PROJECT

Method Statement for Flushing & Cleaning

of Chilled Water Piping

METHOD STATEMENT i
 Contents
PROJECT ........................................................................................................................................... i

Contents .......................................................................................................................................... ii

1 PURPOSE ................................................................................................................................. 1

2 SCOPE ...................................................................................................................................... 1

3 DEFINATION ............................................................................................................................ 1

4 RESPONSIBILITY ....................................................................................................................... 2

5 PROCEDURE ............................................................................................................................ 3

5.1 General Description ........................................................................................................ 3

5.2 Pre-Cleaning / Start-up Checklist .................................................................................... 3

5.3 Preparation ..................................................................................................................... 4

5.4 Initial Static Flushing with Plain Water ........................................................................... 4

5.5 Dynamic Flush ................................................................................................................. 5

5.6 Chemical Cleaning ........................................................................................................... 7

5.7 Final Inhibition ................................................................................................................ 8

5.8 Reinstatement of Plant Items & Back Flushing ............................................................... 9

5.9 Basic Tools And Equipment For Pipe Flushing Activity ................................................. 10

6 BRIEF DESCRIPTION OF FLUSHING PROCEDURE ................................................................... 11

7 APPENDIX .............................................................................................................................. 12

APPENDIX 1 Permit to Work (PTW) .......................................................................................... 13

APPENDIX 2 Job Safety Analysis (JSA) ....................................................................................... 14

METHOD STATEMENT ii
1 PURPOSE
The purpose of this statement is to document the correct procedure and
installation of Mechanical Work for Flushing & Cleaning of Chilled Water Piping
at ... project. Identify the reference documents or applicable codes and
standards, the construction of the ... under ...

2 SCOPE
This method statement is the necessary measures to ensure that all installation
activities
representative.

The scope of this plan is to provide a guideline for the implementation of quality
assurance on Flushing & Cleaning of Chilled Water Piping work that shall be
conducted in carrying out the work in accordance with the required materials and
workmanship specifications, approved MOS, and shop drawings.

3 DEFINATION

TERMS DEFINATION
Project
Owner
Consultant (RE)
Main Construction
MOS Method of Statement
MSA Material Submission Approval
Table 1 Definition

METHOD STATEMENT 1
4 RESPONSIBILITY
NO DESIGNATION QTY RESPONSIBILITY
Responsibility for Overall Commercial,
contractual & technical performances
1 Project Manager 1
associated with specific project. Reporting
to the Project Director.
Planning and supervising installation
2 3
M&E Engineer activities
Inspect, verify, and prepare work statement
3 QA/QC Engineer 1
for a quality installation works.
To provide toolbox and guidance to work
4 Safety Officers 1 and to ensure that work is carries out in a
safe manner
Obtain permit to work, control the
sequence
according to MOS, approved shops
Drawings, and MSA, ensure mechanical
aspect of the work are according to the
specification.
Ensure safe practices are followed and
5 Supervisor 3-5 ensure quality of workmanships during
execution.
Ensure material temporary storage and

practice / standard requirement.

Ensure all the tools being used for the
installation are calibrated and meeting the
.
To carry out all the mechanical aspect of
the Flushing & Cleaning of Chilled Water
6 General Worker 10-15
Piping

Table 2 Responsibility

METHOD STATEMENT 2
5 PROCEDURE

5.1 General Description

The Mechanical Work for Flushing & Cleaning of Chilled Water Piping to be
carried out at Project under

The objective of cleaning and flushing is to remove debris such as slit, sand,
scale, iron oxide deposit, weld slug and other contamination that are present in
new pipe work system.

5.2 Pre-Cleaning / Start-up Checklist

Before start-up of pre-cleaning activity, the following should be considered
as necessary

Check the availability of supply of continues fresh water (Temporary or

permanent as necessary.)
Check availability of power and electricity (Temporary or permanent as
necessary.)
Check the availability of labour/manpower
Check the installation work is completed.
Identify clearly feed and drain point
Make provision for drain from lowest points
Check availability of safety equipment at site and ensure that the workers are
trained in safety requirements.
Check operation of the system pumps or temporary flushing pumps as
necessary.
Check and identify all air vents present in the circuit.
Make the complete chilled water piping (new line) into a single slope by
making necessary bypass connection to the heat exchanger, AHUs, FCUs
etc.
The bypass connection should be sufficiently sized.

METHOD STATEMENT 3
 Check and ensure that all isolating valves enabling circulation in this circuit
and all of the valve condition are fully closed
Ensure that all precision valves and all cooling coils are bypassed as required
To the extent of its applicability on this job, safety precaution in handling of
chemical should be taken on the The person handling the chemical while
mixing shall wear gloves and goggles, Clean water will be made available at
the site by the contractor. The necessary handling information for the
chemical as provided in the MSDS shall be put up at the place where
chemical is being dosed into the system. The chemical specification will be
informed by pipe flushing vendor.
Samples and Sample containers: MEP Contractor shall submit samples in
clear bottles of a type that is locally available during various stage of the
treatment (as provided in the checklist.) These bottles will be labelled with
information of time and location of sample point.

