7560 MSF Method S-1 - Rev. 1

BILFAL HEAVY INDUSTRIES LTD.
P.O. BOX 30025

YANBU 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 FABRICATION OF

MSF EVAPORATOR
1 10-7-2014 JACOB T. SANTOSH Revised as per client comment & Generally Revised
0 5-01-2014 JACOB T. SANTOSH ISSUED FOR INFORMATION
Rev. Date Prepared Approved Description

MH-7560-00-01 Rev. 1 Page 2 of 41
TABLE OF CONTENT
1 INTRODUCTION
General
Project Location
Manufacturing Location
Scope of Works
Reference Method Statements
2 GENERAL PHILOSOPHY OF MSF EVAPORATOR CONSTRUCTION
Characteristics of EVAPORATOR SECTIONS
Typical parts of an Evaporator ‘SECTION’
3 TYPICAL FABRICATION OF EVAPORATOR ‘SECTION’ MODULE
1 Bottom Wall
1.1 Bottom Wall Plate & Fabrication Sequence
1.2 Bottom Wall ‘H’ Beam Stiffeners & Fabrication sequence
1.3 Bottom Wall Frames Assembly
1.4 Bottom Wall Assembly & Sequence
1.5 Wall Lifting arrangements
2 Roof Wall
3 Brine Side Wall
3.1 Brine Side Wall Fabrication Sequence
3.2 Brine Side Wall Assembly Sequence
4 Distillate Side Wall
4.1 Distillate Side Wall Fabrication Sequence
4.2 Distillate Side Wall Assembly Sequence
5 Front Wall- (Only for Section – 1)
6 Partition Wall with Brine weir
6.1 Brine weir Fabrication Sequence
6.2 Partition Wall Fabrication Sequence- Rear side
6.3 Partition Wall Fabrication Sequence- Front side
6.4 Partition Wall Lifting
7 Distillate Trough
7.1 Distillate Trough Fabrication Sequence
7.2 Distillate Trough Transportation
8 Tube Bundle Assembly
8.1 Tube Bundle Fabrication
8.2 Tube Bundle Alignment Sequence
8.3 Trough Installation
MH-7560-00-01 Rev. 1 Page 3 of 41
9 Distillate Water Duct

9.1 Distillate Water Duct Fabrication Sequence
10 Intermediate Piece
10.1 Neck Plate Framing and Girth Flange Welding
10.2 Tube Sheet Welding
10.3 Machining of Girth Flange
10.4 Liner Plate Welding
10.5 DRILLING of Girth Flange
10.6 Final Machining of Girth Flange
10.7 Transportation of Intermediate Piece
4 TYPICAL MODULARIZATION OF EVAPORATOR ‘SECTIONS’
Sequence: 1- Installation of Bottom Wall, Front wall & Sides
Sequence: 2- Installation of Distillate Duct & Partition Wall
Sequence: 3- Installation of Anti-Deflection Supports
Sequence: 4- Roof Wall with Tube Bundle
Sequence: 4.1- Roof Wall Inverting (Method-1)
(Refer Method Statement MG-7560-00-02)
Sequence: 5 Installation of Roof Wall with Tube Bundle
5 CONSTRUCTION OF WATER BOX
Sequence: 1- Construction of HOOF Plate
Sequence: 2- Assembly and welding of HOOF
Sequence: 3- Construction of 2 Pc Miter Elbow
Sequence: 4- Assembly of 2 Pc Miter Elbow
Sequence: 5- Construction of 2 Pc BARREL
Sequence: 6- Assembly of 2 Pc BARREL
6 WATERBOX ASSEMBLY AT YANBU FACTORY
Sequence: 1- HOOF machining and Bolt Hole Drilling
Sequence: 2- Assembly of 2 Pc Miter Elbow to HOOF Assembly
Method- 1
Method- 2
Sequence: 2- Shipment of HOOF Assembly
MH-7560-00-01 Rev. 1 Page 4 of 41
1
INTRODUCTION
GENERAL
This Method Statement is intended to describe the activities and arrangements
required for fabrication, assembly of 20 MIGD, MSF type Evaporator for SWCC’s
Medina Yanbu Desalination plant Phase III Expansion Project.
All works shall be carried out in strict accordance with the codes and standards
specified in DOOSAN’s Material Purchase Specification
PROJECT LOCATION
New MSF Evaporator located at near SWCC’s Medina Yanbu Desalination and
power plant Phase III.
MANUFACTURING LOCATION
All Evaporator parts shall be substantially fabricated and assembled as panels and
frames at BILFAL’s Jubail & Yanbu Workshop facilities. Where appropriate, certain
areas of the fabrication will be completed at site, in conjunction with the stage to
stage joints fitting out operations.
Here below indicate the extent of works performed at BILFAL Workshop shop and
SWCC PHASE – III site.
REFERENCE METHO STATEMENTS
MH-7560-00-02 : Method Statement for Bundle Lifting and Overturning
MS-7560-00-03 : Method statement for Supporting Structure Installation
MH-7560-00-04 : Method statement for Lifting and Transportation of
SECTIONS
MH-7560-00-05 : Method statement for ‘SECTIONS’ Installation
MH-7560-00-06 : Method statement for ‘SITE WORKS’
MH-7560-00-01 Rev. 1 Page 5 of 41
SCOPE OF WORKS
S.No Activity Description Location
1 Evaporator Supporting Steel Structure Fabrication (Sub-Contractor) RIYADH
2 Evaporator Platform Steel Structure Fabrication (Sub-Contractor) RIYADH
3 All external Shell Plates Fabrication and assembly YANBU
4 All external stiffener Fabrication Assy. & Primer Painting YANBU
5 Welding of Stiffener Beams To Shell Plate as per stage Wise YANBU
6 Partition Wall Fabrication and assembly YANBU
7 Brine distribution Box fabrication & Assembly YANBU
8 Tube Support Plate Alignment and welding YANBU
9 Distillate trough Bending JUBAIL
10 Distillate trough Fit-up and Installation YANBU
11 Vent Baffle Duct Fabrication and Installation YANBU
12 Distillate Duct Fabrication and Installation YANBU
13 Demister Support Fabrication and Installation YANBU
14 Complete Fabrication of Nozzles and Man ways YANBU
15 Brine weir & gate fabrication and installation YANBU
16 Intermediate piece: Complete Fabrication JUBAIL
17 Water Box fabrication (HOOF with Flange) JUBAIL
18 Water Box fabrication (All Machining, Miters and Barrels) YANBU
18 Brine Distribution header JUBAIL
19 Internal and External Piping works YANBU
20 Brine and distillate Sump Fabrication YANBU
21 All Bending works Above 2 Meter Width and Up to 7 Meter JUBAIL
ACTIVITIES AT SWCC SITE

