F A B R I C AT I O N

P RO C E D U RE
FOR
E VA P O R AT O R S

MFF
LARSE N & TO U B RO LI MI T E D
H A Z I R A WO R KS , S U R A T
 INDEX
PAGES

1. INTRODUCTION

2.
INTODUCTION
Evaporators as discussed in this booklet refers to the Multi Effect Distillation
Evaporators designed by M/s SIDEM for Desalination Plant with net distillate output
of 5 Million Imperial Gallons per day at RAS AL KHAIMAH, UAE.

SIDEM awarded the manufacturing, supply, inspection control, packing ,delivery &
erection of three units of Evaporators to MFF, L&T Hazira. Each Unit of Evaporator
consisted of:

- Two cylindrical modules each of three cells with Ejecto Compressor

- One cylindrical module made of two cells with one internal distillate condenser

- One Upstream Condenser

- One Down Stream Condenser

- One No of Cooler, Two Nos. of Reheaters

- One No of Upstream Ejector & One No of Down Stream Ejector

STORAGE OF SS MATERIAL:
A) SS Plates :
Vertical Storage :

The Racks used for storing of SS Plates should be SS Lined & Duly Blasted
/Painted

Example for Vertical Storage

Horizontal Storage:

ƒ Do not put the Plates directly on the floor

ƒ It is advisable to use Concrete Blocks for Horizontal Storage of Plates

ƒ All SS Plates , Stored Horizontally , should be covered with Tarpaulin

Example for Horizontal Storage

Comparison between Horizontal storage & Vertical Storage:

It is advisable to store the plates vertically when these are to be used shortly because
of following reasons:

ƒ Search for the required plates is easier

ƒ It is easier to put the plates back in to their position

B) Finished /Semi Finished Components:

High concrete blocks /Wooden Frames used for keeping Finished or Semi Finished
Components

An Example of Storage of Semi-Finished Components

C) Storage of Tubes:

ƒ All tube boxes should be kept on high wooden Blocks

ƒ All tube boxes should be covered with tarpaulin

ƒ While handling the Tube Boxes Evener beam should be used

FABRICATION SEQUENCE:
Rolling of Plates:

During rolling of SS Plates, the following should be taken care of:

ƒ Inspect the roller sharp edges and remove the same

ƒ Thorough cleaning of all rollers by SS wires while rolling

ƒ If rollers are made of CS ,Cover them with Plastic Sheet to avoid direct contact
between SS & CS
ƒ Before rolling Clean the SS Plate surface with broom

ƒ Do not roll CS plates when SS Plates rolling is being done

ƒ After set up tacking ensure to remove slag from the joint and it should not stuck
up on roller while rolling.

LONG SEAM AT BEAM AREA:

- Mark the Lay out on Platform. On this layout weld the rectangular clits with
platform

- Put the rolled plates on this marking. Do not weld the shell plates with the clits
welded on Platform

- Make the fixture with 2-mm plate as shown in fig below

- Put it between the weld root gap

- Insert Wedge in both the sides

- Hammer the wedge until the plates of shell come in to level

- Tack weld the shells

- Use FCAW for making the joint to avoid spatters & consequent grinding

ROLLIN G OF IPE BEAM:

IPE Beam should be received 5-6 days before the rolling of SS plates start.
IPE beams are rolled on ROUNDO STRUCTURAL ROLLING MACHINE.

It is considered that the beams are in length of 12 mtr and ring will be made

in two pieces . Roll both the beams separately. While rolling 700 mm (APPROX.) of

Straight pieces are left on both sides of the rolled beam. Cut off the straight Pieces
While cutting straight pieces care should be take that these are cut along the
radius.
Do not cut along this line
Cut along this line

( To be cut along the radius )

Make the ring by joining the two halves at one place only. Keep the other joint open
(Make Bolting)

Open Joint (Bolting) Closed Joint (Welding)

Size of Template :

Template C = D/6

C D

D = diameter of IPE ring ; C = cord of template

PREFABRICATION OF H BEAM:

It is imperative that the CS material is received nearly one week before the rolling of

SS Plates start otherwise shell with IPE beams will remain idle waiting for H Beams.

While cutting off the Web ID should be kept - 10 mm of the required Dimension

Web OD should be kept +10 mm of required dimension

After welding (making ring of web), ID of web should be cut again to the required ID

It is not required to cut OD again. Even if OD of ring is slightly more, it is

acceptable (Before doing so, confirm it with CLIENT SITE incharge)

Fitup the Inner & Outer Flange. Try to use minimum No of Clits
Perform Inner & Outer Flange Joints by FCAW.

