METHOD STATEMENT FOR
CHILLED WATER FLUSHING
PROJECT NAME: G+3 GEMS METROPOLE SCHOOL ON PLOT NO. 6653091 AT WADI AL
SAFA 7, DUBAI. U.A.E.
M/S GEMS EDUCATION (PREMIER SCHOOLS INTERNATIONAL L.L.C)
CLIENT:
CONSULTANT M/S SUSTAINABLE ARCHITECTURAL & ENGINEERING L.L.C
MEP CONTRACTOR M/S HEAT & POWER TECHNICAL SERVICES LLC
INDEX
S.No Description
Method Statement
1 Method Statement for Chilled Water Flushing.
2 Chilled Water Flushing -Temporary Set Up drawing
3 Details of the temporary Equipment’s
4 Chilled Water Flushing Chemicals – MSDS & PDS
5 Chemical Flushing Project Reference
6 Previous Approvals
Method statement for Chilled Water Flushing REF: CC-MS-CHW-FLU-97-2023
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METHOD STATEMENT
Method statement for Chilled Water Flushing REF: CC-MS-CHW-FLU-97-2023
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Introduction:
This statement provides a method for the pre‐operational cleaning and chemical treatment
for the HVAC chilled water system in the stations to be followed on this site.
Objective:
The objective of pre‐operational chemical cleaning and flushing is to remove debris such as
silt, sand, scale, iron oxide deposits, weld slag and other contaminants that are present in a
new pipe work system during the construction stage. The process of pre‐operational flushing
and cleaning becomes more important as if these contaminants are to remain in the system,
then it directly affects the cooling system efficiency.
Process Overview:
The Secondary Chilled Water flushing will be done as single circuit as detailed below. The
temporary pumps with bag filters will be used to flush the Chilled water circuit.
No System Details Max Pipe Size Required Flushing Flushing Flow System Volume
Flow
1 Chilled Water circuit 300 mm 110% of design flow 740 m3/hr 60 m3
182 l/s
Initial Flushing with Chemical Cleaning Dynamic Flushing
Plain Water
Reinstating the
Final Inhibition and Final Flushing permanent
Passivation Equipment
Method statement for Chilled Water Flushing REF: CC-MS-CHW-FLU-97-2023
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0
PRE‐CLEANING/FLUSHING START UP CHECKLIST
Before startup of any pre‐cleaning activity, the following should be reviewed:
Ensure that all the piping is completed, and pressure tested.
Check availability of supply of continuous fresh water (parameters as DEWA water
supply).
Check availability of power and electricity.
Check availability of labor/manpower (24 hours basis).
Check availability of chemicals required for flushing/cleaning operation at site.
Identify clearly Fresh water inlet point and drain points.
Make provision for drain from lowest points.
Ensure that drainage provision as per the local regulations.
Check the temporary pumps are installed instead of the system pumps and the
temporary make up pump is connected in the suction line of the temporary pump,
Check and identify all air vents present in the circuit.
Install temporary filtration unit in the discharge line of the temporary pump.
Ensure that filter bags are available at site.
Check and ensure that all isolating valves enabling circulation in this circuit are fully
open.
METHOD STATEMENT FOR CHEMICAL CLEANING/FLUSHING
The processes involve the following four states:
A. Initial flushing with plain water.
B. Chemical cleaning.
C. Dynamic flushing.
D. Re‐instatement of plant items and back flushing of FCU’s and AHU’s.
E. Final inhibition and passivation.
Method statement for Chilled Water Flushing REF: CC-MS-CHW-FLU-97-2023
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A) INITIAL FLUSHING WITH PLAIN WATER
The initial static flush should be carried out as detailed below:
Fill the system with plain water using tanker/water available on site for
Circulate the system using the temporary pumps for 8 hours.
After circulating open the drain valves at the lowest point in the system and fill the fresh
water using the temporary make up pump connected to the suction of temporary
circulation pump.
Flushed water should be disposed using the tankers.
Coolchem Engineer to be test the below parameters before adding the cleaning chemicals.