S.No Activity Description
1 Evaporator Supporting Steel Structure Erection
2 Foundation leveling and Grouting works
3 Evaporator Platform Steel Structure Fabrication Erection
4 Slide Bearing Plate Installation
5 Evaporator Section installation
6 Welding and NDE of evaporator Sections
7 Demister Support Installation
8 Inter-stage vent pipe work and orifice plate installation.
9 Hydro-testing of distillate duct
10 Internal pickling and passivation
11 Tube insertion & Expansion
12 Water box Installation
13 Deaeratior External Panels and internals Installation
14 Shell side Hydro Test
15 Tube side Hydro test
16 Demister Installation
MH-7560-00-01 Rev. 1 Page 6 of 41
2
GENERAL PHILOSOPHY OF MSF EVAPORATOR
CONSTRUCTION
DOOSAN provided Design drawings, Shop drawings, Cutting plan and Project
specifications are the governing documents for fabrication, assembly and
installation of the Evaporator Units
Each Evaporator unit shall be fabricated at BILFAL YANBU workshop as 13

individual SECTIONS, which characterize as below. Deaerator and components
shall be fabricated in part by part at shop and finally, assembled at site.
Evaporator Unit Sketch showing Stages and sections
Characteristics of EVAPORATOR SECTIONS

~ Size in Meter Gross Weight
Section Description
(LxBxH) (Kg.)
1 25 x 9.1 x 6.3 Heat Recovery Stage 1 & 2 199.07
12 25 x 10.5 x 6.3 Heat Recovery/Reject Stage 23 & 24 195.99
13 25 x 11.2 x 6.3 Heat Reject Stage 25 & 26 183.02
MH-7560-00-01 Rev. 1 Page 7 of 41
TYPICAL PARTS OF EVAPORATOR ‘SECTION’

(AT FABRICATION SHOP)
MH-7560-00-01 Rev. 1 Page 8 of 41
3
TYPICAL FABRICATION OF EVAPORATOR SECTIONS
Evaporator Sections shall be considerably fabricated and assembled at BILFAL
YANBU Workshop in combination of 2 stages together, called hereafter
‘SECTION’. Each ‘SECTION’ shall include;
1) Bottom Wall
2) Roof Wall
3) Brine Side Wall
4) Distillate Side Wall
5) Front Wall- (Only for Section 1)
6) Partition Wall
7) Tube Bundle Assembly
8) Distillate trough
9) Distillate duct
10) Intermediate Piece and Nozzles
1) BOTTOM WALL
Bottom wall is fabricated with Duplex SS PLATES, stiffened by rolled steel ‘H’
beams FRAME. Each bottom wall shall be fabricated and assembled as section
wise and fitted with sufficient pad eyes for lifting and turning after welding.
In order to minimize excessive metal shrinkage during welding, all H-Beam

stiffeners shall be separately assembled as a FRAME and finally the FRAME to be
welded on wall plate.
Following table and Sketch and table is describing the erection dimensions and
weights of each bottom wall.
Sec-
Sec-1 Sec-
Sec-2 Sec-
Sec-3 Sec-
Sec-4 Sec-
Sec-5 Sec-
Sec-6 Sec-
Sec-7 Sec-
Sec-8 Sec-
Sec-9 Sec-
Sec-10 Sec-
Sec-11 Sec-
Sec-12 Sec-
Sec-13
Length 24.7 24.7 24.7 24.7 24.7 24.7 24.7 24.7 24.7 24.7 24.7 24.7 24.7
Width 9.9 9.8 9.8 9.8 9.9 10.0 10.1 10.3 10.5 10.7 10.8 10.9 11.2
Weight 56.3 55.5 55.5 55.5 56 56.5 57.0 58.0 58.9 59.3 60.4 61.0 50.1
MH-7560-00-01 Rev. 1 Page 9 of 41
1.1) BOTTOM WALL PLATE