For setting of H beam outside the shell, one joint in H beam is kept open:

The opening joint should be staggered as shown in fig below :

200 mm

TUBE SHEET / TUBE SUPPORT PLATE DRILLIN G

Tube Sheet/ Tube Support Drilling is the most critical activity in Fabrication of
Evaporators.

The Drilling for Tube Sheet / Tube support Plates was carried out simultaneously
at various locations -

• M/s Drill Tech

• M/s Saini/Sanjog Engineering

• M/s IHG

• M/s Lunar Engineering

• M/s Nesto Fab

• M/s Neveko
For SIDEM – RAK Project the Tube sheet/Tube support plates were received well in
time because of:

- The Drilled Tube support Plates were used as template for taking impression on
Tube sheet /tube support plates

- The CNC drilled Templates were used to drill Tube sheet /tube support plates

Which were made in advance (Before receipt of Tube sheet /Tube Support Plates)
at L&T Powai & Ms Indus

Defects:
PREFABRICATION OF SADDLES:

Perform the stiffeners welding with Web in 1 G Position rather than 3 G to minimize
undercuts.

Perform the welding of Stiffeners by FCAW to minimize touch up

SETTIN G OF IPE / FABRICATED H BEAMS:

Fit up IPE beam on Shell using minimum Nos of Clits. ( At the max 8 Nos on one
side)
Perform Welding by FCAW.
For SIDEM MOBIN Evaporators the IPE Welding was performed by SMAW due
to which:

- External Touch up was more because of spatters

- Welding finish was not up to the satisfaction of customer

- Due to slag while surface cleaning K2 paste consumption was 30 Mts. / Kg

.whereas while cleaning the FCAW weld paste consumption was nearly 60
Mts./ Kg
CIRCULAR SEAM:

- Perform Fit –up without using clits on Inside surface .Do not weld it on internal
surface

- Perform it the same way as long seam is done.

- Make the fixture with 2-mm plate as shown in fig below

- Put it between the weld root gap

- Insert Wedge in both the sides

- Hammer the wedge until the plates of shell come in to level

- Tack weld the shells

- Use FCAW for making the joint to avoid spatters & consequent grinding
PREFABRICATION & IN SERTION OF CLOSED PARTITION PLATE:
PREFABRICATION & IN SERTION OF EN D COVER :
PREFABRICATION OF SECON D PASS VAPOR BOX :

PREFABRICATION OF C TYPE DEFLECTOR:

PREFABRICATION OF B TYPE DEFLECTOR:
PRFFBRICATION OF SCEEN WIN DOWS:
TUBE SUPPORT PLATES BUN DLE ON GROUN D:
IN SERTION OF TUBE SUPPORT BUN DLE IN SHELL:
PREFABRICATION OF LIFTIN G LUGS
PREFABRICATION OF OPEN PARTITION PLATE:
PREFABRICATION OF N OZZLES :
ASSEMBLY OF IN TERN AL VAPOR BOX WITH OPEN PARTITION
PLATE :
PREFABRICATION OF IN TERN AL VAPOR BOX CLOSED:
PREFABRICATIN OF IN TERN AL VAPOR BOX -WITH DOOR:
PREFABRICATION OF IGLOO:
PREFABRICATION OF IN TERN AL VAPOR BOX DOOR:
PREFABRICATION OF EXTERN AL VAPOR BOX DOOR:
PREFABRICATION OF EXTERN AL VAPOR BOX DOOR:

BEN DIN G OF SUPPORT OF TUBE SUPPORT PLATES:

While bending supports of tube support Plate I should be taken care that all
the supports are not bent in one direction. Half of the supports should be in
opposite direction
BEN DIN G OF Z TYPE DEMISTER SUPPORTS:

BEN DIN G OF SUPPORT OF Z TYPE DEMISTER SUPORT:

TURN OVER :
IN SERTION OF TUBE SUPPORT PLATE BUN DLE
IN SIDE SCAFFOLDIN G :
PREFABRICATION OF IN TERN AL CON DEN SER :
JOIN IN G OF CELLS:
PREFABRICATION OF WALKWAY STEPS :
WELDIN G WALKWAY STEPS WITH SHELL:
PREFABRICATION & IN STALLATION OF SPRAY PIPES :
PICKLIN G & PASSIVATION
TUBES IN SERTION :
PREFABRICATION OF ALUMIN UM LADDER CLAMPS &
ALUMIN UM LADDER :
ASSEMBLY OF EJECTO COMPRESSOR

IN STALLATION OF DEMISTERS:
IN STALLATION OF PIPES OVER DEMISTERS

PREFABRICATION OF EXTERN AL MAN HOLES :

IN STALLATION OF EXTERN AL MAN HOLES :