BG 29/2020

Pre-Commission Cleaning
of Pipework Systems 6 edition th

By Chris Parsloe and Martin Ronceray

In partnership with:
With thanks to our sponsors:
BSRIA and the CSCA acknowledge with thanks the organisations who have sponsored this publication:
BG 29/2020
Pre-Commission Cleaning
of Pipework Systems 6 edition th

By Chris Parsloe and Martin Ronceray

Acknowledgements
The technical information and procedures in this guide were developed with input from industry
representatives and BSRIA staff. BSRIA wishes to thank the following members of the steering group for their
contributions:

Hydrosphere Innovations Ltd

BSRIA
Ashford Environmental Services Ltd
Commissioning Specialists Association
Water Treatment Products Ltd
B & V Chemicals
Geberit Ltd and British Metal Tube Fittings Association
BSRIA
Skanska
Hydrocomm Ltd and Institute of Corrosion
Society of Public Health Engineers
Midland Corrosion Services Ltd
Midgard Ltd
Parsloe Consulting Ltd
NG Bailey Ltd and Building Engineering Services Association
BSRIA
Whitewater Technologies Ltd
Hydroviron Ltd and Closed Systems Control Association

A list of contributors to previous editions of this guide is included in Appendix D.

Every opportunity has been taken to incorporate the views of the contributors, but final editorial control of
this publication rested with BSRIA.

BSRIA is the owner or the licensee of all intellectual property rights in this publication, and in the content published in it.
Consent is granted to users of this publication to reproduce and modify the forms in appendices B and C for use on their
projects in accordance with the following limited licence:
• Our status as the owners of copyright in the content must always be acknowledged. In the case of this publication,
unless otherwise agreed with BSRIA, all extracts must carry the following acknowledgement: “Reproduced from BSRIA
BG 29/2020 Pre-commission Cleaning of Pipework Systems 6th edition”.
• You must not use any part of the content for any purpose(s) other than those set out above without first seeking a
licence to do so from BSRIA.
• If you reproduce and modify any such content in breach of these terms of use, or otherwise breach any of our
intellectual property rights, your rights under this Limited Licence will cease immediately.
All risk associated with the use of material from this publication is assumed entirely by the user. Full terms and conditions can
be found at: www.bsria.com/uk/terms.
© BSRIA May 2020 (Version A)
ISBN 978-0-86022-778-6
 

In memory of Reginald Brown 1953 – 2016

Reginald joined BSRIA in 1989 and was Head of Energy &

Environment from July 1993. He was a popular and highly
regarded expert in his field which was acknowledged within
BSRIA, its members, the wider industry and the media. He
participated in the 2004, 2011 and 2012 updates of BSRIA’s pre-
commission cleaning guide.

Reginald was not only an enthusiast and expert, but someone

who devoted 27 years of his working life to BSRIA and the wider
engineering community. He was known internationally and
gave much-valued advice to young engineers and students.
Reginald loved what he did and it was his passion and hobby
as much as it was his work.

©BSRIA PRE-COMMISSION CLEANING OF PIPEWORK SYSTEMS BG 29/2020 | v

vi PRE-COMMISSION CLEANING OF PIPEWORK SYSTEMS

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 PREFACE

PREFACE
System contaminants such as mill scale, jointing compound and building debris will inevitably be found in
newly fabricated heating and cooling pipework systems. If allowed to remain in the system in sufficient
quality, these contaminants will make the system prone to blockages at strainers, control valves and small-
bore heat exchangers. They may also initiate further corrosion and encourage the growth of
microorganisms.

First edition: AG 8/91

The subject of cleaning pipework systems to remove these contaminants prior to commissioning was first
addressed in the 1991 BSRIA Application Guide AG 8/91 Pre-Commission Cleaning of Water Systems. Many
of the recommendations in this guide were considered unconventional at the time. However, in the
intervening years, experience has shown that systems that are designed and cleaned following this
guidance are less likely to suffer operating problems. The importance of pre-commission cleaning has
increased as modern heating and cooling systems have moved towards energy efficient control, low flow
rates and small-orifice control valves.

Second edition: AG 1/2001

In 2001, the first revision to AG 8/91 was launched as BSRIA Application Guide AG 1/2001 Pre-
Commission Cleaning of Pipework Systems. This guide was intended as a direct replacement for AG 8/91. The
recommendations were revised in order to take on board feedback received since 1991, but also to
address the growing incidence of bacteria-related issues, particularly those related to the presence of
Pseudomonas-like bacteria. For reasons not fully understood, bacterial problems had become more common
during the 1990s. AG 1/2001 therefore contained more information on precautionary measures to avoid
or address bacteria in systems.

Third edition: AG 1/2001.1

The guide was updated in 2004. At this time, it was recognised that there was a serious contamination risk
when new pipework sections were connected to existing systems (such as in shell and core situations). It
was decided that additional guidance was required to address these particular situations. BSRIA AG
1/2001.1 therefore retained the recommendations provided in AG 1/2001, but also had a completely new
stand-alone section which dealt with the issues raised when connecting new pipework to existing
pipework.

Fourth edition: BG 29/2011

This version of the guide incorporated industry feedback from nearly twenty years of flushing and
cleaning using the guide. In particular, it aimed to clarify the roles and responsibilities of the parties,
improve the exchange of information between them and provide consistency between service offerings of
pre-commission cleaning specialists.

Fifth edition: BG 29/2012

The purpose of the 2012 update was to reflect new British and European standards, correct some minor
errors in the 2011 edition, and clarify certain points that had been raised in the intervening year.

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 PREFACE

Sixth edition: BG 29/2020

The 2020 version has been expanded to include topics that were not previously covered, including:
• cleaning precautions for thin-walled carbon steel pipes,
• closed-loop pre-treatment cleaning (CPC) procedures,
• pre-treatment options described in German directive VDI 2035[1],
• corrosion monitoring solutions,
• heat networks and low carbon systems.

Example design diagrams showing flushing and cleaning provisions have been updated to include
common features of modern variable-flow heating and chilled water systems.

Furthermore, section 3 of the guide has been revised to give greater clarity at the inspection and
witnessing stages. Onus is placed on cleaning specialists to produce a sampling and analysis plan with
target limits for various water quality parameters based on their knowledge of system materials, fill water
and the ongoing water treatment regime.

Microbiological limits for total viable counts (TVCs) have been retained at 10,000 cfu/ml in line with
recommendations for the avoidance of biofilms in cooling towers (HSG 274 Part 1[2]). Evidence has
shown that this overall TVC limit can achieve an acceptable level of control over both free-flowing and
surface-adhering bacteria. Microbiological limits for pseudomonads have been revised to 1,000 cfu/ml
(to be tested by plating out on a pseudomonas selective agar) as an additional indicator of the potential
for biofilm growth.

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 CONTENTS

1 INTRODUCTION 1
1.1 Pre-commission cleaning specialists 1
1.2 Scope 1
1.3 Guide structure 2
1.4 Complementary guidance 2
2 DESIGN CONSIDERATIONS 3
2.1 Introduction 3
2.1.1 General 3
2.1.2 Responsibilities 3
2.1.3 When to chemically clean 3
2.1.4 Specification for system cleaning 4
2.2 System chemistry 6
2.2.1 System contaminants 6
2.2.2 Choice of chemicals 8
2.2.3 Typical stages of a clean 8
2.3 Pipework system design 8
2.3.1 General provisions 9
2.3.2 Large-bore pipework 13
2.3.3 Plastic pipework 13
2.3.4 Stainless steel pipework 14
2.3.5 Aluminium components 14
2.3.6 Thin-walled carbon steel pipes 14
2.3.7 Heat networks and low carbon heating systems 15
2.3.8 System facilities 16
2.3.9 System schematic 17
3 INSPECTION AND WITNESSING 26
3.1 Sampling and analysis plan 26
3.2 Monitoring during pre-commission cleaning 26
3.3 Monitoring through to practical completion 30
3.3.1 Installer’s role 30
3.3.2 Systems with corrosion monitoring 30
3.3.3 Post-clean sampling 30
3.4 Practical completion 31
4 INSTALLATION CONSIDERATIONS 34
4.1 Management 34
4.1.1 Management 34
4.1.2 Organisation and planning 34
4.1.3 Record keeping 35
4.1.4 Choice of chemicals 35
4.1.5 COSHH regulations 36
4.1.6 Other risks 36
4.1.7 Consequential damage 37
4.1.8 Permits to discharge 37
4.2 Pipework installation 37
4.2.1 Materials storage 37
4.2.2 Good installation practice 37

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 CONTENTS

4.3 Preparation for flushing and cleaning 38

4.3.1 Method statements and risk assessments 38
4.3.2 Installation checks 38
4.3.3 Drainage 38
4.3.4 Water supply 39
4.4 Procedure for filling and pressure testing 39
4.4.1 System filling 39
4.4.2 System pressure testing 40
4.4.3 Basic procedure for pressure testing 40
4.5 Period between end of clean and practical completion 41
4.5.1 Routine checks 41
4.5.2 Circulation 41
4.5.3 System drain-downs 41
5 SYSTEM DYNAMIC FLUSHING 42
5.1 Flushing objectives 42
5.1.1 Importance of water velocity 42
5.2 Dynamic flushing procedure 43
5.2.1 General considerations 43
5.2.2 Basic stages of a flush 43
5.2.3 Dynamic flushing of primary ring main circuit 45
5.2.4 Dynamic flushing of secondary mains pipework 46
5.2.5 Dynamic flushing of horizontal mains to each floor 49
5.2.6 Final full system flush 53
5.2.7 Reconnection of terminal units and main plant items 53
6 CLOSED-LOOP PRE-TREATMENT CLEANING (CPC) 54
6.1 CPC system filling 54
6.2 CPC dynamic flush 55
7 CHEMICAL CLEANING PROCEDURE 57
7.1 Introduction 57
7.1.1 The importance of pre-flushing 57
7.1.2 The importance of flow 57
7.1.3 The importance of temperature 57
7.1.4 Duration of chemical circulation within the system 58
7.1.5 Disposal of chemicals 58
7.2 Cleaning options 59
7.2.1 Biocide wash 59
7.2.2 Removal of surface oxides 59
7.2.3 Effluent disposal / final flushing 60
7.2.4 Neutralisation 61
7.2.5 Passivation 61
7.2.6 Corrosion inhibitor / biocide dosing 61
7.2.7 Treatment up to practical completion 62
7.3 Ongoing water treatment 62

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8 CONNECTIONS BETWEEN NEW AND EXISTING SYSTEMS 63
8.1 Scope of clean required 63
8.2 Water sampling 63
8.3 Shell and core type projects 64
8.3.1 Provision for future extension 64
8.3.2 Temporary pump sets 65
8.3.3 The cleaning process 67
8.3.4 Maintaining system cleanliness 67
8.3.5 Final connection 67
APPENDIX A – NUMBERS AND LOCATIONS OF SAMPLES 68
APPENDIX B – EXAMPLE FRAMEWORK FOR RECORD KEEPING 69
Pre-commission cleaning system checks 69
Flushing velocity record sheet 71
Coil back flush record sheet 72
Strainer / dirt pocket cleaning record sheet 73
Water sample progress schedule 74
Site analysis record sheet (Part 1 - Flushing) 75
Site analysis record sheet (Part 2 – Chemical clean and dosing) 76
Site analysis – Post cleaning to practical completion 77
System condition on completion of pre-commission cleaning 78
APPENDIX C – EXAMPLE CERTIFICATE OF CONFORMITY 80
APPENDIX D – ACKNOWLEDGEMENTS 81
GLOSSARY OF TERMS 83
REFERENCES 84

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 LIST OF SYMBOLS

Isolating valve Pump

Drain off cock

Pressure gauge

Lockshield valve
Temperature gauge

Double regulating valve

F lexible hose
F ixed orifice flow measurement device
(orifice plate) F lexible coupling

S trainer
F ixed orifice double regulating valve
(commissioning set)
Blanked flange pipe end

Pressure independent control valve

Pressure test point

Differential pressure control valve Non-return valve

Two-port control valve

Automatic air vent

Three-port control valve Water meter

Thermostatic radiator valve

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 INTRODUCTION 1

1 INTRODUCTION
Pre-commission cleaning, as it is applied to heating, cooling and other closed pipework systems, is the
process of bringing the system to a satisfactory state for commissioning and ongoing maintenance of
water quality. This means that:
1. The system water should be free of construction debris, dirt and excessive particulate matter.
2. Internal surfaces should be free of excessive corrosion products and appropriately treated to minimise
ongoing corrosion.
3. Pipework, fittings and terminal units should be free from excessive amounts of settled solids that
could increase the risk of corrosion.
4. Residual levels of suspended solids in circulating water should be low enough to not cause difficulties
with commissioning.
5. Biofilm formation should be minimised by appropriate use of biocides or other control measures and
those bacteria associated with microbiologically influenced corrosion (MIC) should be controlled.

Pre-commission cleaning is usually achieved through a process of flushing and chemical cleaning (where
required) followed by the addition of biocides and inhibitors. Since it is impossible to directly examine all
post-clean internal surfaces, the success of pre-commission cleaning is usually inferred from water
samples that are analysed for a range of parameters typically including suspended solids, iron and bacteria
levels.

