Method of Statement for Chilled Water Flushing

CONTENT
1. Method Statement for Chilled Water Flushing
2. Risk Assessment
 SECTION: 1

METHOD OF STATEMENT FOR CHILLED WATER FLUSHING

  OBJECTIVE/ PURPOSE

The purpose of this method statement is to define the procedure step by step to implement the correct
practices for “Flushing and Chemical Cleaning of Chilled Water system ” through the guidelines contained
herein so as to ensure that the chemical treatment process complies with the procedures to satisfactory
level.
The aim of the method statement is to set out the procedures, precautions to observe during unloading,
storage, lifting and shifting of flushing equipment and chemicals to desired locations and installation
sequence.
The Procedure for offering for Flushing & Chemical Cleaning of Chilled Water system for Inspection the
procedure will be as per the Specifications and Requirement of Engineer.
All works will be carried out in accordance to Site Safety rules and regulations as guided by Main
Contractor HSE Management.

 SYSTEM DETAILS

System Volume: 15 m3

 PRE REQUISITS TO PROCEDURE

• CONSTRUCTION MANAGER:
To liaise with the main contraction/consultant/client and ensure implementation of any comments concern
raised by flushing activities.
To coordinate with the client’s representative, site engineer, Quality controller, safety officer, foreman for
the safe operation of flushing

• SITE ENGINEER:
The provide necessary information and delegates responsibilities to the testing team and to ensure
compliance of the works with the related approved method statements and further coordinate with the
quality controller. To be aware about the sequences and related testing/inspection frequencies and to
mark up as necessary the schematic drawings or appropriate general arrangement in drawings showing
the proposed system/section to be flushed.

• QUALITY CONTROLLER:
To inspect and ensure full compliance of the works with the related approved method statement and
quality procedures
To ensure that the required testing have been conducted according to the approved method statement.

• SAFETY OFFICER:
To make sure that site personal are aware of their responsibilities and having adequate understanding of
the related safety procedures to maintain continuous inspection of the site activities, advise and train the
involved persons to prevent accident or property damage.
  Preparation for Flushing and Cleaning
Installation Check List:
The following preparation checks / works will be carried out prior to commencement of flushing and
cleaning of chilled water system.

• Check and ensure the system is hydrostatically pressure tested and verify Hydro test report.
• Check all in – line valves are in full open position and drain valves are closed.
• Check the provision of air vents at location as per approved drawings and the air vents shall
be welded at highest points in the temporary header connection if necessary.
• The equipment’s like chillers, chilled water pumps, heat exchangers, FCU, AHU etc., will be
isolated or bypassed during the flushing and cleaning process by suitable bypass
arrangement.
• Check and ensure sufficient quantity of chemicals is available as per the requirement.
• Check and ensure the power is available for flushing activity
• Check and ensure water required for flushing activity is available at site
• Check and ensure temporary filling pump is connected to the system
• Check and confirm availability of filling tank and drain tank at site.

 PRE STARTUP CHECKS LIST

1. Ensure that the installation work has been completed and system is leak free & filled with water with
chemicals (More details on section 5)
2. Ensure that all pipes are adequately supported.
3. Ensure availability of continues supply of fresh water via tankers/municipality water and schedules the
same. Check the water quality before using into the system for reference.
4. Ensure the availability of continuous power for makeup pump and circulation pump.
5. Electricity for site lighting.
6. Confirm the availability of operational labor/manpower at site.
7. Confirm the availability of chemicals.
8. Confirm the availability of drainage & disposable tanks for drainage.
9. Confirm the availability of bag filters on site, 25 10, 5, micron to save water and remove suspended
particles.
10. confirmed the future connections, dead end and equipment’s are looped.
11. Confirmed availability of safety equipment’s at site and ensure that workers are trained in safety
requirement.
12. Confirm automatic Air vents are installed at end of each loops of the branches and highest point
 METHOD STATEMENT

 MAKE UP WATER TESTING

Before commencement of flushing activity the makeup water available at site is tested
And confirmed if it matches with details provided in ANNEXURE 1 table1

 FLUSHING STAGE

The system is initially filled water plain water and once full and air removed the system is then
drained from lowest point of the circuit
The above procedure is done to remove large particulate matter from system
The above procedure is repeated 1-2 times till it is confirmed that there is no large particles in
the system being flushed

 DYNAMIC Flushing:
After static flushing the system is refilled and air removed , the circulation will start.

During this stage the filter will be passed by in order to the entire large particles pass and to be
removed from the system.

The above procedure is continued till the water parameters are achieved as detailed in
ANNEXURE 1 table 2.

 Cleaning Chemical Stage:

Once water quality as per dynamic plain flushing stage has been achieved the dynamic
flushing will be stopped. The cleaning chemical HYDREX 5208 will be dosed to the system
with circulation period of 24 hours and during circulation samples are taken every 12 hours
to check the progress of cleaning .

