight bolts side]
Blind Distributor in & Reinstall Floating Head
out with split flange, new
gasket & tight bolts

PG

Drain

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

PG PG

Drain

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

PG

Drain

Water Pump
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IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
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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IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
List of Floating Head Heat Exchangers
Installed in IBN-ZAHR

MTBE PLANT PP PLANT

1. 120-E16 12. 130-XE202 1. 512-E23 12. 620-E04 A/B

2. 120-E17 13. 130-XE203 2. 512-E25 13. 640-E06 A/B
3. 120-E18 14. 140-E17 A/B 3. 513-E32 14. 650-E05 A/B
4. 120-E19 15. 220-E2 A/B 4. 514-E23 15. 650-E13
5. 120-E20 16. 220-E14 5. 520-E23 A/B 16. 650-E55 A/B
6. 120-E21 17. 220-E18 6. 530-E23 A/B 17. 650-E63
7. 120-E22 18. 220-E32 7. 540-E80
8. 200-E2 A/B 19. 220-E36 A/B 8. 613-E10
9. 200-E14 20. 220-E37 A/B 9. 614-E15
10. 200-E30-38 21. 430-E02
11. 410-E02 22. 690-E20 A/B

THE END
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