SS Duplex plates (Wall Plate) placed on a secured working platform. Align the
plate and fit up with SMAW weld support. (Before SAW welding, the root face
shall be welded by SMAW and back side welding to be back chipping and
perform PT before final weld)
Both transverse and long joints welded with Submerged Arc Welding (SAW)
process as per WPS.
FABRICATION SEQUENCE
• Material identification and Stamp Transfer of Raw plate
• Shape Cutting and Grinding of the plate
• Beveling of the plate on transverse and long joints where required
• 200 Ø Hole Cutting for plug weld as per shop drawing
• Preassembly and fit up of plates on plate jigs
• Fit-up Inspection
• SAW full Welding of transverse and longitudinal joints as per WPS
• NDE of Butt Joints as per Specification
• Eventual straightening
• Final Dimensional Check
Sketch showing Wall plate placed on Jigs for Welding

(Typical for All Shell Plates)
MH-7560-00-01 Rev. 1 Page 10 of 41
1.2) BOTTOM WALL ‘H’ – BEAM STIFFENERS

Bottom wall stiffeners are fabricated with rolled steel H beams, cut to required
length, by mechanical saws and make up relevant end profiles as shown below
FABRICATION SEQUENCE OF ‘H’ – BEAM STIFFENERS

• Material identification and dimensional inspection
• Cutting of stiffener beams by Mechanically guided tools (band saw or
Circular Saw)
• Edge profile preparation by Flame cutting or Grinding
• Dimensional check
• Final Inspection
1.3) BOTTOM WALL FRAMES ASSEMBLY

Fabricated ‘H’ Beams are to be placed on ‘A’ frames or a work bench, which shall
be set on level finished floors and commencing from the main transverse beam.
Alignment and leveling shall be adjusted with adequate screw Jacks and leveling
Blocks.
Sufficient level block to be placed over the frame in order to prevent distortion
during welding
Photograph Showing Wall Frame Assembling at SHOP

MH-7560-00-01 Rev. 1 Page 11 of 41
FRAME ASSEMBLY SEQUENCE

• Place each stiffener beams on ‘A’ frames, using with spacer jigs as per stiffener
layout
• Alignment of each beams by special Fit-up Templates and Clamps
• Fit-up of beam framing by tack weld
• Dimensional Inspection of Fit-up.
• FCAW / SMAW Fillet welding of Beams as per WPS
• PT Examination and MT as per ITP
• Final Dimensional inspection.
• Sand Blasting and Primer Painting
1.4) BOTTOM WALL ASSEMBLY

After completion of a SECTION’s bottom wall plate welding, the bottom wall frame
to be placed on a working platform, commencing at the centerline of stiffener
beams as per bottom wall assembly drawing.
Sketch Showing Stiffener Beam FRAME and Wall plate Assembling
BOTTOM WALL ASSEMBLY SEQUENCE

• Place the SHELL plate first on a Working platform
• Perform all set-up welding in order to minimize weld shrinkage during welding
with stiffener Frame
• Marking of Stiffener location
• Positioning of Stiffener Frame using with 2 Cranes
• Fit-up of Stiffener Frame and Wall Plate
• FCAW / SMAW Fillet welding of Beams to plate as per WPS
• Dimensional Check
• Invert the wall (Turn the Bottom Plate side Up and Stiffener Down)
• Reinstate 170 Ø Plate into the cut out and perform Square butt weld (Refer
below Sketch)
MH-7560-00-01 Rev. 1 Page 12 of 41
• Perform NDE
Sketch Showing bottom cut-out plate reinstatement
1.5) WALL LIFTING ARRANGEMENTS

After completion of a SECTION’s wall plate welding with frame, install 4 Lifting
Lugs 4 Tailing Lugs on specified points securing with battens as shown below.
Typical Lifting Point For Bottom and Roof Wall

MH-7560-00-01 Rev. 1 Page 13 of 41
2) ROOF WALL
Roof wall shall be fabricated and assembled as section wise and each section
shall be fitted with sufficient pad eyes for lifting and turning, after welding.
Following table and Sketch and table described the erection dimensions and
weights of each roof wall sections
Sec-
Sec-1 Sec-
Sec-2 Sec-
Sec-3 Sec-
Sec-4 Sec-
Sec-5 Sec-
Sec-6 Sec-
Sec-7 Sec-
Sec-8 Sec-
Sec-9 Sec-
Sec-10 Sec-
Sec-11 Sec-
Sec-12 Sec-
Sec-13
Length 24.32 24.32 24.32 24.32 24.32 24.32 24.32 24.32 24.32 24.32 24.32 24.32 24.32
Width 9.9 9.8 9.8 9.8 9.9 10.0 10.1 10.3 10.5 10.7 10.8 10.9 11.2
Weight 35.1 36.7 36.7 36.7 37.1 37.4 37.8 38.4 39.1 39.8 30.2 40.5 41.3
2.1 ROOF WALL FABRICATION SEQUENCE

Similar to Bottom wall (Refer Point 1)
2.2 ROOF WALL ‘H’ BEAM FABRICATION SEQUENCE