1.1 PRE-COMMISSION CLEANING SPECIALISTS

Pre-commission cleaning should be carried out by trained and experienced operatives working within a
management framework that ensures safe and effective working practices and appropriate record keeping
at each stage of the process, with clear lines of communication to the designer and other parties involved
in the project.

The management procedures of companies offering or overseeing pre-commission cleaning services in

compliance with this guide should ideally be certified to ISO 9001[3] or be audited by an independent
trade association such as the Closed Systems Control Association (CSCA – www.cscassociation.org.uk).

1.2 SCOPE

This guide is intended for newly installed industrial or commercial-sized heating and cooling systems
(typically more than 200 litres) including newly installed extensions to existing systems.

The guidance is not intended to form part of a contractual obligation between different parties. The
recommendations given are intended as good practice guidelines to help ensure that newly installed
systems are left in a suitably clean condition, and that water quality is satisfactory. The cleaning
procedures and results of water quality analysis should always be subject to interpretation by a suitably
qualified cleaning or water treatment specialist in the context of the project and with an awareness of the
proposed ongoing water treatment regime.

The guide should not be used to preclude innovative water treatment solutions. Solutions that adopt a
different approach to those described in the guide should be independently assessed.

Unless otherwise advised by the specifying consultant, this guide should not be applied to:
• existing systems in occupied buildings where access is difficult, and the procedures required may be
impractical – in such cases alternative cleaning strategies and procedures should be adopted.

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 1 INTRODUCTION

• systems that have been in regular operation for a period of more than three months since completion
of the cleaning process – after this period, reference should also be made to BSRIA guide BG 50[4].
• central heating and cooling systems for domestic-sized systems (typically less than 200 litres) – for
these systems reference should be made to BS 7593[5].
• domestic hot and cold water systems (i.e. systems providing water to hot and cold taps), for which
reference should be made to BS 8554[6] and PD 855468[7].

Furthermore, when applied to large heating or cooling networks such as district heating and cooling
systems, the guidance may not be universally applicable, and some practical interpretation and adaptation
may be required. Advice should be sought from the cleaning specialist regarding unusual applications.

1.3 GUIDE STRUCTURE

The success of pre-commission cleaning and the avoidance of subsequent problems will depend on the
design and prior history of the system. In particular:
• The designer should aim to ensure that the system is amenable to cleaning, and remaining clean, and
that appropriate features (such as flushing bypasses and drain points) are included to make this
possible; these issues are discussed in section 2.
• Water quality after completion of the clean should be checked and a procedure for monitoring
between initial fill and practical completion set in place as described in section 3.
• Manufacturing, storage and assembly methods should aim to minimise the ingress of contaminants
and measures should be applied to avoid the build-up of corrosion and bacteriological problems prior
to pre-commission cleaning, as described in section 4.
• Procedures for pre-commission cleaning should follow a recognised and pre-planned approach, as
described in sections 5 and 6.
• Connecting between new and existing systems may have implications for water quality and should be
undertaken with care, as discussed in Section 7.

1.4 COMPLEMENTARY GUIDANCE

This guide is intended to be used in conjunction with BS 8552[8] which describes the requirements for
sampling water from closed systems. The standard covers sampling methodology, the selection of
locations, sampling frequency, storage, transport and analysis methods compatible with the
recommendations set out in this guide.

This guide covers system cleaning and the management of the system after completion of the clean. The
guidance is applicable to the period up to three months after cleaning, but advice is also given regarding
the checks and witnessing appropriate when project practical completion is granted. BSRIA guide BG
50[4] gives guidance on the ongoing maintenance of water quality after three months of operation and
post practical completion.

Throughout this publication, various legislation is referred to. Only legislation currently applicable in
England is stated. In some cases, different legislation applies in different parts of the UK. The full text
of all UK legislation can be found at www.legislation.gov.uk. Further information can be found in the
BSRIA Legislation and Compliance Resource, which can be accessed through the BSRIA website
www.bsria.com.

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 DESIGN CONSIDERATIONS 2

2 DESIGN CONSIDERATIONS
2.1 INTRODUCTION
2.1.1 General

The designer (and their client) should address the requirements for system cleaning at an early stage in the
design of the system. While system cleaning may not be uppermost in the mind of the client or designer
at that time, a system that is easy to clean will probably be easier to commission and more energy efficient
in operation.

The client (being the employer of the design team) has an overall role in ensuring that the
recommendations provided in this guide are considered at each stage of the project and for ensuring that
the recommendations of section 2.1.2 relating to responsibilities are clearly scheduled for subsequently
appointed designers and contracting teams.

The designer should aim to assess:

• what design features (permanent and temporary) need to be incorporated to facilitate the agreed
contract programme, sequence of handover, cleaning process and ongoing water treatment,
• what design features need to be avoided (or bypassed) to facilitate the cleaning process,
• which methods of cleaning are most appropriate for the system,
• whether chemical cleaning is important to the successful operation of the system.

It is suggested that the client or designer consults a suitably qualified and experienced cleaning specialist
at an early stage in the project to review and comment on the proposed design.

Where the design is transferred to another designer, the original design should be validated by the new
designer and cleaning specialist, and a proposed cleaning method should be agreed and verified. This may
necessitate the addition of components or features to facilitate pre-commission cleaning using the
methodologies explained in this guide. The designer should therefore be considered within this guide to
be the party which, for contractual purposes, has the authority to fulfil the design obligation at that
particular stage in the project.

2.1.2 Responsibilities

As early as possible, the client (or the contractual party acting on their behalf) should aim to clarify the
roles and responsibilities of the client, contract administrator, designer, principal contractor and cleaning
specialist for each stage of the works from first fill to practical completion. Reference should be made to
guidance provided in section 4.1.

2.1.3 When to chemically clean

System cleaning will certainly entail thorough flushing with water and may also involve the use of
chemicals to remove and disperse material from the wetted surfaces. Some form of chemical clean may
also be appropriate although chemical cleaning is not essential for all systems.

The decision to clean and the type of clean will depend on consideration of the following factors:
1. System size – the amount of debris which could potentially be released into a system increases with
the size of the system.
2. System materials – systems constructed using materials that are normally corrosion-resistant (such as
stainless steel, copper or plastic) are less likely to contain corrosion debris after installation and are
therefore less likely to require a chemical clean. Furthermore, systems with thin-walled carbon steel

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 2 DESIGN CONSIDERATIONS

pipes may benefit from a non-chemical approach as explained in section 2.3.6. Systems with mild
steel pipes to BS EN 10255[9] or mixed-material systems incorporating mild steel may undergo some
form of chemical clean to remove surface corrosion.
3. Fabrication method – Systems fabricated using modular assembly, offsite prefabrication, and clean
jointing methods (and which are kept dry) are less likely to contain installation-associated corrosion
products and are therefore less likely to require a chemical clean.
4. Complexity of system and sensitivity of plant items – equipment such as chillers, small-bore
control and regulating valves, low water content heat exchangers and flow rate monitoring equipment
will be prone to blockage if dirt is allowed to accumulate in the system.
5. Extension or modernisation of existing systems – before systems are modified or extended, it is
essential to have the water quality in the existing pipework checked and any necessary remedial
measures taken (as recommended by a cleaning specialist), before connecting to new plant or
pipework. Note that the procedures described in sections 5, 6 and 7 of this guide may not be suitable
for existing pipework that has suffered internal contamination or damage. Cleaning and treatment of
existing systems (or new systems incorporating old pipework) should be as advised by a cleaning
specialist.
6. The length of the construction period – if the system is to be left exposed and damp for a
prolonged period during the installation process, then this will increase the time for corrosion or
biofilms to develop and may increase the need for chemical cleaning and a biocide wash.

2.1.4 Specification for system cleaning

The designer should provide adequate information, documented in the form of drawings, schedules and
specifications to enable the pipework systems to be successfully cleaned. It is recommended that the
advice of a cleaning specialist is sought when preparing this information.

The technical requirements for system cleaning should be developed by the designer, with advice from
the cleaning specialist, to define clearly:
1. the scope of works, such as the systems to be cleaned, their functions, and method of operation,
2. the scope and extent of the cleaning process, defining in outline the main stages to be included,
3. the duties and responsibilities of the various parties (client, designer, main or managing contractor,
installation contractor, commissioning engineer and cleaning specialist) so there can be no doubt as to
who is responsible for each activity,
4. the layout of the system in relation to the building form, to be shown on the design drawings, together
with other engineering services where appropriate,
5. the anticipated method by which flushing velocities are to be achieved and associated requirements
such as system pumps, temporary pumps fed from building electrical supplies or engine-driven
pumps,
6. schematic diagrams and data sheets illustrating the design intent and including all the design
information required to flush and chemically clean the system. (See Table 1 for example information
needed),
7. schedules of major plant, equipment and components as well as schedules of materials and
manufacturers’ water treatment recommendations cross-referenced to the design drawings and
schematic diagrams,
8. detailed estimates of system volumes (down to sub-branch and terminal unit level) to allow for initial
calculation of chemical dosing during cleaning and subsequent treatment,
9. features and components intended to help protect and prolong the system life expectancy, such as
side-stream filters, deaerators and corrosion monitoring systems.

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Table 1: Example of design information required to flush and chemically clean the system

Flushing flow rates Mains

Branches

Sizes Pipes
Strainer-basket mesh
Valves
System volume
Dosing pots
Filtration/separation equipment
Drains
Incoming mains water

Locations Isolating valves

Dosing pots
Sensitive equipment such as fan coil units, control valves, filters, and strainers
Dead legs and dirt pockets
Effluent disposal points
System drain points
Access to permitted discharge foul drains
Quick-fill points
Air vents
Temporary pipework connections
Sampling points
Filtration/separation equipment
Power supply points (including voltage, capacity and availability during works)
Permitted/prohibited access routes for equipment

Drawing reference Terminal units

identifications Branches
Valves
Flushing valves

Materials Inventory of materials used in the system (so that compatibility with cleaning and
water treatment chemicals can be assessed)

Temperatures & pressures Full range of system operating temperatures

Means of pressurisation
Maximum system operating pressure
Test pressures of pipework and pressure vessels
Relief valve settings

Environmental conditions Dates when building is open to elements/weathertight/frost protected

Dates when floors are non-fitted/partially fitted/fully fitted

The establishment of management requirements should be related to specific contractual conditions. The
following need to be considered and responsibilities allocated:
• forms of contract and contractual ownership of the design at each stage,
• programme constraints,
• resource levels,
• method statements (requirements and procedures for acceptance) and risk assessments,
• quality assurance procedures,
• site establishment details (i.e. temporary facilities),

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• compliance with industrial relations protocol,

• bonds, warranties and guarantees,
• post-completion ownership.

The time and resources needed to accomplish pre-commission cleaning are often underestimated if the
designer has not taken advice from the cleaning specialist at an early stage and included realistic estimates
in the overall project programme.

Site safety and regulated permit to work systems will normally be organised by the principal contractor or
the client, depending on the nature of the contract works under the Construction (Design and
Management) Regulations 2015 (CDM). The principal designer should ensure that the client is aware of
their duties under the regulations.

The different sources of project information required to fully specify system cleaning should not,
however, preclude the early appointment of a cleaning specialist to advise and assist the designer. The
cleaning specialist could be involved on a consultancy basis during the design stage, with the option of
converting to a subcontractor later.

2.2 SYSTEM CHEMISTRY

2.2.1 System contaminants

The main contaminants found in water systems are:

Installation debris
Many extraneous materials can inadvertently find their way into systems during manufacture, storage and
installation of pipes and components. These include welding slag and metal swarf which can usually be
removed by thorough clean-water flushing. Those that are not so easy to remove include cutting oil,
soldering flux, jointing compounds, mill scale and grease.

Good handling and storage of pipework, and good practice during installation should be encouraged to
limit the ingress of dirt and debris and. This includes keeping materials in clean condition and temporarily
capping incomplete pipework and fittings. Soldered copper pipework should be installed in accordance
with WRAS AIM 9-04-02[11] and manufacturers’ guidance. The joints should be cleaned externally
following cooling and flushed to remove flux residues.

Scale
Scale is a build-up of solid material that normally occurs on the internal heat exchanger surfaces in boilers
or condensers. Scale is a dense, adherent deposition of mineral particles usually composed of insoluble
salts of calcium, magnesium and iron.

Scale is formed when the water is heated or when the pH or alkalinity of the water is changed. The risk of
scale formation depends on the water hardness. The hardness of water is indicative of the amounts of
calcium and magnesium salts present in the water. Scale is not usually present at significant levels in newly
installed and filled systems. However, during operation, hardness salts may precipitate out of solution and
for this reason, scale inhibition methods may be advised by the water treatment specialist.

Corrosion products
Corrosion products in heating and chilled water systems are mainly comprised of iron oxides such as
magnetite and haematite (rust). Copper, zinc and aluminium corrosion products may also be present.

Corrosion in metallic pipework is commonly caused by either oxygen-induced corrosion, galvanic

corrosion or microbiologically influenced corrosion (MIC).