PARAMETERS VALUE (ppm)
Conductivity, (µ Siemens/cm) < 800
TDS, (ppm) < 550
Total Iron, (ppm) < 5 ppm
Nitrite ppm as NaNO2 Nil
B) CHEMICAL CLEANING
Clean water must be witnessed prior to dose Accepta 2877.
Dose required quantities of cleaning agent Accepta 2877 @ 1 kg/m³ of the system volume
using temporary bag filtrations system.
Keep the system in circulation for 24-48 hours.
The Flushed water should be disposed using the tankers.
Up on completion of the above , dynamic flushing to be started.
C) DYNAMIC FLUSHING
Fill the system again with plain water using tanker water or Water available on site for
drinking water.
Keep the system in circulation, using all the temporary flushing pumps.
Slowly open the drain valves at the lowest points in the system and adjust it to equate
makeup and drainage.
Note: The drainage flow must be at the same rate as of make‐up water in order to avoid
system pressure loss.
Temporary filters to be checked and cleaned regularly during dynamic flushing.
After dynamic flushing is over check the water quality and clean the strainer.
Carry out filling, draining & circulating until the water is visibly clear and the below
parameters are met.
Method statement for Chilled Water Flushing REF: CC-MS-CHW-FLU-97-2023
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PARAMETERS VALUE (ppm)
Conductivity, (µ Siemens/cm) < 800
TDS, (ppm) < 550
Total Iron, (ppm) < 2 ppm
Suspended Solids (ppm) < 20
Nitrite ppm as NaNO2 Nil
D) ADDITION OF PASSIVATION CHEMICAL
Fill the system with make‐up water and maintain the system pressure.
Add Accepta 894 Passivation Chemical at the rate of 1 kgs / m3.
Circulate the same for about 12-24 hrs for proper passivation.
During circulation the water will be passed through filter of 5 micron size to remove any
leftover suspended solids and suspended iron.
Up on completion of circulation the backflushing of the permanent equipment to be
carried out using the temporary pump (Please refer the details for the back flushing of
the units).
RE‐INSTATEMENTS OF PERMANENT EQUIPMENTS & BACK FLUSHING
NOC required from equipment manufacturer/supplier (Heat exchangers).
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 equipment.
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 to the container until the
water 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 from the opposite side.
Continue the draining until water 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.
Method statement for Chilled Water Flushing REF: CC-MS-CHW-FLU-97-2023
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Dynamic Flushing: ‐ The purpose of dynamic Flushing is to take out all the left over
suspended particles and debris which are accumulated in the system during back flushing
stage by continuously flushing with make‐up water.
Coolchem Engineer to test and provide the acceptance of water quality, which shall be as
per parameters mentioned below.
PARAMETERS VALUE (ppm)
Conductivity, (µ Siemens/cm) < 800
TDS, (ppm) < 550
Total Iron, (ppm ) < 1 ppm
Suspended Solids (ppm) < 20
Nitrite ppm as NaNO2 Nil
E) FINAL INHIBITION
Passivation & Micro biocide chemicals shall be added at this point. Corrosion Inhibitor
chemical Accepta 2337 to be added to 3 Kgs/m³ of system volume and circulated for 12 to
24 hours.
Micro‐biocide chemical Accepta 2400 to be added @ 0.05 kg /m³ of system volume.
Keeps the system in circulation including all the equipment’s for a minimum period of 12
hours.
Water samples have to be collected from areas selected by Engineer and Coolchem water
analysis reports shall be submitted to confirm the corrosion inhibitor level (Nitrite as
NaNO2– minimum 800 ppm).
A final water analysis report indicating all the required parameters will be tested from
Water Bird.