Similar to Bottom Wall (Refer Point 1.2)
2.3 ROOF WALL FRAME ASSEMBLY SEQUENCE

2.4 ROOF WALL ASSEMBLY SEQUENCE

2.5 ROOF WALL LIFTING

MH-7560-00-01 Rev. 1 Page 14 of 41
3) BRINE SIDE WALL

Brine side wall shall be fabricated and assembled as section wise and each
section shall be fitted with sufficient pad eyes and temporary lifting frames for lifting
and turning after welding.
Following table and Sketch described the erection dimensions and weights of each
brine side wall segment
Sec-
Sec-1 Sec-
Sec-2 Sec-
Sec-3 Sec-
Sec-4 Sec-
Sec-5 Sec-
Sec-6 Sec-
Sec-7 Sec-
Sec-8 Sec-
Sec-9 Sec-
Sec-10 Sec-
Sec-11 Sec-
Sec-12 Sec-
Sec-13
Length 9.5 9.8 9.8 9.8 9.9 10 10.1 10.3 10.5 10.7 10.8 10.9 11.2
Width 5.7 5.7 5.7 5.7 5.7 5.7 5.7 5.7 5.7 5.7 5.7 5.7 5.7
Weight 4.6 4.7 4.7 4.7 4.8 4.9 4.9 5.1 5.2 5.3 5.3 5.6 6.1
3.1 BRINE SIDE WALL FABRICATION

After completion of wall plate splice joint, the brine side wall plate shall be set in
horizontal position on a lifting frame and then, start fit-up of H beam and Rib plate
stiffeners individually
BRINE SIDE WALL PLATE FABRICATION SEQUENCE

• Preassembly and fit up of plates on plate jigs
MH-7560-00-01 Rev. 1 Page 15 of 41
Typical Assembly of Brine Side WALL
3.2 BRINE SIDE WALL ASSEMBLY SEQUENCE

• Place the SHELL plate first on a lifting frame
with stiffener
• Positioning of Main long and transverse ‘H’ beam Stiffener
• Fit-up and tack weld ‘H’ beam stiffeners
• Positioning of secondary stiffeners
• Fit-up of Stiffener secondary stiffeners Including Man way Nozzles
• FCAW / SMAW Fillet Tack welding of Beams to plate as per WPS
• Full welding of stiffeners after installation of Intermediate piece
MH-7560-00-01 Rev. 1 Page 16 of 41
4) DISTILLATE SIDE WALL

Distillate side wall shall be fabricated and assembled as section wise and each
section shall be fitted with sufficient pad eyes and temporary lifting frames for lifting
and turning after welding.
Following table and Sketch described the erection dimensions and weights of each
brine side wall segment
Sec-
Sec-1 Sec-
Sec-2 Sec-
Sec-3 Sec-
Sec-4 Sec-
Sec-5 Sec-
Sec-6 Sec-
Sec-7 Sec-
Sec-8 Sec-
Sec-9 Sec-
Sec-10 Sec-
Sec-11 Sec-
Sec-12 Sec-
Sec-13
Length 9.5 9.8 9.8 9.8 9.9 10 10.1 10.3 10.5 10.7 10.8 10.9 11.2
Width 5.7 5.7 5.7 5.7 5.7 5.7 5.7 5.7 5.7 5.7 5.7 5.7 5.7
Weight 4.6 4.8 4.8 4.8 4.9 4.9 5.0 5.1 5.2 5.4 5.4 5.7 6.2
4.1 DISTILLATE SIDE WALL PLATE FABRICATION SEQUENCE

• Preassembly and fit up of plates on plate jigs (Refer Below Sketch)
MH-7560-00-01 Rev. 1 Page 17 of 41
Typical Assembly of Distillate Side WALL
4.2 DISTILLATE SIDE WALL ASSEMBLY SEQUENCE

• Place the SHELL plate first on a lifting frame
with stiffener
• Positioning of Main long and transverse ‘H’ beam Stiffener
• Fit-up and tack weld ‘H’ beam stiffeners
• Positioning of secondary stiffeners
• Fit-up of Stiffener secondary stiffeners
• FCAW / SMAW Fillet tack welding of Beams to plate as per WPS
• Full welding of stiffeners after installation of Intermediate piece
MH-7560-00-01 Rev. 1 Page 18 of 41
5) FRONT WALL – (ONLY FOR SECTION 1)

Front Side wall shall be fabricated and assembled a single wall construction
composed of Wall plate, stiffener plate and Brine inlet nozzles. Brine distribution
box also constructed together and installed at shop using with temporary supports.
The front wall shall be fitted with sufficient pad eyes and temporary lifting lugs for
lifting and turning after welding.
Completed FONT WALL View with BRINE BISTRIBUTION BOX
(FRONT WALL: Size- Length 24746mm x Width 5829 mm- Total Weight- 23700 Kg)
MH-7560-00-01 Rev. 1 Page 19 of 41
6) PARTITION WALL
Partition walls are fabricated with duplex SS plate. Each partition wall is stiffened
both sides by plates and formed ribs of the same material of the wall.
Partition walls are provided with BRINE WEIR assembly, product water and brine
openings, Distillate weirs, Demister Supports. A complete dimensional check to
be carried out before start further sequence of fabrication
Each Partition wall shall be fitted with temporary pad eyes and lifting frames for
lifting and turning after welding.
6.1 BRINE WEIR FABRICATION SEQUENCE

• Material Identification & Stamp transfer
• Cutting and grinding
• Beveling the plate, intermediate joint and where required
• Bending of the plate
• Pre-assembly of plates
• Fit-up inspection
• Preassembly of Brine weir Gusset Plate and Jump Plate
• SMAW / FCAW Full welding as per WPS
• PT Examination
• Eventual Straightening IF ANY
6.2 PARTITION WALL FABRICATION SEQUENCE: (Rear Side)

• Material Identification & Stamp transfer
• Cutting and grinding the plate including all opening cuts
• Beveling the plate
• SMAW / SAW support welding / full welding as per WPS
• Perform NDE
• Preassembly and fit-up of all Rear Side stiffeners
• Fit-up inspection
• Installation of Demister Support
• PT Examination
MH-7560-00-01 Rev. 1 Page 20 of 41
• Radiography as per specification

