BILFAL HEAVY INDUSTRIES LTD.

P.O. BOX 10138

JUBAIL INDUSTRIAL CITY – 31961
KINGDOM OF SAUDI ARABIA
Email: Tec@bilfal.com
Website: www.bilfal.com

SWCC - YANBU 20 MIGD

MSF EVAPORATOR

Client: DOOSAN HEAVY INDUSTRIES &

CONSTRUCTION Co. Ltd.

METHOD STATEMENT FOR RECOVERY SECTION

TUBE SIDE HYDROTEST
SEQUENCE: 3

0 23-3-2015 JACOB T. S.L. SANTOSH ISSUED FOR INFORMATION

Rev. Date Prepared Verified Approved Modifications

REVISION
MH-7560-00-07-SEQ-3 Rev. 0 Page 2 of 10
METHOD STATEMENT FOR EVAPORATOR HYDRO TEST

TABLE OF CONTENT

Scope

Reference Documents

Responsibility

Sequence of HYDROTEST

SEQUENCE: 3

Tube side Hydrotest Stage 18 to 13

Technical Data

Hydrotest Apparatus

Installation of Hydrotest Apparatus

Hydrotest Preparations

Test Medium Condition

Pressure Gauges

Test Procedures

Pressurizing

Inspection of Evaporator

Draining

RECOVERY Section Conservation

MH-7560-00-07-SEQ-3 Rev. 0 Page 3 of 10
METHOD STATEMENT FOR EVAPORATOR HYDRO TEST

MSF EVAPORATOR RECOVERY SECTION

TUBE SIDE HYDROTEST
SCOPE
This procedure describes the minimum requirements to be followed for conducting
TUBE SIDE hydrostatic testing of MSF Evaporator, Stage 13 to 18, Unit 6 & Unit 7
fabricated and Installed by BILFAL Heavy Industries, for M/s DOOSAN HEAVY
INDUSTRIES & CONSTRUCTION Co. Ltd., at Yanbu SWCC Phase III Desalination
Plant

REFERENCE DOCUMENTS
• ASME SECTION VIII (2010 Ed)
• TEMA C (9th Ed.) & Manufacturer’s Standards
• 70-GDG-MTC-001 : Evaporator General Assembly
• 70-GDG-MTC-069 to 75: WATER BOX RECOVERY Section
• PR-7560-PRT-001 : Pressure test Procedure

RESPONSIBILITY
After completion of all welding, Pickling, Passivation of SS areas and required
inspection activities, the site construction Department shall carry out the necessary
arrangements for conducting the hydrostatic test as detailed in this procedure. The QC
Department is responsible for the inspection and to inform Clients Inspector to witness
testing.

SEQUENCE OF HYDROTEST
The proposed Hydro test sequence shall be as follows

• Sequence 1: Tube Side Hydro test- Stage 24 to 26- (MH-7560-00-07-SEQ1)

• Sequence 2:Tube Side Hydro test- Stage 19 to 23 (MH-7560-00-07-SEQ2)

• Sequence 3: Tube Side Hydro test- Stage 13 to 18(MH-7560-00-07-SEQ3)

• Sequence 4: Tube Side Hydro test- Stage 7 to 12 (MH-7560-00-07-SEQ4)

• Sequence 5: Tube Side Hydro test- Stage 1 to 6 (MH-7560-00-07-SEQ5)

• Sequence 6: Distillate Duct Hydro test – Stage 1 – 26 (MH-7560-00-07-SEQ6)

• Sequence 6: Shell Side Hydro Pneumatic test- Stage 1 to 26 & Deaerator (MH-
7560-00-07-SEQ1)
MH-7560-00-07-SEQ-3 Rev. 0 Page 4 of 10
METHOD STATEMENT FOR EVAPORATOR HYDRO TEST
SEQUENCE 3:
Tube Side Hydro test- Stage 18 to 13

