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METHOD STATEMENT FOR FLUSHING & CHEMICAL

CLEANING PROCEDURE OF CHILLED WATER
SYSTEM

Project :
MEP Contractor :
Document No. :

Document revision status : 0

0 06-22-2008 Issued for Review & Comments

Prepared by Checked by Approved by

Rev. Date Description

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REVISION CONTROL SHEET

REV. NO. DATE PAGE NO. DESCRIPTION

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TABLE OF CONTENTS

1. Scope ………………………………………………………………………………… 4
2. Responsibilities....………………………………………………………………….. 4.5
3. Equipment & Materials……......…………………………………………………… 5
4. Objective……………………………………………………………………………… 5
5. Flushing……………………………………..……………………………………….. 6.7
6. Chemical Cleaning.………………………………………………………………… 8.9
7. Health & Saftey……………………………..…….…………………………………. 9
8. Attachment…………………………………………………………………………… 9

1. SCOPE :

1.0 This method statement specify the detailed requirements and procedures for
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Performing flushing & chemical of all above & under chilled water piping
system with in this project.
1.1 After completing this work of chilled water piping will be ready for the
commissioning and start up.

2. RESPOSIBILITIES:

2.0 The Construction Manager will ensure all preparations & installation works
are carried out according to Project Specification , the progress are carried
out according to the planned program, as per approved method statements
to cooperate with the Main Contractor regarding the implementation of any
comments raised by the company & to ensure all safety & quality
control are implemented.
2.1 The Site Engineer will ensure that the installation works are carried out
according to Project Specification ,Manufacturer data sheet , Approved
Method Statement , Safety Regulations & to distribute responsibilities
to his construction team & provide them with information for the installation
works.
2.2 To ensure the compliance of works with the related approved quality
control procedure & Company requirements & to coordinate with the Q.C.
Engineer to advise for the area raise for inspection.
2.3 To inspect & satisfy of the soundness completed works before requesting
Main Contractor to seek company approval & inspection.
2.4 To initiate inspection & test request from the Company approval through
the Main Contractor.
2.5 To advise the construction team of the specific requirements related to
work quality.

2.6 To maintain comprehensive inspection & test record any further reference
& documentation.

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3. EQUIPMENT & MATERIAL :

3.0 Pump for pumping out flushed water.

3.1 Storage tank to drain flushed water.
3.2 Manual chemical dosing pot.
3.3 Clean water for flushing.
3.5 Chemical to be used.(as per manufacturer recommendation) for approval.

4. OBJECTIVE:

4.0 During construction of pipe work some contaminant will inevitably enter
in to the piping system like dust, welding slag, jointing compound, dirt &
debris. These contaminant if not removed form the system might affect the
performance of the system & shortening the life of the equipment with in
water system, block the cooling coils &wearing of pump blades.
4.1 The objective if flushing is to produce a clean water system free from all
these contaminants to obtain efficient operation.
4.2 However, flushing the system will not remove metal oxides, scales & other
deposits that adhered to the internal pipe surface.
4.3 Therefore, Chemical cleaning is initially required to remove all this deposits
from the pipe.

5. FLUSHING :

5.0.0 Visually check of all piping system must be ready for flushing, all

drain valves must be closed, all isolating valves & strainers are
accessible, and all temporary work must be removed.
5.0.1 Closed isolated valves serving fan coil unit and air handling unit &
bye pass chiller.
5.0.2 Chiller water system must be flushed with clean water as
follows:

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5.0.2.0 The source of water must be in the existing water line

supplying water from the construction. (If permanent
connection from package on need to connect from portable
water connection)
5.0.2.1 The filling point shall be in one of the chiller return or supply
piping test points or pump piping connection test point.
5.0.2.2 If the pressure of the existing line is less than 4 bars, a
temporary shall be used to introduce water in to the system.
5.0.2.3 Ensure that all points in the system that received water
including piping are fully vented water shall be kept for half
an hour.
5.0.2.4 All chilled water pipe system shall be filled with water
including above & underground lines for all building
connected to the chilled yard.
5.0.2.5 A) Drainage water in the chilled yard should be in the drain
valves for the pump & chillers.
B) Drainage water in the building should be from the drain
valve located in the ground floor main access shaft above
the butterfly valve & balancing valve.
5.0.2.6 Draining from pipe system (incase the package 1 is not
ready)we must use flexible hose connection to drain point of
the chiller yard and drain it in a temporary storage tank
located outside the building.(Utilizing one of the drain
manholes as connection pit).This water shall be pumped to
the tanker and carried away to be drained in the area were