• Dimensional control
Partition Wall placed on a Jig for Rear Side Stiffener Installation
Following the above sequence, the Partition wall then to reverse and placed on top
of work the bench for welding Brine weir plate, weir gusset, Stiffener plate and
Jump plate.
6.3 PARTITION WALL FABRICATION SEQUENCE: (Front Side)

• Installation of Brine Weir assembly
• Inspect fit-up assembly
• Preassembly and fit-up of all Rear Side stiffeners
• Stiffener plate Fit-up inspection
• Welding as per WPS
• PT Examination
• Eventual straightening, if required
• PT Examination
MH-7560-00-01 Rev. 1 Page 21 of 41
Partition Wall reversed and placed on Work bench

For Front side Stiffeners, Brine Weirs installation
6.4 PARTITION WALL LIFTING

After completion of fabrication of Partition wall, install sufficient numbers of lifting
Lugs suitable to lift by Spreader Beam as shown below. The completed Partition
wall shall be installed on bottom plate before the erection of side walls.
Completed Partition Wall Lifting with Spreader beam

MH-7560-00-01 Rev. 1 Page 22 of 41
7) DISTILLATE TROUGH
Distillate water tray or trough is a continuous channel section, placed below each
tube support plates and ending up to the demister level.
Each trough is sloped from the brine side to the distillate side along the tube
bundle
Fabrication of Distillate trough shall be carried out in two stages. First stage prior to
welding to ensure the trough plate segment bending is in line with sloped channel
configuration. Second stage, splice welding of each Trough segments using with
special jigs.
Bending of Trough Trough Segments after Bending
7.1 DISTILLATE TROUGH FABRICATION SEQUENCE

• Material identification and stamp transfer
• Beveling of the plate for intermediate joints
• Bending of the plates
• Preparation of place of work (Inside workshop with EOT crane coverage)
• Final inspection of bended Trough segment
• Install trough segments in reverse position on jigs
• Fit-up Trough Segments commencing from Brine side
• Install temporary supports for welding (See Below Sketch)
• Install Backing support for welding from inside of the trough
• Perform Twin GTAW weld as per WPS
• Cutting Slope p
• PT Examination
MH-7560-00-01 Rev. 1 Page 23 of 41
Typical Arrangement for Distillate Trough Fabrication
7.2 DISTILLATE TROUGH TRANSPORTATION

After Fabrication and NDE, The troughs shall be suitably protected for shipment as
follows
• Trough shall be transported by means of large extendable, custom made
trailer (16 to 24 meter)
• Each transportation shall consist of 4 Nos. of Trough and shall be arranged
in stack
• Welding of temporary Lifting lugs at top of Troughs
• The trough is protected by wooden staving during transportation
• Additional Jigs shall be placed on trailer in order to avoid distortion during
transportation
Typical Arrangement for Trough TRANSPORTATION by Long Trailer

MH-7560-00-01 Rev. 1 Page 24 of 41
8) TUBE BUNDLE ASSEMBLY

Tube bundle for each stages of evaporator consist of; 11 numbers of Tube Support
plate, Vent Baffles welded directly to the roof wall and distillate duct segments,
which welded to entire tube support plate.
Two methods of assembling of tube bundle may be performed. The first methods
involve two stage bundles attaching to roof wall, and then invert the roof wall by
using a 500 Metric Ton Crawler Crane and 250 Metric Ton service crane.
Alternatively, single stage Tube bundle, attaching to the roof wall and invert by
using a 250 Metric Ton crawler crane and 2 service cranes
Tube Bundle after alignment for 1 Stage (Typical for all stages)
8.1) TUBE BUNDLE FABRICATION

To suit the proposed fabrication and erection sequence, each tube bundle
shall be completely aligned and welded at shop.
As shown on the below sketch, support plate shall be positioned on their

specified location in a reverse order and welded to roof wall.
MH-7560-00-01 Rev. 1 Page 25 of 41
8.2 TUBE BUNDLE ALIGNMENT SEQUENCE

• Preparation of place of work (Inside workshop with EOT crane coverage)
• Place top wall section on floor, with suitable leveling blocks
• Mark layout of Tube Support positions on roof wall
• Mount Tube Support Plate positioned on their locations in a reverse position
as per type ‘X’ and ‘Z’ sequentially.
• Using temporary brackets and struts to fix them in position.
• Align tube support plates on a preliminary line and then, they shall be
individually adjusted until completion of final alignment done
• Alignment of the tube support shall be achieved using optical instruments or
harmonic wire (Piano wire) with one end held in a tapped bush and pulled
by a Counter Weight. The tension of the wire shall be such, that its
deflection is negligible (refer to typical sketch shown below)
• To avoid excessive distortion of the Tube support plate, use sufficient
number of tie rods linking to the 2 adjacent plates and bolted to the tube
support plates, in order to stiffen the assembly.
• The tie rod shall be kept in place until completion of all welding including
Distillate trough welding
• Following this stage, the tube support plate can be welded to roof wall and
temporary supports can be removed.
• Once, complete the Tube Support alignment and welding, the vent baffles
can be positioned and welded to the tube support plate and to the upper
side of roof plate
MH-7560-00-01 Rev. 1 Page 26 of 41
Typical Arrangement for Tube Bundle Alignment
8.3 TROUGH INSTALLATION