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The corrosion reaction typically occurs between metal surfaces (either different metals, or the same metal
in different environments) connected through the presence of an electrolyte (water). The reaction that
takes place in steel pipework involves the iron dissolving and then further reacting to form iron oxides
and hydroxides to produce solids. Copper is also potentially vulnerable to oxygen-induced corrosion and
its presence can influence the rate of corrosion of steel and aluminium surfaces in the same system.

The principal factors influencing the rate of corrosion are temperature, the types and concentrations of
impurities in the water, and the water flow rate. The chief chemical variables that influence the
corrosiveness of water are its dissolved oxygen concentration, carbon dioxide content, pH and the
amount of dissolved solids.

Corrosion in steel pipework may result in increased levels of suspended solids due to insoluble iron
compounds. The rate of corrosion of steel can be minimised by lowering dissolved oxygen levels, the use
of chemical corrosion inhibitors, raising the pH of the water and avoidance of stagnation.

Measures to reduce corrosion must be compatible with all materials in the system. For example, high pH
may be incompatible with aluminium and some plastics.

Microbiologically influenced corrosion (MIC) of steel is usually caused by sulfate-reducing bacteria (SRB).
These bacteria metabolise naturally occurring sulfate in the water releasing hydrogen sulfide resulting in
localised pitting corrosion and eventual perforation. The risk factors for MIC are high levels of general
bacteria, high levels of biofilm-forming bacteria such as Pseudomonas species, high levels of suspended
solids and low flow rates or stagnation. It should be noted that MIC usually occurs under existing
corrosion debris and therefore is most likely to be a risk following a period of oxygen-induced corrosion.

Microbiologically influenced corrosion (MIC) may not be evident from changes in suspended solids or
iron levels so the risk of MIC is inferred from the presence of the bacteria in system water samples and
other system factors. The risk of MIC is minimised by avoiding stagnation and the use of biocides to
control bacteria levels.

Biological fouling
All natural sources of water (including tap water) contain many different types of bacteria, some of which
may multiply and lead to problems within a pipework system if they encounter suitable conditions for
growth.

Systems left filled and untreated, or which are filled and subsequently drained, can quickly develop a
biofilm layer on pipe surfaces. The biofilm (a mixture of live and dead bacteria and their excretions) helps
the bacteria to resist the action of biocides and seeds bacteria back into the system water. It can also
create the starting environment for microbiologically influenced corrosion (MIC) as mentioned earlier.

During the late 1990s, some bacteria (particularly Pseudomonas species) were linked to a series of damaging
contamination problems. The symptoms included blockages at valves and strainers, sludge formation, and
severe gassing affecting flow rate measurements and commissioning results.

There is no evidence to confirm that Pseudomonas species were directly responsible for these problems –
other bacteria may have been to blame. However, it has been found that where levels of Pseudomonas-like
bacteria (pseudomonads) are high, the risk of these problems is increased. Pseudomonas species are,
therefore, sometimes used as an indicator of the biological quality of system water.

Pseudomonads are amongst a group of bacteria that are nitrate/nitrite reducing and nitrite oxidising
bacteria (NRB). These bacteria can cause rapid loss of nitrite-based inhibitor from the system and so
increase the risk of electrolytic corrosion. Also, the ammonia produced by some of these bacteria when
metabolising nitrite can lead to stress corrosion cracking of brass fittings.

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2.2.2 Choice of chemicals

There are many different chemical products on the market which may be used for the removal or
containment of system contaminants. Many of these are mixtures or formulations of a specific group of
chemicals with proven ability for the purpose. Some have restricted application due to material
compatibility issues. The chemicals may be categorised, depending on their application and nature, in
Table 2.

Table 2: Chemical categories

Agents Actions
Inhibited acid cleaners and To remove surface oxides
formulated cleaning products
Biocides To remove biofilms and reduce bacteria
Biodispersants levels

Passivators To minimise the rate of corrosion

Corrosion inhibitors

Some products are multi-functional containing chemicals from more than one of these categories.

2.2.3 Typical stages of a clean

A typical chemical cleaning programme is likely to include some, or all, of the following procedures:
1. Dynamic flushing to remove loose solids
2. Biocide wash (for systems at risk from bacteria)
3. Removal of surface oxides (for systems with mild steel components)
4. Effluent disposal/final flushing
5. Neutralisation (for inhibited acid cleans only)
6. Passivation
7. Corrosion inhibitor and biocide dosing.

A typical dynamic flushing procedure is described in section 5 and a modified approach using a pre-
treatment clean is explained in section 6. Descriptions for typical chemical cleaning stages are provided in
section 7.

Note that dynamic flushing may need to be carried out several times, after each of the chemical stages of
the cleaning process depending on the procedures employed.

The cleaning specialist should advise the project manager of the proposed sequence of cleaning
procedures, the time needed for each procedure, the time needed for validation of the success of the
clean, and contingency measures should a successful outcome not be achieved at the first attempt.

2.3 PIPEWORK SYSTEM DESIGN

The designer should ensure that the pipework system is designed in accordance with the relevant parts of
the CIBSE Guides.

To facilitate flushing and cleaning, the designer should ensure that the system includes basic fittings,
components and items of equipment to facilitate the process. The designer should therefore have a basic
understanding of the objectives of system cleaning and of the intended cleaning procedure.

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2.3.1 General provisions

System pressurisation
To maintain low dissolved oxygen levels in circulating water, it is essential that, under normal operating
conditions, a positive pressure (relative to atmosphere) is achieved in all parts of the system. The biggest
cause of early pipework failure is a lack of pressurisation whereby air is not removed from the system
during the initial fill, or air is drawn into the system due to negative pressures generated by pumps.

Systems should therefore be designed with pressurisation in mind. Closed system designs should comply
with current guidance and standards relating to the selection and installation of expansion vessels and
associated pressurisation equipment.

Sizing of water supply

A dedicated water supply, adequate for the purpose, should be provided for system flushing where
possible.

Table 3 suggests the minimum size of mains water supply pipe likely to be needed for mains water
flushing. If this is not available (or another source of water is to be used), then an intermediate storage
tank and pumps may need to be provided. Note: these requirements may not be necessary for closed-loop
pre-treatment cleaning (CPC) as described in section 6.

Table 3: Recommended incoming water supply pipe sizes

System volume Minimum mains size (mm)

(litres)
<2000 25
2000 to 10,000 40
>10,000 50

The quality of mains water, or any other source of water used for filling and flushing should be verified by
sampling and analysis two weeks before the initial fill and then periodically thereafter. Where the quality
of water is not suitable then the cause should be investigated and remedial measures taken as necessary.

The initial fill should include the addition of inhibitors and biocide as recommended by the cleaning
specialist to protect the system between pressure testing and pre-commission cleaning. Installation
operatives carrying out remedial work on leaks must be made aware that the system water contains water
treatment chemicals and that appropriate personal protection measures should be used. This situation
should be foreseen in the construction phase plan as required under the Construction (Design and
Management) Regulations 2015 (CDM) and permit to work arrangements.

Regulating and control valves

Regulating and control valves should be sized in accordance with CIBSE Commissioning Code W [ 1 0 ] and
other relevant guidance such that, at the design flow rate, clearances through the valves are maintained as
large as possible. This will help to reduce the risk of blockages.

Achieving recommended flushing velocities through some high resistance valves (such as differential
pressure control valves) may be impractical. The temporary high-head pumps required to achieve
recommended flushing velocities may be too expensive or simply impractical to accommodate.

This problem can be avoided if the pipework design allows control valves and their associated flow
measurement devices to be bypassed during the flushing and cleaning procedure (see Section 2.3.9 for
example layouts). Alternatively, provision can be made to facilitate the temporary removal of valves
during cleaning.

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Dead legs
A dead leg is a section of pipe which, under normal operating conditions, will not experience any flow.
The system should be designed such that the number of dead legs is minimised. In the few situations
where this may be unavoidable, suitably sized drain valves should be incorporated at these points to
facilitate draining and flushing.

Dead legs that have a length of more than 3 pipe diameters should ideally be looped to allow effective
cleaning in full bore, up to and including 50 mm diameter pipework, and 50% bore above 50 mm
diameter. This is to avoid stagnation and allow the circulation of cleaning chemicals. These loops should
incorporate a valve so that they can be temporarily shut off to allow increased flushing velocities in other
parts of the system.

The flow in the loop should be reduced during commissioning and subsequent operation to that required
to maintain minimum exposure to water treatment chemicals. In heat networks and low carbon systems
(as described in section 2.3.7), temperature-controlled bypasses at system extremities may be used to
ensure circulation.

Pressurisation units
Pockets of stagnant water trapped in the expansion vessels and make-up tanks of pressurisation units
have been found to provide potentially ideal conditions for bacterial growth. Connecting pipework should
be kept as short as possible and consideration should be given to the use of flow-through units so that
stationary pockets of water are avoided.

The water supply to pressurisation units should be metered to assist with fault detection and long-term
system monitoring.

Additional “quick fill” points should be provided for system filling and refilling. Quick fill points for
mains water must comply with the relevant provisions of the Water Supply (Water Fittings) Regulations
1999. Mains water supplies must not remain connected to the quick fill points after use.

Strainers
In-line strainers are advisable at various locations in the system to give protection to key system
components primarily during the flushing process and also during subsequent system operation. Their
purpose is to remove large solids before they can enter pumps, chillers boilers and control valves. A
suitable mesh size for this purpose is approximately 0.8 mm.

Strainers should have a basket capable of withstanding the maximum pump head without distortion.
Pressure test points should be provided across strainers so that the pressure drop can be monitored.
Drain valves are recommended on the flanges and/or end caps of Y strainers (DN50 and larger) to
facilitate local draining of the strainer body and adjacent pipework prior to basket removal and emptying.

Pressure test points

Pressure test points in pipework and measuring devices should preferably be located at the side, not at the
top or bottom where they can become air locked or act as dirt pockets. This may necessitate installing
valves and fittings so that their test points are at the side.
Pressure test points may be used for some types of water samples as described in BS 8552[8]:
• pH
• total dissolved solids
• soluble ions including inhibitors
• alcohols and glycols
• soluble biocides
• planktonic microorganisms
• dissolved oxygen

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Pressure test points are not suitable for taking samples for:
• suspended or settled solids
• “total” (i.e. solid plus dissolved) levels of various metals.

Air vents
Air left trapped or circulating in pipe systems may cause the following problems:
• noise at pumps and spring-operated regulating devices
• frothing or foaming (sometimes referred to as the “champagne effect”)
• non-repeatability of flow rate measurements
• inefficient operation of system pumps due to reduced energy transfer between the pump impeller and
circulating water
• increased rates of corrosion in steel pipework due to high oxygen levels

The design should therefore incorporate features to facilitate the removal of air. In general, air vents
should be provided on flow and return pipework at the ends of each horizontal run, and at the tops of
each self-draining section.

During system operation, the water velocity passing air vent connections should ideally be in the range 0.2
to 0.4 m/s. In this range, bubbles move steadily along the tops of pipes and will enter air vent
connections. At velocities above 0.4 m/s, bubbles may be drawn into the centres of pipes and be carried
past the air vent connections. Below 0.2 m/s, bubbles may stop moving altogether.

The rate at which water will enter a pipework system and drain away from it is also influenced by the
venting provision. Air vents of a minimum size of 25 mm should be installed at the tops of large flow
risers to ensure that the system will fill or drain in a reasonable time.

Deaerators
Water in heating and cooling systems may contain significant amounts of dissolved air. This can be a
major contributing factor to ongoing system corrosion and can encourage growth of certain bacteria.

Deaerators work by removing dissolved gases from the water. In doing so, the water is rendered
unsaturated so that it will readily dissolve any remaining trapped air pockets in the system.

Deaerators remove dissolved gases when they temporarily come out of solution due to temperature or
pressure variations. The higher the temperature of the water, or the lower the pressure, the less dissolved
gas it can support.

Temperature differential-based deaerators are, therefore, typically located where the temperature is
highest, such as the outlets from boilers or the inlets to chillers. These products may not be suitable for
basement plant rooms of medium and high-rise buildings as the static head of water will prevent the
dissolved gases coming out of solution.

Pressure differential deaerators are more versatile and can be positioned at any point in the system, even
for high-rise buildings. They work by drawing off a small volume of water around which a near vacuum is
created so that dissolved gases are released. The water is then reintroduced to the system and the process
repeated.

Deaerators can be installed on a temporary basis to resolve problems in systems where venting is
particularly difficult. They may also be installed as permanent features to help remove air entering via
permeable pipe fittings and joints, or due to system drain-down.

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Plant and equipment isolation and bypassing

Systems should be designed to enable the isolation and bypassing of all sensitive plant and equipment
items such as boilers, chillers, heating and cooling coils, chilled beams, terminal units, control valves, and
low-flow regulating valves, during the course of the flushing and cleaning procedure.

Fixed or temporary full-bore bypasses should be provided as close as possible to the plant items they are
protecting. Bypasses should incorporate isolating valves to prevent short circuiting during subsequent
system operation. Where the design of the bypass might create dead legs that exceed three pipe diameters
in length, two isolating valves should be installed (one at each end), within three pipe diameters of the
main flow and return pipes.

