Steps of Heat Exchanger Bundle Pulling

Bundle pulling is the process of extracting the tube bundle from its shell during maintenance or cleaning. The steps involved are:

1. Preparation

✅ Depressurize and isolate the heat exchanger.
✅ Drain any remaining fluid from the unit.
✅ Inspect the area for potential hazards.

2. Breaking the Bundle Free

✅ Use a bundle extractor to apply force and separate the tube bundle from the shell.
✅ Hydraulic jacks or screw drives may be used for added force.

3. Positioning the Bundle

✅ Secure the bundle onto a sliding carriage or rolling support.
✅ Align the carriage with the extraction frame.

4. Extracting the Bundle

✅ Slowly move the carriage along the frame using a winch or hydraulic system.
✅ Maintain stability and prevent sudden movements.

5. Balancing and Removal

✅ Tilt the frame and carriage as needed to balance the bundle.
✅ Ensure workers are at a safe distance during extraction.

Safety Officer Role and Responsibilities in Oil and Gas Refineries

Equipment Used in Heat Exchanger Bundle Pulling

• Bundle Extractors (Puller)– Used to break the bundle free from the shell. Can be truck-mounted or crane-supported.
• Hydraulic Jacks/Screw Drives – Apply force to push or pull the bundle.
• Winches – Assist in moving the bundle along the extractor frame.
• Sliding Carriage – Supports and aligns the bundle for removal.
• Lifting Cranes – Used to lift and transport the extracted bundle.

Common Hazards in Bundle Pulling

• Heavy Load and Structural Risks – Tube bundles are heavy, and improper handling can lead to structural failure.
• Equipment Malfunction – Sudden failure of extractors, winches, or hydraulic jacks can result in dropped loads.
• Pinch Points and Crush Hazards – Risk of body parts getting caught between moving parts.
• Falling Objects – Loose bolts or components can fall, causing injuries.
• High-Pressure Hazards – Residual pressure can cause fluid leaks, burns, or toxic exposure.
• Slips, Trips, and Falls – Oil or fluid leaks can create slippery surfaces.

Safety Precautions for Heat Exchanger Bundle Pulling

✔️ Inspect All Equipment Before Use

• Ensure extractors, winches, and hydraulic jacks are in good working condition.
• Check cables, hooks, and chains for wear and tear.

✔️ Ensure Structural Stability

• Verify that the foundation can support the bundle’s weight.
• Use additional bracing if needed.

✔️ Maintain a Safe Work Zone

• Set up barriers to keep unauthorized personnel away.
• Use high-visibility clothing to improve awareness.

✔️ Wear Proper PPE (Personal Protective Equipment)

• Hard hats to protect from falling objects.
• Steel-toe boots to prevent foot injuries.
• Gloves and eye protection to prevent hand injuries and fluid exposure.

✔️ Use Proper Handling Techniques

• Keep a safe distance from the bundle while pulling.
• Ensure clear communication between workers using radios or hand signals.

✔️ Manage Pressure and Fluids Safely

• Fully depressurize the system before starting.
• Drain all fluids to avoid accidental spills.

✔️ Prepare for Emergencies

• Keep fire extinguishers and first-aid kits nearby.
• Have a clear emergency action plan in case of equipment failure.

Conclusion

Heat exchanger bundle pulling is a complex but essential maintenance process. Without proper precautions, it can be dangerous due to the risks of heavy loads, equipment failure, and hazardous fluids. By following strict safety protocols, using the right equipment, and ensuring worker training, industries can minimize risks and perform the process safely.

For a visual guide on bundle pulling, check out this video demonstration.

Stay safe and prioritize safety over speed!