After completion of Baffle alignment and welding, The Distillate trough shall
be inserted as shown below sketch.
Distillate Trough Installation

MH-7560-00-01 Rev. 1 Page 27 of 41
Distillate Trough Installation Sequence shall be as follows;
• Mark the trough location and elevation on each support plate in

consideration of Distillate water trough slope. The Location and level of
Trough shall be set on floor plate level and then adjust the slope as per
requirement
• Lift the Trough using with suitable spreader beam
• Insert into the Tube bundle, with the concave side, until reach the trough
location / elevation mark
• Perform tack weld to prevent movement from the location
• To avoid distortion, care must be exercised during insertion and welding
with suitable strong back plates.
• Once the trough setting is completed, the welding can be started
• All the welding and NDE completed, perform final dimensional inspection.
9) DISTILLATE WATER DUCT

Distillate water DUCT is continues Trough section, passing throughout all stages,
completely separated from the brine chambers into which, the distillate product
water produced by each stage is channeled
Distillate water duct shall be installed at shop along with each stage to make
access for welding and duct installation activities safer and less strenuous
Longitudinal section showing

Distillate water Duct Installation
MH-7560-00-01 Rev. 1 Page 28 of 41
9.1 DISTILLATE WATER DUCT FABRICATION SEQUENCE

• Material identification and stamp transfer
• Cutting and grinding of plates
• Drilling of Holes where required as per drawing
• Final inspection of Duct plates
• Cutting of manhole plate and accessories
10) INTERMEDIATE PIECE

Complete Intermediate pieces for both evaporators fully fabricated, machined and
drilled in BILFAL JUBAIL factory. Each Intermediate piece shall be constructed in
JUBAIL Factory, as follows
• Neck plates Cutting, beveling &

Neck framing,
• Girth Flange Fit-up
• Dimensional Inspection and NDE
• Girth Flange Flatness check
• Ribs Fit-up & Welding
• Girth Flange welding
• Tube sheet Fit-up
• Tube sheet welding- 2 Pass
Weld Both side
• Dimensional Inspection and
NDE- Leak Test
• Tube sheet welding
• Rough Machining of Girth Flange
• Neck liner plate fit-up and
welding
• Girth Flange Liner Plate Welding
• Drilling Of Bolt holes
• Dimensional Inspection
• Final Machining
• Flange Leak Test
Typical Sectional Details
• Blasting & Painting
• Shipping
MH-7560-00-01 Rev. 1 Page 29 of 41
10.1 Neck Plate framing and Girth Flange Welding

The neck plates shall cut to neck frame size sizes and perform required end bevel
preparations. The first operation is to align the frame plate using with rectangular
plate holder or a positioned with movable clamp to securely hold neck plates
during the frame welding
The Neck frame were formed one at a time, insert into girth flange, using with side
supports for adjusting the plate edge is parallel to the face of girth flange.
Typical Method for Neck Plate and Girth Flange Fit-up
Typical Method for Tube Sheet Fit-up

MH-7560-00-01 Rev. 1 Page 30 of 41
10.2 Tube Sheet Welding

After fit-up of Tube sheet, Perform 2 pass peripheral welding, both side of tube
sheet. Perform leak test for the welding between Tube sheet and Neck Plate. Upon
completion of acceptable test results, proceed for the remaining weld as per WPS.
10.3 Machining of Girth Flange

After completion of welding between neck frame and girth flange, the Girth
Flange face shall be machined for Liner plate welding
10.4 Liner Plate Installation

After machining, entire machined surface of intermediate piece must be
checked to assure conformance with the specified levelness for liner
placement. Once, completed the liner plate placing, perform both plug
welding and fillet welding as per WPS
10.5 DRILLING of Intermediate piece

Up on completion of machining, Intermediate piece move for CNC Bolt Hole
drilling and drilling of Vent / test holes as per drawing.
10.6 FINAL Machining of Intermediate piece

After completion of drilling and Dimensional inspection, Perform final
machining of Flanges as per drawing
10.7 TRANSPORTATION of Intermediate Piece

After completion Fabrication at JUBAIL factory ,arrange 2 Nos. Intermediate pieces
together (face to face) with suitable flange face protection and vertically placed in a
steel shipping frame as shown below sketch. This is to utilize normal Trailers for
transportation.
Packing Arrangements for Intermediate piece Transportation

MH-7560-00-01 Rev. 1 Page 31 of 41
4
TYPICAL MODULARIZATION OF EVAPORATOR
‘SECTIONS’
Each evaporator unit shall build up with 13 Transportation sections as stated in

part 1. Each Section shall be assembled at BILFAL Yanbu Factory, with exclusion
of the Tubing and Demister together with other minor assemblies.
Sequence: 1 (Installation of Bottom Wall, Front Wall & Sides)

1.1 Alignment and leveling of 12 Nos. concrete block (1x1.5x1.5 M High)
Provided minimum 5m gap in between for Transportation
1.2 Place Bottom wall over the concrete block and check leveling
1.3 Install front Wall with Brine Distribution Box
1.4 Install Brine side Wall with Lifting frame
1.5 Install Distillate side Wall with Lifting frame
Temporary Supports for Side Wall

Typical Lifting of wall
MH-7560-00-01 Rev. 1 Page 32 of 41
Sequence: 2 (Installation of Distillate Duct & Partition Wall))

2.1 Install Stage 1 Distillate duct
2.2 Erect Partition wall after welding of Stage 1 Distillate
2.3 Install Stage 2 Distillate duct
Sequence: 3 (Installation of Anti deflection Supports)

