“U Bundle” Heat Exchanger

General Assembly view

Gaskets
Tube side Inlet Shell side Outlet

Shell

Distributor
Saddle

Tube side Outlet Shell side Inlet

Tube Sheet
 “U Bundle” Heat Exchanger
Cross Sectional View
Shell
“U” Bundle Baffle

Distributor Tube sheet

 “U Bundle” Heat Exchanger
Split View of Parts
Gasket Gasket
Baffle
Tube Bundle

Tube sheet
Distributor

Shell
Do Not Start The Job Without a Safety Plan
 “U Bundle” Heat Exchanger
Maintenance Activity Description
Adequate
crane required Blind Inlets-Outlets at Install the bundle puller
plant area
Pull the bundle out
Disconnect and remove
Distributor with gasket

Bundle Puller

Ground level
 “U Bundle” Heat Exchanger
Maintenance Activity Description…..Continuation
Adequate
crane required Lower the bundle and Lift the bundle puller with
take to hydro-jetting area clean bundle and new gasket,
Clean Shell and Distributor ready for reinstallation

Bundle Puller

Ground level
 “U” Bundle Heat Exchanger
Maintenance Activity Description…..Continuation
Adequate
crane required Reinsert the bundle with Lower the bundle puller to
new gasket by bundle puller the ground and take it away

Bundle Puller

Ground level
 “U” Bundle Heat Exchanger
Maintenance Activity Description…..Continuation
 Shell Side Hydro-test
Install front Test Ring Connect water pump Check leakages from
with gasket tubes
Install Blinds in shell Fill the shell by water
Install Pressure Gauge Raise the pressure up to
value given by Inspection Adequate
crane required

PG

Drain

Ground level Water Pump

 “U Bundle” Heat Exchanger
 Shell Side Hydro-test …Check leakages from tubes continuation
PG

“A”

Drain

Gasket Shell
flange
Bolts

Test Ring Gasket

Tube sheet Water

Tube
View from “A”
“U Bundle” Heat Exchanger  Shell Side Hydro-test
PG
….Continuation Details

Shell under pressure

Drain

Tube leak elimination by

tube expansion

Leak

Tube Expander Tool

“U Bundle” Heat Exchanger : Shell Side Hydro-test ….Continuation Details

Test Ring
Tube leak elimination by
PG
plugs
Leaking tube found

Water

Leak
 “U Bundle” Heat Exchanger: Maintenance Activity Description…Continuation
Adequate
crane required Discharge water from Reinstall distributor
shell drain with new gasket &
Remove Test Ring & tight bolts
gasket Blind Distributor in &
out & tight bolts

PG

Drain

Ground level Water Pump

 “U Bundle” Heat Exchanger
 Tube Side Hydro-test ….Continuation Details
Connect water pump & Raise the pressure up to Discharge the water,
pressure gauge tube value given by Inspection remove PG and water
side Check Distributor pump
Fill Tube side by water gasket sealing Remove blinds form
Distributor nozzles and
tight bolts

PG PG

Drain

Water Pump Ground level Water Pump

 “U Bundle” Heat Exchanger
 Shell Side Final Hydro-test ….Continuation Details
Fill Shell side by water Check Tube sheet to Discharge the water,
shell gasket sealing remove PG and water
Raise the pressure up to
value given by Inspection pump
Remove blinds form
shell nozzles and tight
bolts

PG

Drain

Ground level Water Pump

 “U Bundle” 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

Ground level