Any decision to flush or chemically clean through sensitive plant items (for whatever reason) should be
approved by the cleaning specialist and plant manufacturer.

Pumps
The pipework immediately upstream of pumps should be easily removable so that the inlet and impeller
can be inspected prior to pump start-up. The actual pump connections should be via flanges or
proprietary mechanical couplings.

The use of system pumps for dynamic flushing

With all terminal units and high resistance control or regulating valves bypassed, the minimum flushing
velocities recommended in Section 5.1.1 of this guide will, in most cases, be achievable by one of the
following methods:
• the system duty pump operating by itself
• standby and duty pumps operating together
• standby and duty pumps operating together with a temporary flushing pump installed in series or
parallel.

The pipe and pump sizing calculations should reveal which of these three options is necessary.

Provided that strainers are installed upstream of system pumps to prevent damage from large particles,
their use for flushing should usually be acceptable. Water containing high quantities of fine particulate
matter can sometimes cause erosion of pump seals. It may therefore be advisable to replace pump seals
on completion of the cleaning process.

When considering the pumping options, care should be taken to ensure that the minimum net positive
suction heads (NPSH) of pumps are maintained under flushing conditions, so that the danger of
cavitation is avoided. Strainers used to protect pumps during flushing should not be permitted to block.

Physical segregation of zones

In large or complex buildings with water systems that are progressively cleaned and commissioned over
several months there may be significant advantages in physically segregating parts of the building by
means of plate heat exchangers. This avoids previously cleaned parts of the system being recontaminated
and allows them to be circulated with treated water using system pumps while the remainder of the
building is being completed. This approach may reduce the risk of water quality problems and saves time
and cost in the construction programme as well as providing longer-term benefits.

Drainage
The designer should ensure that there are adequate foul drains suitably located relative to flushing points,
which can be used for draining and flushing. Standard 100 mm foul drains are suitable for all points
except the plant room, where larger drains may be required for systems incorporating pipework greater
than 200 mm in diameter.

Where plant rooms are below the mains drainage system and the system discharge water needs to be
pumped, a temporary or permanent drainage tank will need to be provided. A suitably sized submersible

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pump will be required to pump the equivalent of the flushing supply water volume imposed by the
flushing supply rate.

Chemical injection
The designer will need to take into consideration the requirement to inject a relatively large quantity of
chemicals into the system during the chemical cleaning operation. In most cases chemicals can be
introduced from a temporary tank, through a 25 mm female connection at a point on the suction side of
the circulating pump, if this is provided. If a side-stream filtration/separation unit is installed, it may be
possible to introduce chemicals from this unit.

Water conservation
Flushing procedures can consume significant amounts of water, creating practical problems in both the
supply and disposal of the water.

Water savings can be achieved by employing high-flow side-stream filters, or full-bore filters during
balanced and dynamic flushing. This enables recirculation of flushing water, thereby reducing the
discharge to drain. Section 6 of this guide explains closed-loop pre-treatment cleaning (CPC) which is a
filtration-based cleaning solution. The filters utilised are only used for initial cleaning and would be
replaced by smaller units for conventional side-stream filtration on completion of the work.

German directive VDI 2035[1]

The German directive VDI 2035, issued by the Association of German Engineers, is sometimes
referenced by equipment suppliers. The directive is applicable to closed heating systems as a means of
avoiding scale and corrosion. It includes an option whereby the final post-clean fill water, and all top-up
water that enters throughout the life of the system, is demineralised, deaerated and pH controlled. This
approach may reduce or avoid the need for dosing with corrosion inhibitor chemicals.

Implementation of this approach requires the specification of demineralisation and deaeration plant at the
design stage. Measures to achieve and maintain compliance with the directive are outside the scope of this
guide. For further information on this topic, reference should be made to the directive itself and to
specialist suppliers of associated equipment.

2.3.2 Large-bore pipework

In circuits which incorporate pipes more than 100 mm in diameter (typically primary circuits with low
loss headers), it may be difficult to obtain the flushing velocities recommended in section 5.1.1 (Table 7)
of this guide. In these situations, it is advisable to specify for alternative measures to minimise or remove
system dirt. This might include:
• considering off-site prefabrication of large-bore pipe sections to reduce dirt ingress
• design and installation of pipework and fittings so that sections can be easily accessed and physically
cleaned
• incorporating strainers or full-flow filters on the inlets to associated plant items
• incorporating dirt pockets along the length of flow headers to act as a trap for dirt particles
• using chemical dispersants to encourage particles into suspension at reduced velocities

2.3.3 Plastic pipework

All forms of polyethylene, polybutylene and polypropylene plastic pipe used in heating and cooling
systems should be specified with a robust and effective oxygen permeation barrier to reduce the risk of
corrosion in mixed metal and plastic piping systems.

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Plastic pipework presents fewer dirt-related problems than steel and copper pipework, as jointing
methods are usually cleaner and there is no risk of corrosion. However, plastics can still suffer from
biofilm formation, and may take on a layer of iron oxides if they come into contact with contaminated
water from steel pipework in the same system.

Therefore, unless plastic pipes can be kept permanently isolated from steel pipes throughout the pressure
testing, flushing and chemical cleaning procedures, the likelihood is that they will need to be chemically
cleaned in the same manner as for steel pipes.

Note that underfloor heating and cooling systems using plastic pipe (and their manifolds) should be
treated as terminal units and isolated during the initial system clean.

2.3.4 Stainless steel pipework

Although stainless steel may be considered as a corrosion resistant alternative to thin-walled carbon steel
and copper, there are mixed-metal corrosion and chemical compatibility issues that need to be considered
when planning pre-commission cleaning and water treatment. These will depend on the grade of stainless
steel that is specified.

2.3.5 Aluminium components

Aluminium is commonly used in boilers due to its excellent heat transfer properties. The aluminium alloy
used may vary so guidance on appropriate water treatment should be sought from the manufacturer. In
most cases, pH control will be critical to preventing corrosion of aluminium.

A naturally protective barrier of aluminium oxide usually forms on the metal surface, but this oxide film is
only stable in a pH range of approximately 6.5 to 8.5. Outside of this range, the oxide film can begin to
degrade and once degraded, even in a small area, the exposed aluminium beneath will corrode quickly
resulting in pitting.

It is therefore essential that the cleaning specialist is informed of the presence of aluminium in systems to
be cleaned so that a suitable cleaning and ongoing water treatment regime can be implemented. This is
critical as some treatments for steel and copper components aim for pH levels of up to 11. Such a regime
would not be suitable for systems containing aluminium.

As part of the ongoing monitoring regime, it is important that pH levels and total aluminium levels are
regularly measured. Any upwards drift in pH should be corrected by dosing with a pH buffer chemical to
maintain a pH level in the range specified by the component manufacturer (typically 7 to 8.5).

2.3.6 Thin-walled carbon steel pipes

Thin-walled carbon steel pipes for heating and cooling systems are typically supplied with external
galvanising to protect from short term moisture attack. Pipe wall thicknesses are in the range 1.2 to 2 mm
compared to 3 to 5 mm for steel pipes fabricated to BS EN 10255[9]. Hence, there is less safety margin to
allow for corrosion in service. It is therefore important that uncontrolled corrosion is minimised during
storage, cleaning and ongoing maintenance.

Before installation, the pipes should be carefully stored and handled in compliance with the guidance
given in section 4.2.1 of this guide. Once installed and filled, it is essential that the system is maintained in
a fully pressurised condition so that dissolved oxygen levels in circulating water are minimised.

Chemical cleaning has sometimes been found to result in corrosion and pitting of the pipes. It is believed
that partial removal of the organic layer on the bore of the pipe (applied to prevent corrosion during

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storage and transport), may create an active metal surface, which rapidly corrodes when flushed with
untreated, aerated water.

Hence, depending on the guidance offered by the manufacturer, one of the following options may be
appropriate:
• omit chemical cleaning of thin-walled carbon steel pipes, and simply flush the pipes with clean water
before inhibiting. (Note: this might involve installing flushing bypasses so that the pipes can be
isolated and bypassed during some of the cleaning stages.)
• undertake a chemical cleaning procedure that is approved by the pipe manufacturer and which is
supported by their product warranty;
• clean the pipes using a closed-loop pre-treatment cleaning (CPC) regime (as described in section 6 of
this guide) so that any bare metal surfaces are never exposed to untreated oxygenated water;

As with all steel pipework systems, in the period between the end of the clean and practical completion, it
is important that exposure to oxygenated water is minimised. The following precautions are advisable:
• avoid draining the system unless absolutely necessary;
• measure and monitor system pressures at high points to ensure the pressurisation regime is effective
and the system is always filled;
• measure dissolved oxygen levels in the circulating water and ensure that values are as low as possible
and in line with representative values from other well maintained closed systems.

To give early warning of problems throughout the life of the system, it may also be advisable to provide a
corrosion monitoring service, as described in section 2.3.8 below. This will alert the installing contractor
and maintenance team to any changes in operating conditions that might promote corrosion of the pipes.

2.3.7 Heat networks and low carbon heating systems

To achieve reductions in carbon dioxide emissions, heat networks (such as community heating systems,
district heating systems and ambient loop systems) are typically operated with flow or return temperatures
in the range 20 to 40°C. Penalties may be applied by energy providers if return temperatures from end
user systems exceed the design value. Similarly, heating systems in large commercial buildings may adopt
the same low return temperature strategy for the same reason.

As well as operating at relatively low temperatures, flow rates in heat networks may vary depending on
demand, resulting in prolonged periods of relatively low flow. The recirculation of chemicals around the
system is often dependent on temperature-controlled bypasses that only open occasionally when the
temperature of the water drops below a set value. Hence, it may be difficult to implement a “valve
exercising regime” that ensures regular circulation of chemicals to all parts of the system.

This method of operation and the temperature range is likely to make these systems prone to bacterial
proliferation. Bacteria tend to multiply more rapidly at temperatures in the range 20 to 40°C than at
higher temperatures. Without regular circulation of biocides to all parts of the system, pockets of bacteria
may survive in remote, low flow locations.

These are issues that should be addressed by regular monitoring of bacteria levels in various parts of the
system during normal operation. The target bacteria levels indicated in section 3 of this guide are generally
applicable for a three-month period after completion of the clean. After this point, control of bacteria
should rely on regular monitoring and dosing with appropriate biocides (or other control measures) in
accordance with the guidance provided in BSRIA guide BG 50[4]. Whilst it is important to maintain some
control over bacteria levels, it is usually unnecessary and unrealistic to maintain sterile conditions.

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2.3.8 System facilities

Dosing systems
In order to maintain the cleaned system in a satisfactory condition after handover to the client, an
ongoing programme of water treatment will be essential. The introduction of water treatment chemicals
should be via one of the following methods:
• a dosing pot periodically filled with chemical quantities to the cleaning specialist’s instructions. Dosing
pots must be pressure rated at a level compatible with the operating pressure of the system;
• a pumped dosing system under manual or automatic control.

Corrosion and biofouling coupons

Although the condition of a system can be inferred from water samples, corrosion and biofouling
coupons can be useful in allowing direct assessment of the corrosivity of the water and the internal
condition of pipe surfaces.

Corrosion coupons are pieces of metal of the same chemical composition as the pipes or equipment in
the system. Incorporated inside the system but removable, coupons can give a visual indication of the
type and rate of any corrosion that may be occurring. Remote monitoring of corrosion is also possible.
Monitoring technology is available which enables changes in coupon thicknesses to be accurately
measured so that a graph of varying corrosion rates can be produced.

Corrosion monitoring technology and services

Specialist corrosion monitoring equipment is available to measure and record specific corrosion
influencing parameters. As a permanent feature of the system, the data recorded can give the maintenance
team an early warning of conditions likely to promote internal corrosion. This technology allows remote
diagnostics so that site visits are minimised.
Typical parameters that can be measured and recorded at pre-set time intervals include:
• dissolved oxygen
• conductivity (as an indicator of cleaner or inhibitor concentration)
• temperature
• pH
• water make-up volumes
• system pressures
• flow rates
• metallic corrosion rates

If installed prior to the initial system fill, corrosion monitoring equipment can be used by the installing
contractor and cleaning specialist to monitor the various filling and cleaning stages. The recorded results
can be used to demonstrate that the cleaning process was carried out correctly and the that water quality
was properly maintained in the period leading to practical completion.

Side-stream filtration/separation
Side-stream filtration can help to preserve the condition of the system after cleaning by capturing residual
suspended solids in the circulating water and reducing the accumulation of settled solids in low flow areas
and terminal units. For best effect, it should be applied as soon as possible after cleaning.

Side-stream filtration is suitable for most systems and strongly recommended for systems over 2500 litres.
Typically, 5% of the circulating water should be diverted through the side-stream filter.

Removal of suspended solids also helps to limit bacterial growth. However, the filter units themselves can
provide ideal conditions for proliferation of bacteria if they are not regularly checked and cleaned. Filters

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should therefore be easily maintainable and fitted with a differential pressure indicator or BMS sensor so
that they can be cleaned, or media replaced in accordance with manufacturers’ recommendations.

