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 REJECT SECTION

TUBE SIDE HYDROTEST

0 25-1-2015 JACOB T. S.L. SANTOSH ISSUED FOR INFORMATION

Rev. Date Prepared Verified Approved Modifications

REVISION
MH-7560-00-07-SEQ-1 Rev. 0 Page 2 of 9
METHOD STATEMENT FOR EVAPORATOR HYDRO TEST

TABLE OF CONTENT

Scope

Reference Documents

Sequence of HYDROTEST

SEQUENCE: 1

Tube side Hydrotest Stage 24 to 26

Technical Data

Hydrotest Apparatus

Installation of Hydrotest Apparatus

Hydrotest Preparations

Test Medium Condition

Pressure Gauges

Test Procedures

Pressurizing

Draining

Reject Section Conservation

MH-7560-00-07-SEQ-1 Rev. 0 Page 3 of 9
METHOD STATEMENT FOR EVAPORATOR HYDRO TEST

MSF EVAPORATOR REJECT SECTION

TUBE SIDE HYDROTEST
SCOPE
This procedure describes the minimum requirements to be followed for conducting
TUBE SIDE hydrostatic testing of MSF Evaporator, Stage 24 to 26, 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-076 to 79: WATER BOX Reject 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-1 Rev. 0 Page 4 of 9
METHOD STATEMENT FOR EVAPORATOR HYDRO TEST

SEQUENCE 1:
Tube Side Hydro test- Stage 24 to 26

Evaporator Layout

REJECT SECTION: Hydro test layout

MH-7560-00-07-SEQ-1 Rev. 0 Page 5 of 9
METHOD STATEMENT FOR EVAPORATOR HYDRO TEST

TECHNICAL DATA
1. BLIND FLANGE

Location Flange Size Stud Bolt with 2 Nuts

Stage 26 (Brine Side) OD 2198 x 108mm Thk 1 3/4” x 310mm Lg x 60 Nos
Stage 24 (Dstl. Side) OD 2198 x 108mm Thk 1 3/4” x 310mm Lg x 60 Nos
Vent Nozzles 2” ASME 150# x 6 Sets 5/8” x 90mm x 4 Each
Drain Nozzles 3” ASME 150# x 6 Sets 5/8” x 100mm x 4 Each

2. BOLT TORQUE (Valid for Reject Section Inlet and Out Let Blind Flanges)
Location Flange Size Bolt A540-B23 Torque (KgM)
Stage 26 (Brine OD 2198 x 108mm Thk 1 3/4” 450
Side)
Stage 24 (Dstl. OD 2198 x 108mm Thk 1 3/4” 450
Side)

3. Total Volume of Water Required (Only For Reject Section) - ~530 Cubic Meter
Water

4. TEST PRESSURE- See Below Pressure Test Chart

Pressure Test Chart For

Reject Section
MH-7560-00-07-SEQ-1 Rev. 0 Page 6 of 9
METHOD STATEMENT FOR EVAPORATOR HYDRO TEST

HYDRO TEST APPARATUS

No Description Figure
1 Blind Flange (for Reject Section
Inlet and Outlet)

2 Blind Flange 2”-150# & 3”-150#

3 Water Level Checking Hose

4 BALL Valves (Used for Manifolds)

5 GAUGES (0 to 10 Bar G.)

For Reject Section Only

6 EPDM Rubber Gasket 2” & 3”-

7 EPDM Rubber Gasket for Blind

Flange Reject Section Inlet and
Out Let

8 Gasket for Water Box Manhole

MH-7560-00-07-SEQ-1 Rev. 0 Page 7 of 9
METHOD STATEMENT FOR EVAPORATOR HYDRO TEST
9 Wrench

10 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 24 to 26 (Reject
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.
MH-7560-00-07-SEQ-1 Rev. 0 Page 8 of 9
METHOD STATEMENT FOR EVAPORATOR HYDRO TEST

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.
• 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 reject 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 1.5 nor more than
4 times that pressure.
TEST PROCEDURE

PRESSURIZING
• The test pressure shall not be applied until the metal and water are about the
same temperature.
MH-7560-00-07-SEQ-1 Rev. 0 Page 9 of 9
METHOD STATEMENT FOR EVAPORATOR HYDRO TEST
• 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.
• Hydrostatic pressure shall be held for a minimum 10 Minute, at the design
pressure. During this period, the reject 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 24 to 26
• Once the inspection found satisfactory, the hydro test pressure then shall be
increased up to 4.88 BarG. Measured on the shell top of the stage 24. (See
Hydro test Layout)
• The test pressure shall be maintained for 30 Minutes. During this period, the
reject tube bundles and water boxes shall have no leakages.

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- BarG, each water box
vent connection shall be sequentially open staring from stage 24 to 26

REJECT 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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