no body will be hurt including the environment. The same

procedure used for draining water in the building.
5.0.2.7 Draining the same way continuously until the system
completely empty of water.
5.0.2.8 Refill the chilled water pipe system with water and flush
again.

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5.1 Dynamic Flushing:

5.1.0 The chilled water system shall be filled with water as described
In section 5.0.2.0 & 5.0.2.1 , air vented and circulated using
one primary pump in to 2 hours. ( Temporary pumps must be
used in initial flushing around the chilled bypass line if its
possible to start the permanent pump until the time of
flushing). Make up water shall be available to compensate
simultaneously.
5.1.1 Strainer screen within the system must be cleaned interval
regularly until the screen shows on dirt inside.
5.1.2 Drain valves for pumps & chillers on ground floor of each
building main entrance shaft must be open to drain one a time
to obtain maximum velocity. Circulation must b continuously
filling and drain.
5.1.3 Flushing this way ( Circulating & Draining ) must be continue
for at least a period of 24 hours.
5.1.4 Water sample must be clear from suspended matter and also
must be accept by the water treatment specialist prior to the
start of chemical cleaning.

6. CHEMICAL CLEANING

6.0 Initial Chemical Cleaning :

6.0.0 Chilled water system must be drain partially and fill with clear water.
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6.0.1 Chemical cleaning material ( Ferroquest 5236 ) must be added

( using 5 liter of manual dosing pot in the chiller yard chemical room )
to the water system while its being filled.
6.0.2 Using 5 liters of manual dosing pot, dose of Ferroquest 5236 at a
rate between 10 to 20 kg / 1000 liters volume of water depending on
the severity deposits to be removed as consulted by the water
treatment specialist.
6.0.3 Continue of water until the system is completely filled.
6.0.4 Circulate the treated water for the period of 24 to 36 hrs , then open
the drain valves the pumps in the ground floor main entrance shaft of
its building &b flush while make up water continue to compensate.
6.0.5 The flushed & treated water must be drained using hose connected
to temporary storage tank ( utilizing one of the tanker and carried
away to dump site location were no people & environmental
contamination.
6.0.6 During the clean up & final flush up , laboratory test is to be carried
out until the water treatment specialist accepted.

6.1 Chemical Dosing :

6.1.0 After successfully completing the chemical cleaning process as

stated in the above , pumps to be dosed ( using the manual 5 liters

dosing pot ) with the treated chemical CORRSHIELD NT 4292 and
SPECTRUS NX 1442.
6.1.1 Dosage of CORRHIELD NT 4292 must be 3.5 kg / cu. M. of water
volume.
6.1.2 For SPECTRUS NX 1422 , dosage must be 100 ml . / cu M of water
Volume.
6.1.3 Treated water be circulated for the period of two hours, water sample
will be check by the water treatment specialist to confirm the

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corrosion inhibitor level is with in correct range .

6.1.4 When the final water sample is acceptable by the water treatment
specialist the result of the water test will be submitted to the
company.

7. HEALTH AND SAFETY

7.0 All installation will in accordance with project safety plan and the
Main Contractor Safety Rules and Regulation.
7.1 Strictly follow manufacture Contractor Safety recommendation for handling
and use of the materials.
7.2 Ensure all involve personnel are aware of the same.

8. ATTACHMENT

8.0 Attachment checklist for flushing and chemical cleaning :

8.0.0 Checklist of Flushing

8.0.1 Checklist for Commissioning.
8.0.2 Water sample test format
8.0.3 Safety data sheets for Chemical.

--------------------------- Procedure Ends --------------------------------------

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