During pre-commission cleaning, filtration and recirculation of flushing water can significantly reduce
overall water consumption (as described in Section 6). In this case a larger side-stream filtration unit is
temporarily fitted to accommodate up to 100% of the flushing flow rate. This can then be replaced with a
smaller unit prior to practical completion for long term use.

Full-flow filtration
In certain circumstances, full-flow filtration may be specified. A duplex filter is the most appropriate
solution as the filters can be cleaned or replaced without the need to shut the system down.

Magnetic filtration
Magnetic filtration is frequently used on small heating systems to remove abrasive iron oxides (magnetite)
from circulating water. In larger systems, some form of side-stream or full-flow filtration (that can
remove all solids) is preferred.

2.3.9 System schematic

Figure 1 illustrates the typical features of hydraulic circuits for buildings served by low-level primary plant.
The features labelled A to G are explained in the following Figures 2 to 8.

The schematic incorporates both primary and secondary circuits serving vertical risers and various
terminal units fed via horizontal distribution mains. Suitable provisions are shown within the schematic
for filling, venting and draining of each sub-system.

Please note that Figure 1 is only provided to assist the reader in locating relevant guidance in the text and
does not represent a real system. In practice, as preparation for the cleaning process the appointed
cleaning specialist should carry out a pre-start survey of the system, as designed or installed, to check that
the necessary features are included.

The numbering of components in Figures 2 to 8 corresponds to the numbered points in the text which
follows each diagram.

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Figure 1: Example system schematic

Typical air handling unit circuits F

Top of riser
automatic air
vent

Typical radiator circuits

G
E

Typical fan coil circuits

Dosing pot
PRV

A Mixing
bypass
Low
loss
header Buffer/thermal
store

C
B Sidestream
Primary filters
circuit

Pressurisation
unit

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Figure 2: Detail A – Provisions at heating and cooling plant items

2
3 5 1
4

1 Primary plant items such as heat sources, cooling sources and heat exchangers, together with associated
pumps and control valves should be protected by strainers. Strainers should be fitted as close as possible to
the components they protect and should be provided with a means of local isolation. If the manufacturer
recommends a strainer at the plant inlet, connection, then two strainers may be required (see item 5 below).
2 A line-size bypass should be included to enable dirty water to be flushed around the circuit without passing
through plant items. Pipe lengths between the bypass and plant items should be kept as short as possible.
Alternatively, plant items may be looped out as described at item 3 to achieve the same result.
3 Pipework and fittings immediately adjacent to primary heat and cooling plant should be readily demountable
to facilitate visual inspection of the inner surfaces of the heat exchangers. This may also allow plant items to
be looped out (by connecting a temporary hose between flow and return connections), so that the full length
of the connecting pipes can be included in the flushing and chemical cleaning process. Similarly, plant items
supplied with integral pumps may incorporate demountable sections that enable the coils to be looped out.
4 Adequately sized drain connections for flushing and cleaning purposes should be fitted on both sides of major
plant items. Drains should be line-size for pipes up to 50 mm diameter and 50 mm for all larger pipe sizes.
5 If there is a significant length of steel pipe between the pump and any plant item which cannot easily be
looped out during the clean, an additional strainer should be included at the inlet point. Note: some plant
items already include an integral strainer for protection.
6 A flow measurement device should be provided to measure the entire flow through the circuit and suitably
located so that flushing flow rates can be measured.

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Figure 3: Detail B – Provisions in primary circuits with thermal stores

Low loss
header

Buffer/thermal
store

Primary
circuit 4

1 7

2 7
5 8

6
Pressurisation
unit

1 The fill point should be sized in accordance with Table 3. It should be located on the inlet side of system
pumps effectively creating a neutral point during flushing and subsequent operation.
2 Blank flanges or removable caps should be fitted to the ends of primary headers to facilitate the removal of
settled solids from the header.
3 A manual air vent should be provided on horizontal headers where system filling may be a problem.
4 Thermal stores should be isolatable and fitted with an adequately sized drain valve designed and located in
such a way as to enable settled debris at the bottom of the vessel to be flushed out. A flushing bypass is
optional but, if vessels are large, would reduce the amount of water flushed to drain during the cleaning
process. An access hatch should be incorporated to facilitate inspection and physical cleaning of internal
surfaces when necessary.
5 A drain should be provided so that the connecting pipe from the pressurisation unit can be flushed out to
remove biofilm. This will help to control bacteria levels in the water entering the system.
6 Metering of water into the system will help establish system volumes and hence chemical dosing levels. It will
also identify if water is being lost from the system during operation.
7 Adequately sized flushing drains should be provided in the main primary and secondary return pipes to
facilitate the flushing of each circuit.
8 A manually operated three-port isolating valve enables the incoming mains water to be directed to either the
storage vessel or direct to the quick fill connection for initial system filling.

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Figure 4: Detail C – Provisions at secondary pumps

4 PRV

2
1

1 A single strainer should be used to provide protection for the three-way mixing valve and secondary
pump.
2 A means of manually overriding the automatic control of the three-way mixing valve should be provided
so that, during the flushing and cleaning processes, raw water or chemicals can be drawn in via the
primary injection circuit.
3 Flushing fill points, sized in accordance with Table 3, may be fitted prior to each secondary circuit pump
for the purpose of secondary circuit flushing.
4 Chemical dosing pots can be located around each of the secondary pump sets for separate dosing of each
circuit. If fitted with a constant flow regulator such as a non-actuated pressure independent control valve
(PICV) set to maintain a trickle flow, the dosing pot can act as a permanent bypass for variable flow
pumps. Adequate space should be allowed around the dosing pot for safe introduction of chemicals and
draining of contents from the base.
5 Where fitted, side-stream filters should ideally be located in parallel with secondary circuit return pipes
and fitted with their own pumps rather than being reliant on system pumps for flow. This will ensure that
the filters will not interfere with flows and operating temperatures in secondary circuits.

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Figure 5: Detail D – Provisions at horizontal mains serving small terminals such as fan coil units

1 3
2

1 To prevent the ingress of contaminants, connections to terminal units should ideally be taken from
the top of the main, or at an angle of 45 degrees to the vertical, rather than the side or bottom.
Terminal connections of 15 mm or less do not generally require the fitting of vents and/or air
bottles because they are effectively self-purging.
2 In-line strainers with a mesh size of approximately 0.8 mm should be fitted at main branches from
risers to remove debris that might otherwise become trapped in control valves or settle at low
points.
3 An end-of-line bypass should be fitted which may take the form of a temperature-controlled bypass
such as a pressure independent control valve (PICV) controlled to open when the sensed
temperature in the pipe drops below its setpoint value. The PICV should be isolatable and
demountable to facilitate flushing. Note: other types of flow control bypass are possible but
whatever option is chosen, a means of removing any high resistance components should be
provided to enable a low resistance flushing path.
4 To release air during system filling, each pipework section should contain manual air vents at high
points.
5 Line-size flushing bypasses should be fitted across terminal units located upstream of control valves
and regulating valves, and as close as possible to the terminal unit. It is particularly important to
avoid the need to flush through high-resistance control valves since these may prevent the
achievement of acceptable flushing velocities. Materials between the bypass and terminal unit will be
excluded from the chemical clean, and should therefore, ideally, be constructed from non-ferrous
materials such as copper or plastic.
6 Drain valves should be installed on return connections from terminal units to facilitate flushing of
the units. High-resistance components such as flow measurement devices and PICVs should be
located in the return pipe downstream of the drain. This will create a low resistance path from the
flow side through the unit to the drain enabling flushing flow rates through the coil to be
maximised.

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Figure 6: Detail E – Provisions at horizontal mains serving steel radiators

3
1

1 High resistance differential pressure control valves (DPCVs) in the main flow pipes will need to be isolatable
and demountable to enable flushing velocities in the pipes to be maximised.
2 Branches serving groups of steel radiators should be piped in copper at all sizes below 25 mm diameter. If
the circuit is fed by larger steel pipes, a flushing bypass will be required to enable steel pipes to be chemically
cleaned whilst the copper pipes remain isolated.
3 For large branches, an end-of-line bypass should be fitted such as a PICV controlled to open when the
sensed value reaches a set temperature. The PICV should be isolatable and demountable to facilitate flushing.
(Note: other types of flow control bypass are equally acceptable depending on the design objectives.)
4 End-of-run flushing drains should be provided to enable copper mains pipes to be flushed to drain.
5 Steel radiators should not be included in the normal flushing and cleaning process, but if contaminated could
be subjected to a power flush process as described in BS 7593[5].

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Figure 7: Detail F – Provisions at air handling unit coils and heat exchangers

1 Major terminal unit coils and plate heat exchangers should be protected by local strainers which
provide the additional function of protecting the associated control valve and flow
measurement device.
2 The flushing bypass valve should be a full-bore line-size valve. The bypass line should be located
as close as possible to the coil or heat exchanger and its associated control valve. This will
prevent any contaminated water from entering the coil during the flushing process.
3 Drain valves should be installed on return connections from the coil/heat exchanger to facilitate
flushing. High-resistance components such as flow measurement devices and PICVs should be
located in the return pipe downstream of the drain. With the strainer basket temporarily
removed, this will create a low-resistance path from the flow side through the coil/heat
exchanger to drain enabling flushing flows to be maximised.

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Figure 8: Detail G – Provisions at risers

2 3
4 1

1 Air vents and associated pipe connections should be line-size up to 25 mm, then 25 mm minimum for all
larger pipes.
2 Air vents can be either isolatable automatic type or manual incorporating quarter-turn ball valves at
convenient locations. For manual air vents that are run to a convenient location, isolation may be required
at both ends to prevent the pipe run becoming a dead leg.
3 Automatic air vents should be isolated during normal system operation to avoid the risk of leakage.
4 The isolating valves protecting automatic air vents should ideally be located within three pipe diameters of
the nearest flow pipe to avoid creating an excessive dead leg where bacteria could multiply.
5 Adequate clearance must be left above the floor to facilitate the coupling of flexible full-bore drain hoses –
typically 300 mm minimum. A flanged end should be provided for emptying and cleaning of dirt pocket
surfaces.
6 Pipe lengths above dirt pocket isolating valves should be less than three pipe diameters in length to avoid
creating an excessive dead leg where bacteria can multiply. Dirt pockets (below the isolating valve) should
be at least five pipe diameters in length to allow capacity for debris collection. A flushing drain should be
located at the base of the dirt pocket to facilitate flushing of secondary circuits.

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3 INSPECTION AND WITNESSING

3.1 SAMPLING AND ANALYSIS PLAN

To record, monitor and control water quality through each life stage of the system, a sampling and
analysis plan should be prepared by the cleaning specialist as described in BS 8552[8]. This should include
descriptions of:
• the objectives of sampling
• the numbers and locations of samples to be taken
• the analyses to be carried out
• guidelines for interpreting the results.

The sampling and analysis plan should be developed with and agreed by:
• the cleaning specialist
• the installing contractor
• the commissioning manager
• the building management system (BMS) contractor

The plan should be bespoke and appropriate to each project. In particular, the plan should set out a full
list of water quality parameters to be achieved at the end of the clean and at practical completion with
values as recommended by the cleaning specialist.

3.2 MONITORING DURING PRE-COMMISSION CLEANING

The overall success of a system clean is dependent on the thoroughness of each individual stage of the
clean. Inspection and witnessing of the cleaning method should be conducted as the work is in progress.
With reference to the cleaning stages defined in sections 5 to 7 of this guide, under normal circumstances
the following activities should provide a suitable record of the cleaning process and its outcome.
1. In the weeks leading up to pressure testing
Obtain water quality information from the local water supply undertaker. Also take project-specific
samples from the following locations:
• the incoming mains water supply point
• the proposed filling/flushing water connection point
Test the samples for total viable count (TVC), pseudomonads, and sulfate-reducing bacteria (SRB).
Compare the results with previous results from the same locations, where available.
Note: Any connecting pipework between the source water sample point and system fill point is often a
source of bacteria and should be flushed and disinfected (in accordance with PD 855468[7]) before use.
Check the level of bacteria once disinfected.

2. Between system filling and pre-commission cleaning, at intervals of not more than four
weeks, with final sample taken one week before commencement of pre-commission cleaning
Take samples in the numbers and locations suggested in Appendix A, Table 8 and analyse for TVC,
pseudomonads and SRB. The results should be interpreted by the cleaning specialist and may
influence the cleaning and disinfection strategy. In extreme cases where the water quality deteriorates
to an unacceptable degree, if advised by the cleaning specialist, remedial action may include dumping
the water and refilling with fresh water and biocide. Sampling is not required where the system has
been filled for two weeks or less.

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3. During all flushing stages
Witness flushing velocities and check for compliance with the values indicated in Table 7 of this guide.
Check the cleanliness of strainers and dirt pockets in all parts of the system. Flows should be recorded
and, if appropriate, demonstrated during the first flush to ensure that all possible debris is removed
from the system.
Note: Assuming the same system setup, flushing equipment and consistency of labour, subsequent
flushes will experience the same flow rates and need not be witnessed.