To avoid distortion, care must be exercised before the installation of roof wall with
tube bundle. Approximate 4 to 5 numbers of adjustable posts shall be placed at
free end of each Modular section.
These adjustable posts shall be removed only after the erection and welding of
evaporator section module at site.
MH-7560-00-01 Rev. 1 Page 33 of 41
Anti Deflection Support Installation
Sequence: 4 (Roof Wall WITH Tube Bundle)

The first step in the installation of Roof wall with Tube bundle is to invert from the
fabrication working table. Two methods of inverting the roof wall may be
performed.
The first method involves using with two crawler cranes, having capacity of 350
Metric Ton and 2 service cranes with capacity of 110 Metric ton. For details,
See Method Statement MH-7560-00-02- for Bundle Lifting and
Overturning
Roof Wall with Tube Bundle (ROOF BUNDLE) after Fabrication

MH-7560-00-01 Rev. 1 Page 34 of 41
Sequence: 5 (Installation of Roof Wall with Tube Bundle)

Upon completion of the inversion of roof wall with tube bundle, as per Method
Statement MH-7560-00-02, Align the roof wall in line with two symmetrically
positioned side wall openings for water box.
Installation of Roof Wall with Tube Bundle
When the roof wall was perfectly aligned with bottom section, carefully lower the
roof wall into bottom section as shown above. Using temporary brackets to fix the
roof wall in position where necessary
As the roof wall seated properly on bottom section, perform fit-up and welding
MH-7560-00-01 Rev. 1 Page 35 of 41
5
WATER BOX FABRICATION
Water boxes are of rectangular shapes and the double water boxes are
connected in a welded 180° mitered bend configuration. For all stages the
water boxes are made by CS plates cladded with Cu Ni 90/10. Each water
box has a manhole on the inlet side and has connections for vent, drain
and temperature gauge.
The water boxes will be bolted to the shell Intermediate Piece at site. Each Water
boxes shall be fabricated and partially assembled at shop.
Sequence: 5.1 : Construction of Hoof Plate

• Material Identification
• Stamp Transfer
• Cutting, Grinding, Beveling
• Clad Removal
• Check by Copper Sulphate Solution after clad removal as per ITP
• Rolling of Clad Plate Petals
MH-7560-00-01 Rev. 1 Page 36 of 41
Sequence: 5.2 : Assembly and welding of ‘HOOF’

• Setting of Fabricated Girth flange on Water Box Fixture
• Assembly of two Petals on Girth flange using with temporary supports
• After fit-up of two petals, assemble remaining two petals
• Fit-up of petals and Dimensional Inspection
• Root Grinding
• PT Examination
• Flush Grinding (Internal Weld only
• Welding of Girth Flange and Hoof Plate by GTAW / SMAW as per WPS
• Restoration of Clad by Weld Deposit
• Final Inspection
• NDE
• Dispatch To Yanbu Factory
Assembled Water Box Hoof Hoof After Assembly

MH-7560-00-01 Rev. 1 Page 37 of 41
Sequence: 5.4 : Construction of 2 Piece Miter Elbow

• Stamp Transfer
• Clad Removal
• Rolling of Clad Plate
• Fit-up Assembly
• Root Grinding
• PT Examination
• Weld Deposit
• NDE
Miter Section After Assembly
Sequence: 5.5 : Assembly of 2 Piece Miter Assembly

• Assembly of Miter Barrel with Barrel
• Fit-up of Miter and Dimensional Inspection
• Root Grinding
• PT Examination
• Weld Deposit
• NDE
MH-7560-00-01 Rev. 1 Page 38 of 41
Sequence: 5.6 : Construction of 2 Piece BARREL

• Stamp Transfer
• Clad Removal
• Rolling of Clad Plate with Extra length for site adjustment
• Fit-up Assembly
• Root Grinding
• PT Examination
• Weld Deposit
• NDE
Barrel After Assembly
Sequence: 5.7 : Assembly of 2 Piece BARREL

• Assembly of Barrel with Barrel
• Fit-up of Miter and Dimensional Inspection
• Root Grinding
• PT Examination
• Weld Deposit
• NDE
• External Blasting and Painting
• Packing for dispatching to site
MH-7560-00-01 Rev. 1 Page 39 of 41
6
WATER BOX ASSEMBLY- AT YANBU FACTORY
Water box assembly completion (for Single and Double Waterboxes ) will be
carried out at YANBU Factory, providing additional length on BARREL for site
adjustment. This to allow for optimum water boxes , Intermediate Pice
alignment, radial (axial) plumb and parallelity of mating flange faces
Sequence: 6.1 : HOOF Machining and Bolt Hole Drilling

• Receiving inspection of HOOF assembly
• Set up Hoof assembly Section to fixture for Machining and drilling
• Machining of Girth Flange face & Hoof Plate welding before liner plate
installation
• Liner Plate Fit-up and Welding
• Drilling Of Bolt holes
• Final Machining
Sequence: 6.2: ASSEMBLY of 2 Pc. Miter Elbow To Hoof Assembly