5.3 Preparation
It is essential that in order to enable the flushing procedure to be completed
successfully, all the item listed in the pre-cleaning / flushing start-up check list which
are described as the above are provided prior to commencement of the process.
The process involves the following four states:
1. Initial static flush with plain water
2. Dynamic flushing
3. Chemical cleaning
4. Final inhibition and passivation
5. Re-instatement of plant items and back flushing.

5.4 Initial Static Flushing with Plain Water

Fill the system with plain water using either mains supply or tinkered water
and temporary pumps.
After filling the system drain the entire system should be carried out twice.
Fill the system again.
Circulate the system using the system pump for 8 hours

METHOD STATEMENT 4
 During circulation, The Y strainer in the pump suction must visually checked
and cleaned at least once an hour
After circulation open the drain valves at the lowest point in the system.
Flushed water should be disposed out of the storm water drain or disposal
tanks provided at site.
The system is the again refilled and dynamic flushing started

5.5 Dynamic Flush

Keep the system circulation, using the system flushing pumps
Open the clean water feed to the system ( or temporary feed if applicable )
Slowly open the drain valves at the lowest point in the whole system and
adjust it to adequate makeup and drainage.

Note: The drainage flow must never be more than the clean make up water flow as
to avoid system pressure loss and drainage During dynamic flushing it is important
that the velocity of the circulating water is sufficient to force all debris from the
system pipe works

Velocity Requirement:
The water velocity require for flushing must be sufficient to pick up and carry
the majority of the dirt debris in the system. Although it is quite feasible for much
larger particles to find way into the system, most of the debris will be below 5mm in
diameter.
The system pumps shall be able to match / achieve one of the following condition
given below.
A velocity in the system should be at least 10% higher than the design velocity, it will
achieve when all the permanent system pump are in operation, or a minimum
velocity so as to remove particles up to 5mm as per BSRIA AGI / 2001 please find
below minimum velocity to be maintained in the system with pipelines of different
nominal size.

METHOD STATEMENT 5
 NOMINAL PIPE SIZE (mm) VELOCITY (m/sec) FLOW RATE (L/sec)

15 0.96 0.20
20 1.00 0.37
25 1.03 0.60
32 1.06 1.08
40 1.08 1.49
50 1.11 2.45
65 1.15 4.25
80 1.17 4.98
100 1.21 10.47
125 1.24 16.41
150 1.26 23.98
200 1.31 45.00
250 1.35 73.00
300 1.37 107.00

Note: The system will have different pipe line but the above mentioned velocity
should be achieved in the larger pipe size of the system.

Flow reading must be taken at every available branch and riser measuring
station to ensure the correct velocities are being achieved.
If the pumps cannot match / achieved these parameters the system at the
same time it will necessary to manipulate the system by closing certain
section to force the pumps total flow through the open section of the system
thus achieving the required flow velocity, The closed section will be then be
opened and then the open section will be closed so the required velocities will
have been achieved across the system.

Note : The opening and closing must be carried out in this order to ensure no

Carry out filling, draining & circulating until the water is visibly clear.
During the dynamic flushing all strainer that have flow through them must be
checked and cleaned regularly until no more deposits are found in them.
Temporary filters to be checked and cleaned regularly during dynamic
flushing, on completion of dynamic flushing all must be isolated before
chemical cleaning.

METHOD STATEMENT 6
 The Water treatment third party will confirm acceptance of water quality,
which shall be as per parameters mentioned below or is the same quality as

PARAMETERS VALUE ( PPM )

Ph 7.5 8.5

Conductivity ( µ Siemens / cm ) Max 800

TDS (ppm) Max 400

Chlorides (ppm) Max 200

5.6 Chemical Cleaning

The main purpose of cleaning and flushing using chemical is to remove all the
debris and any other contamination that cant be remove with other method. Cleaning
using chemical to make sure the new pipe work system running in safe condition.
Prior to start-up of chemical cleaning, close all drain valves which were opened
during dynamic flushing.

Dose required quantities of cleaning agent (as suggested by chemical

supplier) using temporary tank / pump system or manual dosing pot. The
chemical B-12 @ 1 -1.5 kg / m³ of system volume and should be circulated 24
hrs and maximum of 72 hours.
The pump are switched on and will continue for a minimum period 24 hours
until the recorded dissolved iron level have plateau.
When dissolved iron level reaches a constant value clear the system of
contaminated water by carrying out the filling & draining procedure stated in
step B until the water sample taken from a minimum of 2 separate drain point
on the system show the water per parameters as mention below or is the
same quality as the water being filled into the system, whichever is of the
quality.