4. On immediate completion of the pre-chemical clean dynamic flush

Carry out:
• a visual inspection of the water to confirm cleanliness
• a dissolved iron test. The dissolved iron concentration of the system water should not exceed
3 mg/l.

5. During the chemical clean

Witness dissolved iron levels and check that the clean is concluded at a point where dissolved iron
levels remain stable after the addition of more cleaning chemical. This will confirm that the cleaning
chemical is not saturated and that the plateauing of dissolved iron levels is due to the absence of iron
oxide corrosion products in the system.

6. On completion of the chemical clean

Carry out:
• a visual inspection of strainers. Clean and/or replace strainers as required.
• a visual examination of corrosion/biofouling coupons or removable pipe sections (if fitted).

7. Seven days after final dosing of corrosion inhibitors and biocides

• take samples of system water in accordance with BS 8552[8] for physical, chemical and
microbiological testing
Note: The requirements for the number and location of samples are summarised in Appendix A.
For detailed guidance on sampling procedures, sample handling, analytical methods and statistical
treatment of results refer directly to BS 8552.
• test for physical and chemical parameters using the methods referenced in BS 8552 and interpret
the results in accordance with Table 4 and its accompanying explanation.
• test for TVC, pseudomonads and SRB levels using the methods referenced in BS 8552 and
interpret the results in accordance with Table 4 and its accompanying explanation.

It is important that for the samples to be indicative of the success of the clean, the system water should
be routinely circulated during the preceding week and system integrity maintained. There should be no
loss of water from the system or further addition of chemicals during this period. Any other
commissioning or maintenance activity on the system could potentially influence the results and should
ideally be deferred until after the seven-day period. If this is not possible then the implications should be
assessed, and mitigation measures agreed with the cleaning specialist in advance of the work being carried
out.

The values indicated in Table 4 are based on practical experience of what can readily be achieved for the
majority of heating and chilled water systems after cleaning. It should be noted that where values are
provided, these are intended for newly installed systems and may not be achievable for the re-cleaning of
existing systems that have suffered contamination or corrosion over prolonged periods.

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Given uniform circulation, the chemical and microbiological results from all locations should lie within
the limits indicated in Table 4. For values that are outside of these limits, the causes should be identified
and the cleaning specialist should offer an assessment of the relative risks associated with accepting the
non-compliant values.

As indicated, for some of the parameters listed, the cleaning specialist will need to specify acceptable
limits in advance. These should be identified in the cleaning specialist’s sampling and analysis plan, taking
into account site-specific factors such as:
• the system materials and their relative surface areas
• the incoming water quality
• the proposed cleaning method
• the proposed ongoing water treatment and corrosion control strategy.

Microbiological limits for total viable counts (TVCs) have been set at 10,000 cfu/ml, in line with
recommendations for the avoidance of biofilms in cooling towers (HSG 274 Part 1[2]). Experience
suggests this overall TVC limit provides acceptable control over both free-flowing and surface-adhering
bacteria. Microbiological limits for pseudomonads have been set at a notional level of 1000 cfu/ml as an
additional indicator of biofilm. Pseudomonads should be tested by plating out on a pseudomonas
selective agar so that results are directly comparable with overall TVC counts.

However, it is important to recognise that even the cleanest of systems may contain small areas of biofilm
with recurrent bacteria growth. This does not imply that there is an imminent risk of operating problems.
Microbiological monitoring and control will be required throughout the life of the system not just at the
pre-commission cleaning stage.

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Table 4: Guidelines for system water seven days after completion of pre-commission cleaning

Physical and chemical parameters

Parameter Guideline

Total alkalinity (mg/l CaCO3)

Chloride (mg/l Cl)
As recommended by the cleaning specialist in their sampling and
Sulfate (mg/l SO4) analysis plan
Conductivity (µS/cm)
Total dissolved solids (gravimetric) (mg/l)
Suspended solids* (mg/l) Less than 30 mg/l at main pump during circulation
Less than 45 mg/l at system extremities and terminal units

pH As recommended by the cleaning specialist in their sampling and

analysis plan depending on system materials and water treatment
regime
Dissolved iron (mg/l) Less than 3 mg/l or as recommended by the cleaning specialist in
their sampling and analysis plan
Total iron (mg/l) Less than 6 mg/l or as recommended by the cleaning specialist in
their sampling and analysis plan
Dissolved copper (mg/l) Less than 1 mg/l or as recommended by the cleaning specialist in
their sampling and analysis plan
Total copper (mg/l) Less than 1 mg/l or as recommended by the cleaning specialist in
their sampling and analysis plan
Total aluminium** (mg/l) Less than 1 mg/l
Chemical inhibitor levels As recommended by the cleaning specialist in their sampling and
analysis plan
Bacteria levels
Result Interpretation
TVC at 30°C  10,000 cfu/ml*** The water quality is acceptable. Continued routine monitoring is
AND pseudomonads <1000 cfu/ml at 30°C**** required.
AND sulfate-reducing bacteria (SRB) absent *****
TVC at 30°C >10,000 cfu/ml*** Action may be necessary. The cleaning specialist should advise.
OR pseudomonads > 1000 cfu/ml at 30°C****
OR sulfate-reducing bacteria present*****
* Solids refers to the insoluble material extracted from the sample point at the maximum available flow from the drain point.
**Requires checking only if the system contains aluminium components
***cfu = colony forming units
****Analysis of pseudomonads should be by plating out on pseudomonas selective agar rather than by filtration
*****SRB should be determined by a five-day test (i.e. a single sample split into four inoculated tubes to give 92% probability of
detection as indicated in BS 8552[8], Table C1)

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3.3 MONITORING THROUGH TO PRACTICAL COMPLETION

Water quality should continue to be regularly monitored and maintained until practical completion.
The purpose of this monitoring is to give early warning of potential problems so that remedial action may
be taken, and to demonstrate that the condition of the system is stable and fit for handover.

The sampling and analysis plan (as described in section 3.1) should explain the extent of monitoring
required for individual projects.

It should be noted that the cleaning specialist may be contracted to undertake monitoring of water quality
during the period leading up to practical completion but cannot be responsible for the achievement of
practical completion guidelines as that may depend on factors outside of their control.

3.3.1 Installer’s role

It is important that the installing contractor is made aware of the activities that may cause internal pipe
conditions and hence water quality to deteriorate. The installer should be aware of the guidance provided
in section 4.5 of this guide.

3.3.2 Systems with corrosion monitoring

Where a corrosion monitoring service is installed and operating (as described in section 2.3.8), the data
should provide an accurate indication of water chemistry through to practical completion without the
need for water sampling. However, sampling for microbiological water quality may still be required.

3.3.3 Post-clean sampling

In systems with no other means of measuring and recording water quality, regular water samples should
be taken to ensure there is no significant deterioration in water quality.

Samples (chemical and microbiological) should be taken every two weeks unless otherwise agreed. In
addition, system water should be checked for inhibitor levels as soon as possible after any significant
exchange of water i.e. when more than 10% of the system volume is exchanged.

The recommended scope of routine monitoring (location and number of samples depending on the size
of the system) is generally as defined in BS 8552[8] and summarised in Appendix A.

Monitoring of chemical and physical water quality between pre-commission cleaning and practical
completion may be carried out using portable test kits but final analysis before practical completion
should be undertaken by an independent laboratory. All methods should meet the relevant performance
requirements detailed in BS 8552. Dipslides and ATP site test kits can provide an approximate indication
of bacteria levels and can be used to monitor microbiological trends. Tests for nitrite-reducing bacteria
are not advised as test results can be misleading.

It is recommended that the following parameters are monitored during the period after completion of the
clean:
• dissolved oxygen
• conductivity
• turbidity (or visible solids)
• pH
• total and dissolved iron
• total and dissolved copper

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• total and dissolved aluminium (if present in the system)

• dissolved zinc (as an indicator of dezincification in brass fittings)
• chemical inhibitor levels
• bacteria levels

The cleaning specialist should provide an interpretation of the results obtained. It is normal for the levels
of these parameters to change relative to the results achieved straight after completion of the clean. In
most cases, the values obtained are not as important as the trend in values.

Changes to values might be interpreted as follows:

• Dissolved oxygen: Values should be stable or decreasing. Increases in dissolved oxygen may indicate
water loss from the system or ingress of air due to inadequate pressurisation.
• Conductivity: System drain-downs, or the addition of chemicals will cause water conductivity to vary.
This can be a useful means of keeping track on drain-down or dilution events.
• Solids: Solids filtered from samples taken at the main circulating pump may increase if corrosion is
taking place. Solids in samples from low-velocity areas, such as dirt pockets or terminal units may
increase simply because solids are settling out in these locations.
• pH: The pH of the water may vary if water is drained from the system or additional chemicals are
added. Values should remain within the limits specified by the cleaning specialist.
• Total and dissolved iron: Total iron levels may increase if corrosion is occurring and dissolved levels
may increase when corrosion inhibitor chemicals are added. Increases in either value suggest the
presence of corrosion material, but stable values are not usually indicative of a problem.
• Total and dissolved copper: Increases in total and dissolved copper may be indicative of copper
corrosion and should be addressed by the cleaning specialist.
• Total and dissolved zinc: Increases in total and dissolved zinc may be indicative of dezincification of
brass or dissolution of zinc plating/galvanised surfaces.
• Total and dissolved aluminium: Increases in total and dissolved aluminium in a system containing
aluminium would usually be indicative of aluminium corrosion.
• Chemical inhibitor levels: Reductions in corrosion inhibitor levels might be due to water being
drained from the system or bacterial activity (for example nitrite-reducing bacteria depleting nitrite
levels).
• Bacteria levels: Increasing bacteria levels may indicate the presence of a biofilm in the system
prompting some action to improve conditions such as biocide dosing and ensuring full circulation.

3.4 PRACTICAL COMPLETION

Analysis of samples for practical completion should be carried out by a recognised laboratory. All
methods should meet the relevant performance requirements detailed in BS 8552[8]. Results obtained by
differing methods should not be combined for the purpose of calculating means or trends. For the
numbers and locations of samples required in relation to the size of the system, reference should also be
made to BS 8552, as summarised in Appendix A.

Table 5 gives guidance on the interpretation of results for practical completion where the completion
date is not more than three months after completion of the clean. If the practical completion date is
beyond this period, the interpretation of results may need to take into account the additional
considerations explained in BSRIA guide BG 50[4].

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To demonstrate the stability of water quality, at least two sets of sample results are required, taken at least
two weeks apart, with no dosing or system interference (for example drain-downs) in the two weeks
preceding the first set of samples and in the period between samples.

Where multiple samples have been taken at multiple locations around the system, the values should be
interpreted as follows:
• For physical and chemical results, the arithmetic mean of the results should not exceed the values in
Table 5.
• For microbiological results, no individual value should exceed the values in Table 5 (which quotes the
same values as those in Table 4).

In both cases, if the recorded values cover a wide range, or if one value differs significantly from the
others, the causes should be investigated. A single result that exceeds the practical completion guideline
need not preclude handover provided that the cause of the exceptional result has been established and,
where necessary, appropriate remedial measures are possible.

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Table 5: Guidelines for practical completion

Physical and chemical parameters

Parameter Guideline for practical completion
(unless otherwise agreed by the specifier)

Total alkalinity (mg/l CaCO3)

Chloride (mg/l Cl)

As recommended by the cleaning specialist in their sampling
Sulfate (mg/l SO4) and analysis plan

Conductivity (µS/cm)

Total dissolved solids (gravimetric) (mg/l)

Suspended solids* (mg/l) Less than 30 mg/l at main pump during circulation

pH As recommended by the cleaning specialist in their sampling

and analysis plan

Dissolved oxygen** As close to zero as possible, but actual value to be interpreted

by the cleaning specialist based on the method of
measurement.

Dissolved iron (mg/l) Less than 3 mg/l or as recommended by the cleaning specialist
in their sampling and analysis plan

Total iron (mg/l) Less than 15 mg/l or as recommended by the cleaning

specialist in their sampling and analysis plan

Dissolved copper (mg/l) Less than 1 mg/l or as recommended by the cleaning specialist
in their sampling and analysis plan

Total copper (mg/l) Less than 1 mg/l or as recommended by the cleaning specialist
in their sampling and analysis plan

Total aluminium*** (mg/l) Less than 1 mg/l

Total zinc (mg/l)**** Less than 1 mg/l or as recommended by the cleaning specialist
in their sampling and analysis plan

Chemical inhibitor levels As recommended by the cleaning specialist in their sampling

and analysis plan

Glycol level If present – as recommended by the cleaning specialist in their

sampling and analysis plan

Bacteria levels

All values within the limits indicated in Table 4.

Applicable to at least two sets of sample results taken at least two weeks apart, with no dosing or system
interference in the two weeks preceding the first set of samples and in the period between samples.