Evaporator Tube Side Hydro test- KEY PLAN

Detailed Test Layout

MH-7560-00-07-SEQ-3 Rev. 0 Page 5 of 10
METHOD STATEMENT FOR EVAPORATOR HYDRO TEST
TECHNICAL DATA
1. FLANGE & BOLTING DATA
Location Flange OD X THK Stud Bolt with 2 Nuts
Stage 18 (Distillate
Side) Dummy Water M33 x 265 mm Lg x 114
3244 x 3812 x (75 +75)
Box and Intermediate Nos
Piece
Stage 17&16, 15&14,
Double Water Box M33 x 265 mm Lg x 114
3244 x 3812 x (75 +75)
with Intermediate Nos for Each Stage
Piece (Distillate Side)
Stage 18 &17, 16 &
15, and 14 & 13
M33 x 265 mm Lg x 114
Double Water Box 3244 x 3812 x (75 +75)
Nos for Each Stage
with Intermediate
Piece (Brine Side)
Stage 13 (Distillate
Side) Dummy Water M33 x 265 mm Lg x 114
3244 x 3812 x (75 +75)
Box and Intermediate Nos
Piece
2” ASME 150# x 6 Sets
Vent Nozzles 5/8” x 90mm x 4 Each
Each
3” ASME 150# x 6 Sets
Drain Nozzles 5/8” x 100mm x 4 Each
Each

2. BOLT TORQUE (Valid for RECOVERY Section Inlet and Out Let Flanges)
Location Flange Size Bolt A540-B23 Torque (KgM)
Stage 18 to 13
(Brine Side and
Distillate side)
M33 x 265 mm
Double Water 3244 x 3812 x (75 +75) 210 to 250
Lg x 114 Nos
box to
Intermediate
Piece
Stage 18, 13
(Distillate Side)
Dummy Water M33 x 265 mm
3244 x 3812 x (75 +75) 210 to 250
Box and Lg x 114 Nos
Intermediate
Piece
2” ASME 150# x 6 5/8” x 90mm x 4 Standard
Vent Nozzles
Sets Each Each Torque
3” ASME 150# x 6 5/8” x 100mm x Standard
Drain Nozzles
Sets Each 4 Each Torque
MH-7560-00-07-SEQ-3 Rev. 0 Page 6 of 10
METHOD STATEMENT FOR EVAPORATOR HYDRO TEST

3. Total Volume of Water

Total Volume of Water Required for
SEQUENCE 2 Hydro test = ~1050 Cu M. Water

4. TEST PRESSURE-
See Below Pressure Test Chart

Pressure Test Chart For RECOVERY Section

HYDRO TEST APPARATUS

No Description Figure
1 DUMMY water box with Blind
Dish Head

2 Blind Flange 2”-150# & 3”-150#

MH-7560-00-07-SEQ-3 Rev. 0 Page 7 of 10
METHOD STATEMENT FOR EVAPORATOR HYDRO TEST
3 Water Level Checking Hose

4 BALL Valves (Used for Manifolds)

5 GAUGES (0 to 40 Bar G.)

For Recovery Section Only.

6 EPDM Rubber Gasket 2” & 3”-

7 EPDM Rubber Gasket for Blind

Flange Recovery Section Inlet
and Out Let

9 Gasket for Water Box Manhole

10 Wrench
MH-7560-00-07-SEQ-3 Rev. 0 Page 8 of 10
METHOD STATEMENT FOR EVAPORATOR HYDRO TEST
11 Hydro Test Manifolds (Filling Line,
Pressure Indicator and Pressure
Relief Valve)

INSTALLATION OF HYDROTEST APPARATUS

ASSEMBLING FOR LARGE BLIND FLANGES ON WATER BOXES

• Ensure the Erection of all the water box from stage from 18 to 13 (Recovery
Section Inlet and Outlet) eventually tighten as per approved Bolt torque
• Before place the gasket to the water box flange (Stage , check that the Gasket
seating surface on the flange is clean without grease or dirt
• Holding the Gasket pieces with care to avoid any damage. Place the gasket on
the Water Box Flange in such a way that the respective surface are uniformly in
contact
• After placing Gasket, Lift the Blind Flange by proper lifting lugs and set in place,
ensuring that a good alignment is getting among the bolt holes and the
respective girth flange holes
• After align the bolt holes, insert the stud Bolt in the holes and place the nuts,
tighten them uniformly with hand wrench.