Two methods of attaching Miter piece to Hoof assembly may be performed. The
first method involves attaching the hoof assembly to the top of a fixture and then
install miter elbow from down side using by chain blocks.
Alternatively, after completion of machining and Drilling of bolt holes for the HOOF
flanges, remove the hoof assembly from the jigs and place on Level blocks.
MH-7560-00-01 Rev. 1 Page 40 of 41
METHOD: 1
• Place the Hoof with fixture on

adequately braced column frame\ as
shown in sketch
• Set up and bolted the Hoof Section on
column frame
• Insert Miter elbow from down side
using by chain blocks
• Mark of Hoof Plate cutting line
• Cutting of HOOF plate to suit the miter
elbow
• Fit-up examination
• SMAW / FCAW Full welding as per
WPS
• PT Examination
• Flush grind external and internal welds
• Weld Deposit / Clad Restoration
• Installation of Reinforcing Pad
• SMAW Full weld as per WPS
• Assembly of Vent and Drain connection
nozzles
ASSEMBLY of 2 Pc.Miter Elbow To Hoof
• Assembly of Thermo well, Lifting Lugs
Assembly
and external stiffeners
• Fit-up Examination
• SMAW Full welding
• Final Dimension
• External Blasting and Painting
• Packing for dispatching to site
MH-7560-00-01 Rev. 1 Page 41 of 41
METHOD: 2
• Place Hoof assembly on level blocks suitable for
internal welding
• Install Miter elbow using by crane
• Mark of Hoof Plate cutting line
• PT Examination
• Flush grind external and internal welds
• Weld Deposit
• Assembly of Reinforcing Pad
• SMAW Full weld as per WPS
• Assembly of all connection nozzles, Thermo well,
Lifting Lugs and external stiffeners
• Fit-up Examination
• SMAW Full welding
• Final Dimension
Sequence: 6.3: Shipment of HOOF Assembly

All Double water boxes are to be shipped to Site as 3 parts, such as two numbers
of HOOF with Miter assembly and one Barrel. After completion of all Blasting and
painting, following activities to be performed
• Mount shipping Covers
• Placing protection materials for Flanges and Bevel Ends
• Visual Check
• Mound adequate saddle supports
• Shipping of water Box
Typical Transportation Arrangement for WATERBOX

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BILFAL HEAVY INDUSTRIES LTD.

P.O. BOX 30025

SWCC - YANBU 20 MIGD

Client: DOOSAN HEAVY INDUSTRIES &

METHOD STATEMENT FOR FABRICATION OF

0 5-01-2014 JACOB T. SANTOSH ISSUED FOR INFORMATION

Rev. Date Prepared Approved Description

9 Distillate Water Duct

ACTIVITIES AT SWCC SITE

Each Evaporator unit shall be fabricated at BILFAL YANBU workshop as 13

Evaporator Unit Sketch showing Stages and sections

Characteristics of EVAPORATOR SECTIONS

TYPICAL PARTS OF EVAPORATOR ‘SECTION’

In order to minimize excessive metal shrinkage during welding, all H-Beam

1.1) BOTTOM WALL PLATE

Sketch showing Wall plate placed on Jigs for Welding

1.2) BOTTOM WALL ‘H’ – BEAM STIFFENERS

FABRICATION SEQUENCE OF ‘H’ – BEAM STIFFENERS

1.3) BOTTOM WALL FRAMES ASSEMBLY

Photograph Showing Wall Frame Assembling at SHOP

FRAME ASSEMBLY SEQUENCE

1.4) BOTTOM WALL ASSEMBLY

Sketch Showing Stiffener Beam FRAME and Wall plate Assembling

BOTTOM WALL ASSEMBLY SEQUENCE

Sketch Showing bottom cut-out plate reinstatement

1.5) WALL LIFTING ARRANGEMENTS

Typical Lifting Point For Bottom and Roof Wall

2.1 ROOF WALL FABRICATION SEQUENCE

2.2 ROOF WALL ‘H’ BEAM FABRICATION SEQUENCE

2.3 ROOF WALL FRAME ASSEMBLY SEQUENCE

2.4 ROOF WALL ASSEMBLY SEQUENCE

2.5 ROOF WALL LIFTING

3) BRINE SIDE WALL

3.1 BRINE SIDE WALL FABRICATION

BRINE SIDE WALL PLATE FABRICATION SEQUENCE

Typical Assembly of Brine Side WALL

3.2 BRINE SIDE WALL ASSEMBLY SEQUENCE

4) DISTILLATE SIDE WALL

4.1 DISTILLATE SIDE WALL PLATE FABRICATION SEQUENCE

Typical Assembly of Distillate Side WALL

4.2 DISTILLATE SIDE WALL ASSEMBLY SEQUENCE

5) FRONT WALL – (ONLY FOR SECTION 1)

Completed FONT WALL View with BRINE BISTRIBUTION BOX

6.1 BRINE WEIR FABRICATION SEQUENCE

6.2 PARTITION WALL FABRICATION SEQUENCE: (Rear Side)

• Radiography as per specification

Partition Wall placed on a Jig for Rear Side Stiffener Installation

6.3 PARTITION WALL FABRICATION SEQUENCE: (Front Side)

Partition Wall reversed and placed on Work bench

6.4 PARTITION WALL LIFTING

Completed Partition Wall Lifting with Spreader beam

Bending of Trough Trough Segments after Bending

7.1 DISTILLATE TROUGH FABRICATION SEQUENCE

Typical Arrangement for Distillate Trough Fabrication

7.2 DISTILLATE TROUGH TRANSPORTATION

Typical Arrangement for Trough TRANSPORTATION by Long Trailer

8) TUBE BUNDLE ASSEMBLY

8.1) TUBE BUNDLE FABRICATION

As shown on the below sketch, support plate shall be positioned on their