Project: Ruwais Refinery Expansion MEP Consultant : Takreer
Method Statement Title: Date :19.06.2012
Chilled Water Flushing/Cleaning
Project : Ruwais Refinery Expansion
MEP Consultant : Takreer
Water Treatment Specialist : Water Bird Water Treatment Chemicals
L.L.C.
P. O. Box. 27126
Al Quoz Industrial Area
Dubai, United Arab Emirates
Tel: 04 - 3405961
Fax: 04 - 3405962
Email:
[email protected] TU
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CHILLED WATER SYSTEM
Introduction
This statement provides a method for the cleaning, flushing and Passivation for the
HVAC chilled water system in the stations to be followed by Water Bird.
Objective
The objective of cleaning, flushing and passivation is to remove debris such as silt,
sand, scale, iron oxide deposits, weld slag and other contaminant that are present in a
new pipe work system. The passivation process inhibits the system from corrosion.
The process of pre-operational flushing and cleaning becomes more important as if
these contaminants are to remain in the system then it directly effects the cooling
system efficiency and reduces flow through the system.
These contaminants also prevent formation of uniform protective passivating layers
which further leads to corrosion in the system.
Based on the above, it is of paramount importance to ensure that a proper pre-
operational cleaning/flushing programme is carried out before the system is put into
normal operation.
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METHOD OF OPERATION
PRE-CLEANING/FLUSHING START UP CHECKLIST
General
Before startup of any pre-cleaning activity, the following should be considered:
1. Check availability of supply of continuous fresh water (Temporary or
permanent as necessary).
2. Check availability of power and electricity (temporary or permanent as
necessary).
3. Check availability of labour/manpower (24 hours basis).
4. Check availability of chemicals required for flushing/cleaning operation at site.
5. Check installation work is completed.
6. Identify clearly feed and drain points.
7. Make provision for drain from lowest points.
8. Check availability of safety equipments at site and ensure that the workers are
trained in safety requirements.
9. Check operation of system pumps or temporary flushing pumps as necessary.
10. Check and identify all air vents present in the circuit.
11. Install temporary cartridge filtration units.
12. Make the complete chilled water piping (new line) into a single loop by
making necessary bypass connections to Heat Exchangers, AHU’S FCU’S etc.
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13. The bypass connection should be sufficiently sized.
14. Check and ensure that all isolating valves enabling circulation in this circuit are
fully open.
15. Ensure that all precision valves and all cooling coils are bypassed as required
**) Please provide the flushing bypass.
16. To the extent of its applicability on this job, safety precautions in handling of
chemicals should be taken on site. The persons handling the chemicals while
mixing shall wear gloves and goggles. Clean water will be made available at
site by the contractor. The necessary handling information for the chemicals
as provided in the MSDS shall be put up at the place where chemicals are
being dosed into the system.
17. Samples & Sample Containers: MEP contactor shall submit samples in clear
bottles of a type that is locally available during various stages of the treatment
(as provided in the checklist.) These bottles will be labeled with information
of time and location of sampling point.
Preparation
It is essential that in order to enable the flushing procedures to be completed
successfully, all of the items listed in pre-cleaning/flushing startup checklist which are
described as above are provided prior to the commencement of the process.
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Method Statement for Chemical Cleaning/Flushing
The processes involve the following four states:
A) Initial static flush with plain water.
B) Chemical cleaning.
C) Dynamic flushing.
D) Re-instatement of plant items and back flushing.
E) Final inhibition and passivation.
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A) Initial Static Flush with Plain Water
The initial static flush should be carried out as detailed below:
Static Flushing Method
• Fill the system with plain water using either mains supply or tankered water.
• Circulate the system using the temporary pumps for 8 hours.
• After circulating open the drain valves at the lowest point in the system.
• Flushed water should be disposed out in the storm water drain or disposal
tanks provided at site.
.
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B) CHEMICAL CLEANING
• Dose required quantities of cleaning agent (as suggested by chemical supplier)
using temporary tank/pump system or manual dosing pot.
• Add CS-39 @ 1.5 kg/m³ of the system volume.
• The pumps are switched on and will continue for a minimum period of 24
hours.
• Flushed water can be disposed out to the storm water drain at 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.
C) DYNAMIC FLUSHING
• Keep the system in circulation, using all the flushing pumps.
• Open the clean water feed to the system (or temporary feed if applicable).
• Slowly open the drain valves at the lowest points in the whole system and
adjust it to equate 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.
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• Carry out filling, draining & circulating until the water is visibly clear and
the below parameters are met.
• After dynamic flushing is over the system to be circulated for 2 hrs (static
flushing) and check the water quality and clean the strainer.
• Temporary filters to be checked and cleaned regularly during dynamic
flushing, On completion of dynamic flushing all temporary filters must be
isolated.
• Water Bird to test and confirm acceptance of water quality, which shall be as
per parameters mentioned below
PARAMETERS VALUE (ppm)
pH 7.5-8.5
Conductivity, (µ siemens/cm) Max 800
TDS, (ppm) Max 400
Dissolve Iron, (ppm as Fe) Max 0.5
Chlorides, (ppm) Max 200
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D) Re-instatment of plant items & back flushing
• Ensure constant make-up water is supplied
• Go to each individual plant item and attach a hose to the return pipe-work drain
off cock, ensure the un-attached end is in a drain or suitably sized container to
take more than the volume of the items coil and flow & return pipe-work twice.
• Close The by-pass
• Open the flow isolation valve ensuring the return DRV is still fully closed.
• 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 valves serving the plant item, Remove the strainer (where applicable)
clean and replace.
• Open both the flow and return valves ensuring the flushing by-pass is fully closed.
• Continue these steps with every previously isolated plant item on the system.
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E) Final Inhibition
• Passivation & Microbiocide chemicals shall be added at this point. Circulate the water
for 4 Hours. Nitrite Molybdate Corrosion Inhibitor chemical CLT-540 to be added to
5 Kgs./m³ of system volume & microbiocide chemical ML-13 G to be added @ 100
ml/m³ of system volume.
• Keeps the system in circulation including all the equipments for a minimum
period of 12 hours.
• Water samples have to be collected from designated areas and Water Bird shall
confirm the corrosion inhibitor level.
• A final water analysis indicating all the required parameters shall be submitted
by Water Bird.
PARAMETERS VALUE
pH 8.5- 9.5
Conductivity, (µ siemens/cm) Max. 3000
TDS, (ppm) Max. 2000
Dissolved Iron, (ppm as Fe) Max 0.5
Chloride, (ppm) Max. 200
Nitrite, (ppm) Min. 250
Molybdate (ppm) Min. 50
