This document provides assembly, component, and maintenance details for a floating head heat exchanger. It includes general assembly and cross-sectional views labeling major components like the shell, tube bundle, floating head, and distributor. Step-by-step maintenance procedures are described for activities like removing the bundle, hydrotesting the shell and tube sides, eliminating tube leaks, and final hydrotesting before unit startup. Safety and proper housekeeping during maintenance are emphasized.

2. 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. 3
Floating Head Heat Exchanger
Cross Sectional View
Baffle
Shell
Distributor Back cover
Tube Bundle
Floating Head

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

5. 5
Do Not Start The Job Without A Safety Plan

6. 6
Bundle Puller
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
Ground level

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

8. 8
Bundle Puller
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
Ground level

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

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

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

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

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

14. 14
FLOATING HEAD Heat Exchanger
PG
Check bundle to shell
gasket sealing
Check Back cover
gasket sealing
Fill Shell side by water
Drain
FLOATING HEAD Heat Exchanger
 Shell Side Final Hydro-test ….Continuation Details
Install Back cover with
Gasket
Water Pump
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
Connect water pump

15. 15
FLOATING HEAD Heat ExchangerFLOATING HEAD Heat Exchanger
Handover & Final House Keeping
 Close Work permit Remove tools and equipment
 Clean and wash the area  Remove scaffold after unit start-up
By Maintenance