METHOD STATEMENT 7
 Flushed water can be disposed out to the storm water drain at the site subject
to compliance with the norms set by municipality for disposal of water,
otherwise it may be taken away by tankers and disposed of in a suitable
location.

PARAMETERS VALUE ( PPM )

Ph 7.5 8.5

Conductivity ( µ Siemens / cm ) Max 800

TDS (ppm) Max 400

Chlorides (ppm) Max 200

5.7 Final Inhibition

When the correct water condition had been achieved with the system
Circulation pump, close all the drain point
Passivation and microbiocide chemical shall be added at this point. Circulate
the water for 4 hours. Corrosion inhibitor chemical 2910 at the rate of 3.4 kg /
cu. mtr of the system volume. microbiocide chemical 651 to be added @ 0.05
kg / m³ of system volume.
Water sample has to be collected at the end at the end of this stage and if
found with dissolved iron level higher than the previous value (analysis to be

out to make the water clean.

period of 24 hours
r
minimum
700 ppm)

METHOD STATEMENT 8
 A final water analysis indicating all the required parameters shall be submitted
by the water treatment Third Party.

PARAMETERS VALUE ( PPM )

Ph 9.0 10.5

Conductivity ( µ Siemens / cm ) Max 3000

TDS (ppm) Max 2000

Dissolved Iron ( ppm as Fe) Max 0.5

Chloride ( ppm ) Max 200

Nitrite (ppm ) chem. 2910 Max 700 - 1300

Biological control
Chilled water system is an ideal breeding ground of bacterial and other micro-
organism and it is necessary to control biological growth in the system, Supplier
recommendation entail shock dossing of biocide chemical chem. 651 @ 0.05 kgs per
cu. mtr, The product is closed into the system using the manual dosing pot and is
closed once every three months in order to control the growth of micro-organism,
therefore, it is very important that residual level are constantly monitored and
maintained

5.8 Reinstatement of Plant Items & Back Flushing

When the correct water conditions have been achieved with the inhibition
reinstatement and back flushing of all plant items (Coils, heat ex-changer etc.) can
begin.
Ensure constant make up is supplied
Close the bypass
Open the flow isolation valve ensuring the return DRV is still fully closed.
METHOD STATEMENT 9
 Slowly open the drain cock and let water flow into the drain or container until it
is visibly clear.
Close the drain cock
Close the flow isolation valve
Open the return DRV
Slowly open the drain cock and let water flow into the drain or container until it
is visibly clear
Close the drain cock
Close all the valve serving the plant items, Remove the strainer (Where
applicable) clean and replaced
Open both the flow and return valve ensuring the flushing by-pass is fully
closed
Continue this step with every previously isolated plant item on the system.

Note: After re-instatement of all plant items the level of inhibitors must be re-checked
and re dosed as necessary.

5.9 Basic Tools And Equipment For Pipe Flushing Activity

To start this activity, this following tools and item can be use for this activity :
Tool box / tool kit
Meters / gauges
Power tools
Temporary pump
Chemicals

METHOD STATEMENT 10
6 BRIEF DESCRIPTION OF FLUSHING PROCEDURE

Water Filling

Potable water will be filled from a high point in the chilled water line preferably in the
AHU room or downstream of the drain point. The filling point position is critical and
care must be taken to ensure that fresh water make up water is not drained
immediately after filling.

Source of Water

Existing potable water supply available in the station will be used. Otherwise water
will be supplied from tankers. And it would be compensated against the total system
volume

Circulation Water

Water will be circulated with the help of the system pumps, during circulation, care
should be taken that water temperature does not rise to an unsafe limit for pump. In
such case, either the circulation should be temporary stopped; otherwise water
should be partially drained and refilled with freshwater.

Drainage of Water

Water will be drained from the low point in the system, The water can be drained into
the floor drain line, It can be also collected in a small tank and pump out to soak
away ground outside the building, Third party ( Specialist in water treatment ) will
guide whether the quality of water is suitable for drainage into sewer system / storm
water system or for land pump system. drainage, if it is not possible to drain into this
system, Then the drained water will be collected in a tank and will have to be taken
out of station premises for disposal by tankers to comply with the local drainage
practices.

METHOD STATEMENT 11
Bypass the Vital Equipment

Bypass line is provided for every AHUs and FCUs. The main inlet and outlet valves
of cooling coil will be closed. Bypass valve will be opened. Wherever bypass line is
not provided, the supply and return water pipelines will be disconnected from the unit
and connected to each other with a temporary hose or pipe.

Air Vents

The air vent is provided at selected high point and will be used for air entry and exit
during drainage and filling operations.

Water will not be circulated through the Cooling coil and plate heat exchangers until
the pipe are clean and the quality of water is reasonably good.

7 APPENDIX
1. APPENDIX 1 Permit to Work (PTW)
2. APPENDIX 2 Job Safety Analysis (JSA)

METHOD STATEMENT 12
APPENDIX 2 Job Safety Analysis (JSA)

METHOD STATEMENT 12