* Solids refers to the insoluble material extracted from the sample point at the maximum available flow from the drain point.
Note: no limit has been set for solids at terminal units. The levels of solids in terminal branches are difficult to predict since
these are often low velocity locations and prone to settlement of solids.
** A single dissolved oxygen value at the inlet to the circulating pump should be recorded for information only. The installer
should be notified if the measured value is high relative to other closed systems. This may be indicative of inadequate
pressurisation leading to air ingress and accelerated corrosion of metals, especially if air pockets are forming.
*** Requires checking only if the system contains aluminium components
**** Zinc levels higher than 1 mg/l may indicate problematic dezincification of brass. Alternatively, raised zinc levels in
systems with thin-walled carbon steel pipe may be due the zinc coatings on some fittings and are not of concern.

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4 INSTALLATION CONSIDERATIONS
4.1 MANAGEMENT

4.1.1 Management

The system installer’s objective is to provide a pipework installation which is as clean as is practically
achievable, and which meets the designer’s requirements for flushing and chemical cleaning. To achieve
this, appropriate programme time periods should be agreed (during the design stages) with the client,
designer, principal contractor and trade contractors, so that properly managed resources are allocated to
the process of system installation and cleaning.

The system installer should review the design approach within the contract documents (following the
guidance within section 2 of this guide) to understand the project’s requirements and to answer the
following questions:
• what system features and facilities have been provided, and will additional features be required to
enable thorough cleaning of the system?
• who is to carry out system flushing and chemical cleaning and were they appointed to give advice at
the design stage?
• what other attendances may be required to enable the works to be carried out?
• how should the cleaning process be programmed in relation to system installation and other
commissioning activities including system balancing, BMS works, and construction internal works
sequencing?

Where the installer has reviewed the contract documents and programme, and has concerns with the
durations, they should advise their employer accordingly with revised programme timeframes appropriate
for the selected cleaning method.

4.1.2 Organisation and planning

This section is applicable where the installer has confirmed the previously agreed cleaning method or is
using a cleaning specialist that has been involved throughout the previous stages of the works.

Together they should:

1. Establish effective lines of communication between the cleaning specialist and other parties involved
(such as the BMS and flow balancing trade contractors).
2. Produce a set of working drawings to meet the specifics of the chosen cleaning method, if not
already shown on the design drawings. These drawings should show the details of any temporary
facilities required.
3. Review the contract documents as suggested in Section 4.1.1, to ensure that the requirements for
chemical cleaning are correct and seek clarification where necessary.
4. Acquire and confirm all necessary information from the designers (previous or current).
5. Retain all documents and literature provided with each delivered item of equipment for use by the
cleaning and water treatment specialist and for inclusion in the operating and maintenance manuals.
6. Advise the designer on any modifications that may be required to the system design to facilitate the
agreed cleaning method.
7. Once the system is installed, verify that proposed flushing and cleaning features have been installed
in compliance with the design. A pre-commission cleaning checklist should be prepared for this
purpose.
8. Develop a system filling plan detailing how systems are to be filled including sectional filling of large
systems.

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9. Determine the potential for partial or phased cleaning of a system and locate suitable isolating valves
to prevent cross-contamination. Spading-off may be possible as a viable alternative to the permanent
installation of valves. Progressive records should be kept of a staged cleaning process. Record
drawings, marked up to indicate which sections have been flushed, will help to achieve this objective.
10. Prepare an outline system-specific method statement and programme for the cleaning procedure,
outlining the main stages of the clean for approval by the designer and construction team. This
should include realistic allowance for contingencies. Any problems or uncertainties related to the
design of the water systems or access to resources should be flagged to the designer and
construction team so that they can be resolved before committing to the overall construction
programme. The method statement should subsequently be expanded by reference to system
schematics and the agreed cleaning programme so that it can be used for witnessing by the
witnessing authority.
11. Prepare a risk assessment with supporting health and safety information for approval by the
designer, site safety supervisor and principal contractor.
12. Agree witnessing and reporting stages for confirmation that the system cleaning is being conducted
in accordance with the agreed procedure, and that the results of the clean are acceptable.
13. Obtain approval from the local sewerage undertaker for the disposal of contaminated flushing water
and in particular, for the disposal of cleaning chemicals (see section 4.1.8 below). This will require
knowledge of the chemicals to be used and when the programme will require their discharge to
drain. It is recommended that this is reviewed at the design stage and the installation stage with the
cleaning specialist. If approval cannot be obtained, make preparations for removal of the waste by
other means.

4.1.3 Record keeping

It is essential that complete and accurate records are created for all works associated with the system. In
particular, the cleaning contractor should maintain detailed records of work carried out and resulting
water quality at all stages of the project starting with first fill and extending to practical completion. A
framework for record keeping is provided in Appendix B.

4.1.4 Choice of chemicals

Proposals for the chemicals to be used for system cleaning, corrosion inhibition and bacteria control
should be made by a cleaning specialist in consultation with the system designer and the future water
treatment specialist where the client has advised their preferred choice. In order to propose the most
appropriate chemicals for the site conditions and circumstances, the cleaning specialist will need to know:
• the method of construction, such as fabrication and jointing methods (this will indicate the potential
degree of contamination from excess jointing materials and installation debris)
• the materials of construction, for example, for pipework, jointing compounds, gaskets, seals, and
valves (so that the cleaning specialist can ensure that any chemicals used will have no adverse effects
on system materials)
• whether prefabricated parts of the system have been water pressure tested off site, and if so, how long
ago (if prolonged, this may indicate deterioration of internal pipe surfaces)
• the anticipated period between installation of the system and first fill (if prolonged, this may indicate
deterioration of internal pipe surfaces)
• the anticipated period between first fill of the system and the start of the chemical clean (if prolonged,
this may indicate deterioration of internal pipe surfaces)
• whether the system has been previously dosed with chemicals, and if so, what type and for what
purpose (Note: residues from previous chemical dosing may interfere with the action of new
chemicals; chemical compatibility is a specialist subject that should be confirmed by the cleaning
specialist).

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• any known restrictions on the disposal of chemicals through public drains (approval must be obtained
from the sewerage undertaker before chemicals can be flushed to drain (see section 4.1.8 below); this
may influence the selection of chemicals).

4.1.5 COSHH regulations

Chemical cleaning can be a hazardous operation. It may involve the use of temporary equipment
generating high pressures, and the application of sometimes relatively aggressive and toxic chemicals in a
site environment which is notoriously difficult to control. Safety of plant and personnel is a major
concern.

The Control of Substances Hazardous to Health Regulations 2002 (COSHH) require that the employers,
such as the contractor and the chemical cleaning subcontractor (including the self-employed), implement
a number of measures. Employers must carry out suitable and sufficient assessments, so that all the
necessary measures to control any hazardous substances can be implemented. Substances that are
hazardous to health include any substances that are labelled as dangerous under the CLP Regulation
(European Regulation (EC) No 1272/2008 on classification, labelling and packaging of substances and
mixtures).

The assessments should cover the substances present, (and any other forms into which they may be
transferred), what harmful effects they may have, what harmful substances are given off during their use,
who may be affected by them, to what extent and period of time they are at risk, how the exposure is
likely to happen and under what circumstances, and what precautions are required to be implemented in
the event of an incident occurring.

In addition, these assessments should make reference to the Health and Safety at Work Act 1974, and to
the duty of care on people carrying out the chemical cleaning process, since the process itself could be
hazardous rather than the actual substances.

Assessments must be completed and recorded before undertaking any chemical clean. This then enables
them to be reviewed if substances, processes or other matters are altered at some later date. It is the
employer’s responsibility to ask for COSHH assessments from contractors and specialists with overall
responsibility for the site. No chemical clean should be attempted without full discussion of all the safety
implications associated with using possibly hazardous chemicals on a customer’s site.

4.1.6 Other risks

The cleaning specialist and operatives must abide by the main contractor’s site safety policy and site safety
plan including the appropriate use of personal protective equipment and permits to work.

The overall risk assessment carried out by the cleaning specialist and operatives must include the general
hazards encountered on construction sites such as:
• working with electricity
• working with machinery
• working at height
• trips and falls
• manual handling.

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4.1.7 Consequential damage

The failure of a temporary fitting while circulating large volumes of water, with or without chemicals,
through a building could result in very significant damage. The cleaning specialist should consider all
reasonable means to reduce the risk of failure and to mitigate the effect of any failure that could occur.

Suitable measures for the safe use of temporary pump sets are described in Section 8.3.2.

4.1.8 Permits to discharge

Water flushed to drain as a result of the pipework flushing and cleaning process is classified as trade
effluent. It is therefore a legal requirement to obtain a trade effluent temporary consent from the local
sewerage undertaker. Legally, the sewerage undertaker must respond (either granting or denying consent)
within a two-month period. Hence, applications for trade effluent temporary consent should be made at
least two months before any flushing activities are due to commence. The application will require
information on the gross volume, flow rate and chemical composition of the discharge. This also applies
to any planned drain-down of system water in use.

This issue is also addressed at section 7.1.5 in relation to the chemical cleaning procedure.

4.2 PIPEWORK INSTALLATION

The installer of the system should ensure that care is taken to limit the amount of dirt entering the system
during installation. The installer should also be aware of the preparation and pre-planning considerations
necessary to ensure successful flushing and cleaning.

4.2.1 Materials storage

Careful storage of pipes and fittings can help to limit the ingress of dirt and debris. Installers should
request that the principal contractor or client allocates storage space in an environment that is clean, and
not subject to temperature swings where condensation might occur.

The following storage principles should apply to all materials and components manufactured or
prefabricated offsite:
• materials and components should be stored in a secured and controlled area away from other trades;
• materials and components should be delivered and stored in packaging supplied by the manufacturer
or stockist;
• pipes should be sealed at their ends so that no damage can occur to the outside bore;
• pipes should be stored at least 200 mm off the floor.

Furthermore, material and components should not be installed into locations where they may be exposed
to the damaging effects of dirt and moisture (for example externally without weather protection).

4.2.2 Good installation practice

Good installation practice is an important precursor to the flushing and cleaning procedure. The
following practices should be the minimum standard which is acceptable:
• Lengths of pipework and components should be inspected prior to installation and any contaminants
removed.
(Note: Pipe cleanliness is particularly important in view of increasing incidences of bacterial
contamination linked to dirt and other nutrients in pipework.)

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• Care should be taken to prevent the ingress of solder, jointing fibres and jointing compounds into the
pipework system.
• Soldered copper pipework should be installed in accordance with WRAS AIM 9-04-02[11] and
manufacturers’ guidance avoiding excessive use of flux. The joints should be cleaned externally
following cooling and flushed internally to remove flux residues.
• Whenever possible, the use of WRAS-approved jointing compounds should be considered as these
will not provide nutrients for bacteria.
• When jointing compounds and fibres are used, only the absolute minimum amount should be applied,
especially at joints to sensitive control or flow measurement devices. Jointing compound should not
be applied to copper compression fittings.
• Prefabricated sections of pipework and fittings, bench-assembled prior to installation, should be
inspected internally and any contaminants removed.
• Strainer drain caps should not be over-tightened (particularly for small bore strainers in copper pipe),
since the force required to open them may cause damage to adjacent pipework.

Prior to any connections being made, particular care should be taken to ensure that all temporary devices
for protecting equipment during transit and storage have been removed.

Open ports of vessels, plant items and pipework ends should be temporarily blanked off until final
connections are made. Before final connections are made, a last inspection should be carried out to
ensure that items such as tools and welding rods have not been inadvertently left within the system.

All cisterns and tanks should be protected during the installation phase of the works and thoroughly
flushed prior to connection to the pipework system. Large thermal stores may benefit from a bypass to
reduce flushing volumes (see Figure 3).

4.3 PREPARATION FOR FLUSHING AND CLEANING

When preparing a system for pre-commission cleaning, consideration should be given to the following
issues.

4.3.1 Method statements and risk assessments

Prior to commencing work, all operatives should be briefed by the cleaning supervisor with copies of the
method statement, system schematics and daily plan of works to ensure that everyone involved has a clear
understanding of their specific responsibilities. Risk assessments should also be reviewed at this time and
updated as necessary.

4.3.2 Installation checks

Prior to filling the system, a thorough inspection of all pipework, fittings and plant should be made to
ensure that the system is complete and watertight, and all plant, terminal units and end-of-run bypass
isolating valves and manual vents are closed.

4.3.3 Drainage

Adequate drainage should be made available, often necessitating direct access to manholes. Drains should
be complete and tested for free running at the proposed discharge rate prior to use. Transfer from fixed
connection flushing drains to the drainage point should be via large-bore, heavy-duty, reinforced flexible
pipes.

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4.3.4 Water supply

A suitable and sufficient source of clean water should be available for filling, flushing and refilling. All
mains and borehole water supplies contain some level of bacteria. The cleaning specialist should advise
on the suitability of the available water sources for filling and flushing and whether the chosen water
source should be treated before use. The minimum water quality at the point of use for filling a typical
low temperature hot water or chilled water system is suggested in Table 6. Other systems may have more
stringent requirements.

Table 6: Fill water quality

Parameter Suggested range

Sulfate (mg/l SO4) <250 mg/l
Chloride (mg/l Cl) <250 mg/l
pH 6.0 to 8.5
Hardness As recommended by water treatment specialist
TVC <1000 cfu/ml
Pseudomonads <1000 cfu/ml at 30°C

If the raw water quality is not adequate then it should be treated to comply with either the values in Table
6 or the recommendations of the cleaning specialist.