Final Parameters:
PARAMETERS PARAMETERS VALUE
pH 8.5‐10.5
TDS, (ppm) <2,000 ppm
Total Iron (ppm) < 1ppm as Fe
Nitrite, (ppm) as NaNO2 800-1000 ppm as NaNO2
TSS (ppm) < 30 ppm
Total Hardness (ppm) <100 ppm as CaCO3
Total Alkalinity (ppm) <250 ppm as CaCO3
Chlorides as Cl- <150 ppm
Method statement for Chilled Water Flushing REF: CC-MS-CHW-FLU-97-2023
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Details of Flushing Flow/ Building
System Volume (Approximately) 60 m3
Max Pipe 300 mm
110% of the design Flow 738 m3/hr
Temporary pump flow 800 m3/hr
Details of the temporary Equipment/ Building
Temporary Circulation Pump: 55 Kw with Max flow of 400 m3/
hr. – 2 Nos.
Temporary Bag Filtration System: 400 m3/hr.
Details of the Chemicals Used / Building
S.No Chemical Dosage Chemical to be
Rate Dosed
1 Accepta 2877, Neutral pH Cleaner 1 Kg/m3 60 Kgs
2 Accepta 894 Passivation Chemical 1 Kg/m3 60 Kgs
3 Accepta 2337, Nitrite Based Corrosion Inhibitor 3 Kg/m3 180 Kgs
4 Accepta 2866, Micro biocide 0.05 Kg/m3 3 Kgs
MSDS attached for the above chemicals.
Method statement for Chilled Water Flushing REF: CC-MS-CHW-FLU-97-2023
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CHILLED WATER FLUSHING
TEMPORARY SET UP DRAWING
Method statement for Chilled Water Flushing REF: CC-MS-CHW-FLU-97-2023
16
COOLCHEM – TEMPORARY SET UP
Method statement for Chilled Water Flushing REF: CC-MS-CHW-FLU-97-2023
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DETAILS OF TEMPORARY EQUIPMENT’S
Method statement for Chilled Water Flushing REF: CC-MS-CHW-FLU-97-2023
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Kirloskar Brothers Limited
Pump Performance Curve
60
45 Power
Power - kW
30
15
50 100
Minimum Continuous Safe Flow (MCSF)
45 90
40 80
Efficiency
35 329 mm 70
30 60
Efficiency - %
Head - m
25 50
20 255 mm 40
15 30
10 20
5 10
0 0
4
NPSHr
NPSHr - m
0
0 50 100 150 200 250 300 350 400 450 500 550
Flow - m3/h
Customer : Coolchem Chemicals Trading LLC Pump Size/ Stages : DB 150/32/ 1
Customer enquiry : Speed, rated : 1470 rpm
Project : Default Based on curve number : HD10229B0 Rev 0
Quote number 174131 Viscosity : 1.00 cSt
Item number 035 Cq/Ch/Ce/Cn [HI2010] : 1.00 / 1.00 / 1.00 / 1.00
Quantity 1 Minimum recommended driver rating : 55.00 kW / 73.76 hp
Flow, rated : 400.0 m3/h Performance testing standard : ISO 9906 / ANSI-HI 14.6 Gr
2B
Differential Head : 33.00 m
Date last saved : 03 Oct 2019 12:42
Fluid density rated : 0.998 kg/dm3
Notes:
Efficiency : 84.44 %
1. Performance at shut off condition is approximate.
Power, rated : 42.51 kW
2. Rated impeller diameter is approximate.
NPSH required : 2.93 m
3. Only duty point is guaranteed as per testing standard.
Liquid Type/ Application : Water
Kirloskar Brothers Limited · · ,
Phone:
Version: 19.3.4
Kirloskar Brothers Limited
Pump Performance Datasheet
General
Customer : Coolchem Chemicals Trading LLC Quote number : 174131
Customer Enquiry No. : Pump model : DB 150/32
Project : Default Stages :1
End user :- Based on curve number : HD10229B0 Rev 0
Tag number : 035 Date last updated : 03 Oct 2019 12:42
Service :- Quantity of pumps :1
Operating Conditions Liquid
Flow, rated : 400.0 m3/h Liquid handled : Water
Suction pressure, rated / max : 0.00 bar.g / 0.00 bar.g Additional liquid description : Fresh Water
Discharge pressure, rated : 3.23 bar.g Temperature, max : 50.00 deg C
Head, rated (requested) : 33.00 m Solids diameter, max : 0.00 mm
NPSH available, rated : Value not specified Solids in suspension by volume : 0.00 %
Frequency : 50 Hz Specific gravity, rated / max : 0.998 / 0.998 kg/dm3
Performance Viscosity, Rated / Max. : 1.00 cSt / -
Pump speed, rated : 1470 rpm Driver & Power Data
Impeller Dia, Rated (Approx.) : 329 mm Driver sizing specification : API 610 / ISO 13709
Impeller diameter, maximum : 329 mm Margin over specification : 0.00 %
Power, rated : 42.51 kW
Impeller diameter, minimum : 255 mm
- :-
Efficiency at duty point : 84.44 % - :-
Driver Rating : 55KW
NPSH required / margin required : 2.93 m / 0.50 m
Pressure Data
MCSF : 70.97 m3/h
Maximum working pressure : 3.68 bar.g
Cq/Ch/Ce: [-] : 1.00 / 1.00 / 1.00
Maximum allowable working pressure : 16.00 bar.g
Water eq. duties (Qw/Hw/Ew) : 400.0 m3/h / 33.00 m / 84.44 %
Maximum allowable suction pressure : 1.96 bar.g
Suction / Delivery nozzle size : 200 mm / 150 mm
Hydrostatic test pressure : 18.34 bar.g
Noise level : 90 dB
Construction
Vibration level (RMS) : 5.1 mm/s
Basic construction : End Suction Pump-OH1
Test standard : ISO 9906 / ANSI-HI 14.6 Gr 2B
Impeller type : Enclosed
Starting condition : Closed Delivery Valve
Selection status : Acceptable
Material
Rec. Pipe Size (Suc / Del) : 300 mm / 250 mm
MOC Code : 56MOC
Material (Casing / Impeller / Shaft) : CI IS210:FG260 (012) / BR IS:318
GR-LTB2 (110) / ST ST ASTM A276-
410 ANLD (253)
-
:-
Kirloskar Brothers Limited · · ,
phone: · Website:
Version: 19.3.4
BAG FILTER
APPLICATION BAG FILTER HOUSING
Bag Filtration units specially designed to use for flushing
activities.
A Bag filter works by the principle of microfiltration. The liquid
is purified in bags by passing small permeable pores. Bag
filters can be used for large amounts of water.
The sizes of these pores are between the 1 - 200 micron.
During the flushing activities the bag sizes being used are 1,
5, 10 or 25 microns depending on the site conditions.
Bag filters are very effective tool during flushing activities
and it improves the flushing by removing suspended matters
from network and save the requirement of water.
The filter shell is made of carbon steel material with
internally epoxy coated rated for 150 psi. The vessels are with
top opening supported Hydraulic lid lift to open bag filtration
units for placing new bags and removal of dirty bags.
The bolts are swing type bolts easy to open without special
tools. The drain point is available at bottom and air vent is
available at the top of filter tank.
Since the bag is locked in at the top of the vessel all the dirt
is trapped inside the bag. The filter vessel never requires
cleaning after use. The bags are supported/installed in side FILTER BA
stainless steel perforated basket strainers.
BGFS 200 BGFS 450
Max. Flow Rates (m /hr)
3
200 450
Number of Basket 3 12
IN/OUT unions 6” 10”
Dimensions (L x W x H) (m) 1.0 x 0.5 x 2.0 2.0 x 1.5 x 2.4
Operating pressure Maximum 10 Bars
CHILLED WATER FLUSHING
CHEMICALS – MSDS & PDS
Method statement for Chilled Water Flushing REF: CC-MS-CHW-FLU-97-2023
PROJECT REFERENCE LIST
Method statement for Chilled Water Flushing REF: CC-MS-CHW-FLU-97-2023
PREVIOUS APPROVALS
Method statement for Chilled Water Flushing REF: CC-MS-CHW-FLU-97-2023
Method statement for Chilled Water Flushing REF: CC-MS-CHW-FLU-97-2023
