IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

Prepared by Carlo Leoni

[Stationary Section Adviser]-10 January 2007

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

200- E 2 General Assembly view
Gaskets

Tube side Outlet

Shell side Inlet [Gas]

Shell

Gasket
Floating Head

Bundle

Back Cover

Distributor
Saddle

Shell side Outlet

Tube side Inlet [Gas]
Tube Sheet

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

200-E2 Floating Head Heat Exchanger
Cross Sectional View
Floating Head
Tube Bundle

Distributor

Baffle

Shell

Back cover

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

200-E2 FLOATING HEAD Heat Exchanger

Split View of Parts
Gasket

Split ring

Gasket

Tube sheet

Distributor

Gasket

Gasket

Tube Bundle

Tube sheet

Spacer

Floating
Head

Back Cover

Shell

Floating
Head Detail

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

200-E2

Do Not Start The Job Without A Safety Plan

5

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

200-E2 FLOATING HEAD Heat Exchanger [In the Plant]

Maintenance Activity Description
200 T Crane
to be used

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

Back cover with gasket

Pull the bundle out and

remove gasket

Bundle Puller

Ground level

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

200-E2 FLOATING HEAD Heat Exchanger [In the Plant]

Maintenance Activity Description..Continuation

200 T Crane
to be used

Lower the bundle and

Clean Shell and covers

take to hydro-jetting area

for chemical cleaning

in the field

Bundle Puller

Ground level

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

200-E2 FLOATING HEAD Heat Exchanger [At IZ Service Yard]

Maintenance Activity Description..Continuation
100 T Crane
to be used

Clean the bundle by

hydro jetting in the
cleaning area

Chemical cleaning of
the bundle in a bath
for about 48 Hrs and
hydro jetting again.

Bundle

Tank
Chemical solution

Ground level

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

200-E2 HYDRO TEST IN THE TEST VESSEL [At IZ Service Yard]

Shell Side Hydro-test

Insert the bundle in the
test vessel
Install front Test Ring with
gasket

Install back Test Ring

with gasket

Install Blinds in test

Raise the pressure up to

vessel

value given by Inspection

Install Pressure Gauge

Check leakages from

tubes

Connect water pump

Fill the vessel by water

PG

100 T Crane
to be used

Water Pump

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

200-E2 FLOATING HEAD Heat Exchanger [At IZ Service Yard]

Shell Side Hydro-test Check leakages from tubes continuation

PG

A
Water

View A

Water

View B

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IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

200-E2 FLOATING HEAD Heat Exchanger [At IZ Service Yard]

Shell Side Hydro-test .Continuation Details
Discharge water, remove test
rings, extract the bundle from
test vessel
Take back the clean bundle
A
to the plant, ready for
reinstallation

PG

Tube leak elimination Details

B

Shell under pressure

100 T Crane
to be used
Detail A
[By Expansion both sides]

Leak

Detail B
[By Plug both sides]
Leak
Tube Expander Tool

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IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

200-E2 FLOATING HEAD Heat Exchanger [In the Plant]

Maintenance Activity Description..Continuation

200 T Crane
to be used

Lift the bundle puller with

clean bundle and new gasket,
ready for reinstallation

Bundle Puller

12

Ground level

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

200-E2 FLOATING HEAD Heat Exchanger [In the Plant]

Tube side Hydro test in the Plant
200 T Crane
to be used

Reinsert the bundle by

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

Install Floating head with

gasket
Install pressure gauge and
water pump for testing

Install distributor gasket

Fill by water and test the

gasket sealing indicated by
arrow

Install distributor
Blind distributor inlet &
outlet

Discharge water and

remove blinds

PG

Bundle Puller

Water Pump

13

Ground level

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

200-E2 FLOATING HEAD Heat Exchanger [In the Plant]

Maintenance Activity Description..Continuation
Install back cover gasket
Reinstall the back cover by
chain block

Check the sealing of the

gasket indicated by arrow
during plant start-up
Hot bolting during
operation

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Ground level

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

200-E2 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

and hot bolting completed

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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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