After 24 hours of circulation with cleaning chemical, dynamic flushing will restart and
continued in order to maintain the water quality as detailed in ANNEXURE 1 TABLE 3 is
achieved
  Water Disposal for the cleaning process:
Under no circumstances should chemical waste / drain be discharged into surface water drains. Unless prior
approval is taken with regard to the water quality. As a normal practice waste water after chemical cleaning
is discharge to using tankers.

After cleaning process water quality is achieved the passivation chemical HYDREX 2924 will be
added and circulate the system for 24 hours.

During this stage filter bags are installed in the bag filer system The system after the
stipulated residence time is dynamically flushed till water quality reaches value as
detailed in ANNEXURE 1 Table 4.

 Final Chemical Stage:

Once water quality as detailed in ANNEXURE 1 TABLE 4 is maintained HYDREX 7310 (Biocide
chemical will be added with circulating the system for 1 – 2 hours. After that HYDREX 2856 will be added as
Final chemical (Corrosion Inhibitor).
In addition to that water analysis will be applied in order to confirm that all the parameters are
within the recommended limits as detailed in ANNEXURE 1 Table 5.

 The System Treatment till the hand over:

If the system is not to be put into normal operation for a prolonged period, (i.e.) more than one month, then
the system water should be regularly monitored and circulated during this time, and if necessary further
dosed until the system is handed over and put into normal operation.

 Sampling Frequency:

One sample would be collected during the following stages for testing & approval purposes.
1) Plain water flushing.
2) Cleaning Chemical Circulation.
3) Final Flushing
4) After addition of Final Chemicals to the system.
  SAMPLING POINT S

Samples shall be collected randomly from the following locations.

1) Lowest Point
2) Farthest point
3) Top of circuit
4) Random sample from F.CU, AHU and AHU.

 Method of Statement Summary:

The flushing & chemicals cleaning of the each loop/ section of pipe work comprises of following
important stages.

Sr Name of chemical
Stage description Remark
Nos to be add in stage
1 Plain water flushing / static --- Water test result with water sample
flushing need to submit consultant approval
for next stage start
2 Plain water Dynamic flushing --- Water test result with water sample
need to submit consultant approval
for next stage start
3 Chemical cleaning Addition Water test result with water sample
VEOILA WATER need to submit consultant approval
SYSTEM
for next stage start
4 Post cleaning chemical dynamic Water test result with water sample
flushing - Addition of passivation VEOILA WATER need to submit consultant approval
SYSTEM
chemical-Back flushing for next stage start
5 Corrosion inhibitor addition and
Water test result with water sample
biocide addition VEOILA WATER
SYSTEM need to submit consultant approval
Final flushing stage
  SCOPE MATRIX

item Description OTC Veolia Remark

A-preliminary preparation
By pass installation, looping, all
1
mechanical works
Pressure testing the chilled water pipe
2
network.
Preparing the assigned area for placing
3
the flushing equipment’s
Provision of drain points and air vents at
4
suitable points of circuits.
Deliver the Temporary Flushing
Equipment Like Pump, Hoses, Filter,
5
Bag Filters, etc. (as detailed in the
technical offer)

6 Unloading & placing the cleaning skid

Achieving the connection between

7 cleaning equipment’s & the connection
to the chilled water pipeline.
Deliver the chemical required for all
8
Stages.
9 Installation of sampling points

10 Remove sensitive parts from circuit

Assuring that all valves and passes in
11
the circuit are in fully open position
12 All necessary work permit for the site
 Scaffolding and addition support if
required for any leaks during the entire
13
flushing process.
14 Method statement
Bypass arrangement for all terminal
15
units including FCU and AHU (if
Abblicable).
B-process
1 Providing power for flushing

2 Waste water disposal

3 Providing fresh water

4 Supply of temporary electrical pumps
Providing the service engineer for
5
supervision
Supply of temporary filling of booster
6
pump for makeup water
Supply of bag filtration system with
7
bags
Supply of waste and fresh water
8
storages tanks
Analysis required in all stages of the
9
Flushing process.
ANNEXURE 1

 The Parameters During Each Stage:

• Makeup water quality
Parameters Values
pH 6.5 – 8.50
Conductivity (µ s/cm < 500
TDS ppm < 350
Total Iron, ppm < 0.1
Appearance Colorless
Chloride ppm Max 150
Suspended solids <5

• Water quality before adding cleaning chemical:

Parameters Values
pH 7 .5-10
Conductivity (µ s/cm < 1500

TDS ppm < 1000

Total Iron, ppm < 5.00

Suspended solids < 50
• Water quality before adding the passivation chemicals:

Parameters Values
pH Above 8.5
Conductivity (µ s/cm < 1500
TDS ppm < 1000
Total Iron, ppm < 2 .00
Appearance Clear
Suspended solids < 20

• Water quality before adding final chemicals:

Parameters Values
pH 8.5 to 10.50
Conductivity (µ s/cm < 2250
TDS ppm < 1500
Total Iron, ppm < 1 .00
Appearance Clear
Suspended solids < 20
Nitrite NA
 • Water quality after adding the final chemicals:

Parameters Values
pH 8.50 to 11
Conductivity (µ s/cm For reference
TDS ppm For reference

Total Iron, ppm < 1 .00

Appearance Clear/pink
Suspended solids < 20
Nitrite ppm Min 600 ppm No2

Chilled water Cleaning & Passivation Check list:

 PRE OPERATIONAL CHECK

S No ACTIVITY REMARKS
1 Check if Installation of system is complete
2 Check Availability of Fresh water
3 Check if valves or system with close tolerance are
removed or bypassed
4 Check availability of fresh water and power
5 Check connection for makeup and Tank for fill up
of system
6 Check availability of drain points in the circuit
7 Check if end point of circuit are looped for
circulation
8 Check operation and availability of air vents
9 Provide hose connection from drain points
10 Check availability of chemicals at site
11 Check availability of safety equipments at site
12 Check temporary bag filter connection and
operations
13 Check operation of circulating Pumps
 Make up WATER STAGE

S No ACTIVITY REMARKS
1 Fill the system with fresh water
2 Drain the system water
3 Repeat above step till large particulate matter is
removed from the system
4 Fill the system again with fresh water
5 Start the inline circulation pumps
6 Circulate for 24 Hours
7 Start dynamic flushing
8 Once water comes reasonably clear put the proceed
to next step
9 Check quality of water
10 SWT to submit report

 CHEMICAL CLEANING STAGE

S No ACTIVITY REMARKS
Close all drain points which were open during
1
plain water flushing
2 Add cleaning chemical as per recommendation
Start circulation pumps and avoid opening drain
3
during chemical circulation
Advice workers and people not to use water from
4
system via posters and circulars
Circulate system water with cleaning chemical for
5
48- 72 Hours
6 After 48 hours SWT to submit report
7 SWT to advice start of draining the system
 PASSIVATION CHEMICAL TREATMENT

S No ACTIVITY REMARKS
After chemical cleaning drain the system
1
completely
2 Refill the system with fresh water
3 Start circulating pump and start dynamic flushing
4 Put bag filter in line and continue flushing
Once cleaning chemical traces are removed add
5 passivation chemical and circulate without
draining for 6- 8 hours

6 Start dynamic flushing again

7 Continue till water runs clear

8 SWT to submit report
Back flushing of FCU, AHU.HE and chillers /
9
condenser to commence
10 Water quality to be tested by SWT

 FINAL CHEMICAL STAGE

S No ACTIVITY REMARKS
1 After Required water quality is achieved
Add final Inhibiting chemical & Micro biocide and
2
circulate for 6 hours
3 After 6 hours take sample for test
4 Final Check and certification by contractor
  WATER ANALYSIS REPORT FORMAT:

CLIENT: NO: DATE:

ADDRESS:
SITE/PLANT:
CONTACT:
TEL: FAX:
SYSTEM:
CONTROL Plant
PARAMETER
LIMITS Room
Appearance / Colour
pH 9-10.5
P' Alkalinity, ppm as CaCO3
M' Alkalinity, ppm as CaCO3
Total Hardness ppm as CaCO3
Calcium Hardness, ppm as CaCO3
Calcium, ppm as Ca²⁺

Magnesium, ppm as Mg²⁺

Total Dissolved solids, ppm <2000
Cond. µs/cm
Chloride, ppm as Cl
Copper, ppm as Cu
Iron, ppm as Fe <1
Silicate, ppm as SiO2
Nitrite, ppm as NaNO2 800-1200
Molybdate, MoO4 ppm
Orthophosphate, PO4 ppm
Phosphonate, ppm
Total Suspened Solids, ppm <20
Turbidity, FAU

Observations & Recommendations

 SECTION: 2

RISK ASSESSMENT AND HEALTH AND SAFETY CONTROL MEASURES

 Health and Safety Control Measures
• Safety
Safety risk assessment will be performed for every job or task, which has the potential for
harm.
Ensure Personal Protective Equipment (PPE) is available with all the workers involved in the
installation / erection work.
All required equipment and tools should be checked before start of work for suitability and
integrity.
All safety Guide lines will be adhered
Necessary permits to work to be obtained as per the site requirement
Ensure all MSDS will provide during the task performance and training is done to explain
MSDS and COSHH.

• Risk Assessment
In addition to their safety induction received at their arrival on site, all workers will have a
toolbox meeting and briefed about the risks of their specific work task, prior to start of works.

• Protective & Safety Equipment

Handling of chemical equipments - safety boots, safety helmet, safety goggles, rubber hand
gloves, overalls, Loading, unloading and shifting of flushing equipments - safety helmet, safety
boots, and safety hand gloves