HYDRO TEST PREPARATIONS

Prior to pressure testing, the inside and outside surface (wherever accessible) of
the Tubes Bundle and inside of Water Box inside shall be thoroughly cleaned of
all slag, scale, dirt, grit, weld spatter, paint, oil etc.
MH-7560-00-07-SEQ-3 Rev. 0 Page 9 of 10
METHOD STATEMENT FOR EVAPORATOR HYDRO TEST
• All the water box drain connections shall be closed by Blind flanges or
connected to the relevant piping / valves except which are used for Filling and
draining.
• Vents shall be provided at the highest point of the water box to purge possible
air pockets while the tube bundle is being filled with water.
• Necessary Manifolds shall be fabricated for attachment of pressure gauges on
both Higher point and Lower point

TEST MEDIUM CONDITION

• Potable water shall be used as the test medium & shall be free of sediments.
• Filling water having a TDS content ≤ 40mg/Kg for RECOVERY Tube bundle and
Water boxes
• Temperature of the water during hydrostatic testing shall be maintained at not
less than 10° C throughout the testing cycle.

PRESSURE GAUGES
• Two numbers of dial indicating gauges shall be directly connected to coil, one at
the upper portion and the other at the lower portion.
• The gauges shall be calibrated against a standard deadweight tester.
• The pressure gages shall be graduated over a range of about double the
intended pressure but in no case shall the range be less than neither 1.5 nor
more than 4 times that the test pressure.

TEST PROCEDURE
PRESSURIZING
• The test pressure shall not be applied until the metal and water are about the
same temperature.
• Before applying pressure, the Water box bundle shall be examined to see that it
is tight and that all low pressure filling lines and other appurtenances that should
not be subjected to the pressure have been disconnected.
• The Water box surface temperature shall be maintained minimum 10 ° C
throughout the testing cycle.
• The pressure shall increase slowly to the required test pressure as indicated in
above pressure Test Chart.
MH-7560-00-07-SEQ-3 Rev. 0 Page 10 of 10
METHOD STATEMENT FOR EVAPORATOR HYDRO TEST
• Hydrostatic pressure shall be held for a minimum 10 Minute, at the design
pressure. During this period, the RECOVERY tube bundles and water boxes
shall have no leakages.
• Check any leakage or water tracing from both brine and distillate side Tube
expansions. This can be inspected from inside of Trough stage 18 to 13
• Once the inspection found satisfactory, the hydro test pressure then shall be
increased up to 11.27 Bar G. Measured on the shell top of the stage 13. (See
Hydro test Layout)
• The test pressure shall be maintained for 30 Minutes. During this period, the
RECOVERY tube bundles and water boxes shall have no leakages.

INSPECTION OF EVAPORATOR TUBE BUNDLE

• Hold the Bundle at hydrostatic test pressure 11.27barG for ~30 Minutes.
Following the application of the hydrostatic test pressure, an inspection shall be
made of all joints. This inspection shall be made at a pressure not less than
Pressure 8.7 Bar (Test pressure 11.27 / 1.3) in order to ensure no visible
leakage in evidence.
• In the event of any leakages, the test shall be discontinued and the remedial
work may carry out.
• Defective tube expansion, if any, showing leakage shall be re expanded using
the same parameters stated in WORK METHOD STATEMENT FOR EVAPORATOR
Revision 2.

DRAINING
• After completion of hydrostatic pressure holding time, the pressure shall be
released slowly from top point by opening the vent.
• When the pressure inside the water boxes is equal to -0- Bar G, each water box
vent connection shall be sequentially open staring from stage 18 to 13
RECOVERY SECTION CONSERVATION
After completion of draining and venting of the tube bundle, close all the
connections nozzles used for draining / venting of the tube bundle shall be closed
properly in order to prevent the entry of dust and other contaminations. These
stages shall be maintained in this closed condition till the final piping connection

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