Even where the microbiological quality of raw water complies with Table 6, treatment of the initial fill
water may help to reduce the risk of bacteriological problems. However, health and safety requirements
must be taken into account when dosing biocides, since there is a possible risk of site personnel coming
into contact with harmful chemicals should the system leak or fail during pressure testing. The
implications of dumping this water to drain during subsequent cleaning activity also need to be
considered.

Temporary site mains, used to fill and flush pipework systems, have been known to harbour large
numbers of bacteria. It is recommended that all temporary mains are cleaned and chlorinated in
accordance with PD 855468[7] before being used for system filling or flushing.

Minimum recommended sizes of supply pipe when using mains water for flushing are indicated in Table
3. Connections between the mains water supply and system must comply with the backflow prevention
requirements of the Water Supply (Water Fittings) Regulations 1999 (see subsequent Section 4.4.1).

4.4 PROCEDURE FOR FILLING AND PRESSURE TESTING

4.4.1 System filling

In order to minimise biofilm development and consequent risk of bacteria-influenced problems, it is

desirable to minimise the delay between first wetting of the pipework and pre-commission cleaning
(ideally to less than 48 hours). Where this is not possible the installing contractor should ensure that the
system is filled with biocide-dosed water, and if advised by the cleaning specialist, a corrosion inhibitor
should be added. Chemicals should be pulse-injected into the pipework system to a predetermined
concentration, depending on the chemicals selected by the water treatment specialist.

Systems should not be filled unless there is a means of automatic system pressurisation capable of
maintaining all parts of the system at a positive pressure relative to atmosphere. This should preferably be
in the form of a packaged pressurisation unit to provide automatic top-up in the event of water loss from
the system.

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The rate at which the system fills will be dependent on the available fill pressure in relation to the system
height and size. Air vents should be provided as recommended in Section 2.3.1.

The system will normally be filled by one of the following methods:

• Temporary connection from the mains in compliance with the Water Supply (Water Fittings)
Regulations 1999. An acceptable connection is a verifiable backflow preventer with reduced pressure
zone (commonly known as an RPZ).
• Temporary connection from the fire hydrant pipework provided that permission is obtained from the
fire authority and water supply undertaker in advance and the water quality has been verified as
acceptable through testing.
• Installation of a temporary tank and pump arrangement where the main supply capacity is insufficient
for direct connection.
• An alternative source of clean water that complies with water quality guidelines in Table 6.

To avoid problems associated with the adequacy or cleanliness of the supply, a temporary main for the
sole use of the installing contractor is preferable.

Closed-loop pre-treatment cleaning (CPC) methods may assist in reducing bacterial contamination and
corrosion after the initial fill and during system pressure testing. The procedure for system filling when
utilising a pre-treatment clean is described in section 6.

4.4.2 System pressure testing

Prior to the commencement of the cleaning procedure, the entire system should be pressure tested to
recommended industry guidelines such as BESA TR6[12].

If terminal units were not isolated during the fill and pressure test, then they should be subject to an
appropriate cleaning regime.

If prefabricated pipework or equipment has been hydraulically pressure tested off-site prior to installation,
it may subsequently have developed an internal layer of corrosion and biofilm, even if subsequently
drained. The cleaning specialist should be notified of this possibility.

4.4.3 Basic procedure for pressure testing

If the system is to be pressure tested in sections, then the following procedure applies to each section in
turn.
1. Disconnect the sections of pipework immediately upstream of all pumps and inspect for any
contaminants which could damage the impeller. Remove any such contaminants and refit the
pipework section.
2. Open sufficient isolating valves as is necessary to fill and vent the primary ring main, secondary risers
and horizontal distribution mains. All terminal units and major plant items must remain isolated,
with bypasses and/or loops opened.
3. Fill the system with water (dosed with biocide if possible) in accordance with the recommendations
of the cleaning specialist and vent the system mains.
4. With all terminal units and plant items still isolated, pressure test the system.
Note: After cleaning is completed, a full pressure test of the system will be possible without
contaminating the terminal units.

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4.5 PERIOD BETWEEN END OF CLEAN AND PRACTICAL COMPLETION

Internal pipework conditions and the consequent water quality can deteriorate rapidly if systems are not
properly managed during the period leading up to practical completion. It is important the installing
contractor keeps an accurate record of events that may affect water quality.

4.5.1 Routine checks

The following checks carried out routinely through to practical completion will help to preempt corrosion
and water quality problems before damage can occur:
• Operating pressures: Pressure checks at pump gauges and system high points will indicate if the
pressurisation regime is effective. Gauge pressures in all parts of the system should be indicating
values greater than 0.7 bar under all operating conditions.
• Fill water volumes: Metering of the water entering each system will indicate whether there is any
uncontrolled water loss from systems.

4.5.2 Circulation

In order to maintain bacteria levels within acceptable parameters, it is helpful to ensure that all parts of
the system achieve flow as frequently as possible and are not left permanently isolated. Valve exercising
regimes may be appropriate whereby actuated control valves are programmed to open at least once every
24 hours, during an unoccupied period when the heating or cooling sources are not in operation. If pipes
have been sized with allowances for load diversity, the valve exercising regime may need to open groups
of valves in stages. Alternatively, if a low carbon strategy is in place (as described in section 2.3.7) it may
be necessary to rely on the action of temperature-controlled bypasses to provide regular circulation.

4.5.3 System drain-downs

System drain-downs after completion of the clean should be avoided whenever possible.

During the period leading up to practical completion, the cleaning or water treatment specialist
responsible for monitoring water quality in the systems should be informed of any works or incidents
which incur a loss of water including:

• partial draining and refilling

• pipework modifications
• major leaks.

These events may lead to a significant deterioration in water quality with the potential to make re-cleaning
of the systems a necessity. If the cleaning specialist is notified of these events, appropriate measures can
be put in place to minimise damage.

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5 SYSTEM DYNAMIC FLUSHING

5.1 FLUSHING OBJECTIVES

The main objective of the flushing process is to remove as much dirt and debris from the pipework
system as possible in order to reduce the likelihood of blockages and to create the best possible
circumstances for a successful chemical clean and subsequent water treatment regime.

Flushing does not have to involve the discharge of large amounts of water to drains. Closed-loop pre-
treatment cleaning (CPC) solutions exist involving dynamic circulation methods, as described in Section 6
of this guide.

The level of cleanliness achievable by system flushing is very much dependent on the flushing facilities
included at the design and installation stages. Provision should be included in the system for adequate
filling, venting, flushing and/or bypassing of equipment as detailed in the preceding design and
installation sections of this guide.

5.1.1 Importance of water velocity

The water velocity used for flushing should be sufficient to dislodge and transport the dirt and debris
likely to be found in the system. Most of the dense debris to be found in a typical system will be below
5 mm in diameter. Table 7 indicates flushing velocities for horizontal pipework that have been found to
be effective in practice.

Table 7 indicates the flushing flow rate and consequent velocity for steel pipes from 15 mm to 150 mm
nominal diameter conforming to BS EN 10255[9], medium wall series and for steel pipes from 200 mm to
300 mm nominal diameter conforming to BS EN 10216-1[13] (Table 5) at the minimum preferred wall
thickness.

The flushing flow rate for pipes of other thicknesses and materials or conforming to other standards can
be calculated according to the actual internal diameter. In general, the flushing velocities from Table 7
may be used for pipes of the same nominal diameter.

The recommended minimum flushing velocity should be that indicated in Table 7, or the design velocity
plus 10%, whichever is the greater, and achievable using the permanently installed system pumps.

For pipe sizes larger than those shown in Table 7, the flushing flow rate should be the design flow rate
plus 10%.

The flushing velocity should be selected based on the largest pipe size in the system (or section of
pipework) to be flushed. Where achieving the recommended minimum flushing velocities in large-bore
pipes is impractical, consideration should be given to alternative methods of cleaning as described in
Section 2.3.2.

District heating and cooling systems may be designed and constructed for phased delivery, with the
intention to operate them at reduced flows until subsequent phases are connected. Furthermore, these
systems may have large diversity allowances especially if hot water loads are random and intermittent. In
such cases, it may be impractical or even impossible to achieve the recommended flushing velocities in all
parts of the system. To facilitate flushing of these systems, mitigation strategies should be considered at
the design and installation stages.

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Table 7: Recommended minimum flushing velocities and flow rates

Nominal pipe Internal Flushing velocity Flushing flow

size (mm) diameter (mm) (m/s) rate (l/s)

15 16.1 0.96 0.20

20 21.7 1.00 0.37
25 27.3 1.03 0.60
32 36.0 1.06 1.08
40 41.9 1.08 1.49
50 53.2 1.11 2.47
65 68.9 1.15 4.29
80 80.9 1.17 6.01
100 105.3 1.21 10.5
125 129.7 1.24 16.4
150 155.1 1.26 23.8
200 206.5 1.31 43.9
250 260.4 1.35 71.9
300 309.7 1.37 103.2

5.2 DYNAMIC FLUSHING PROCEDURE

5.2.1 General considerations

Wherever possible, the guidance given in section 2.3.1 on water conservation should be observed.
Filtration can be used to minimise not only water use but also effluent discharge (as described in section
6).

All items of plant that are sensitive to sediment should remain isolated and bypassed throughout the
flushing procedure.

Care should be taken to ensure that pumps are not allowed to operate against a closed head for prolonged
periods. This situation should be avoided whenever possible.

Temporary connections to the water source should always be attended when in use and isolated when not
attended.

5.2.2 Basic stages of a flush

The procedure for system flushing should follow the main stages described in Sections 5.2.3 to 5.2.7. The
flushing operation is demonstrated by reference to the system schematic in Figure 9. It is assumed that
the procedures for filling and pressure testing, as described in Section 4.4, have been completed, and that
the system is filled and ready for dynamic flushing.

The valve numbers referenced in the text refer to the valve numbers shown in the schematics.

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Figure 9: System schematic showing valve reference numbers

Typical air handling unit circuits

Top of riser
automatic air
vent

16

15 17

Typical radiator circuits

13

12 14
Typical fan coil circuits

10

9 11

7 8

Dosing pot
PRV

3 Mixing
Low bypass
loss
header
Buffer/thermal
store

Primary Sidestream
circuit filters

2 4
6
5 1

Pressurisation
unit

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5.2.3 Dynamic flushing of primary ring main circuit

In order not to circulate contaminants from large-bore pipes to other parts of the system, the primary
ring main should be dynamically flushed first. The primary ring main is likely to be the area where
recommended minimum flushing velocities are most difficult to achieve. Parts of the primary circuit may
therefore have to be cleaned by one of the alternative measures described in Section 2.3.2.

In circuits with multiple heating or cooling sources, the branches serving those plant items should be
flushed first.

Example Procedure
1. Isolate the secondary circuit by closing valves 3 and 4.
2. Confirm that the major plant items connected to the primary ring main are isolated and bypassed.
3. Insert primary pump strainer baskets.
4. Connect a reinforced flexible hose of adequate diameter to drain valve 1 and run the hose to drain.
5. Close isolating valve 2 and ensure all other valves in the primary circuit are open.
6. Flush each plant circuit in turn with the others isolated. With the ring main fully primed and vented,
gradually open drain valve 1 and the flushing supply valve (valve 5) simultaneously such that positive
pressure is maintained at the inlet to the primary pump (Figure 10).

Figure 10: Flush to drain with return pipe isolated

Secondary
circuit

3
Low loss
header
Buffer/thermal
store

Primary
circuit

4
2
Primary
pump 5 1
Pressurisation
unit

7. Turn on the primary pump. Open isolating valve 2. Rebalance drain valve 1 until the drain rate again
balances the mains flow rate at valve 5. Monitor the primary pump motor current to ensure that the
full load current is not exceeded.

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8. Circulate water through the primary pump and monitor the pressure drop across the pump strainer to
ensure that the manufacturer’s recommended maximum pressure drop is not exceeded and pump
cavitation problems are avoided (Figure 11). Note: throughout the cleaning operation, pressure drops
across all strainers involved in the dynamic flushing and cleaning processes should be regularly
monitored and their pressure drops recorded to ensure that they do not become blocked.

Figure 11: Flush to drain with primary ring main operational

Secondary
circuit

3
Low loss
header
Buffer/thermal
store

Primary
circuit

4
2
Primary
pump 5 1
Pressurisation
unit

9. Measure the flow rate at the primary pump to determine the flushing velocity being achieved. Ask
the witnessing authority to witness the flow rate achieved and record the value.
10. Run the pumps until the drain water runs clear.
11. Stop the primary ring main pump. Close valve 1 and the flushing supply valve (valve 5)
simultaneously. Isolate and clean the primary pump strainer.
12. Replace the strainer basket.
13. Repeat the process for the other plant circuits until the strainer no longer collects sediment.
14. Carry out a final flush with all primary pumps operating simultaneously to maximise the flows in the
primary ring main.

5.2.4 Dynamic flushing of secondary mains pipework

In order to achieve the highest possible flushing velocity in the main secondary circuit pipework, the
valves on all secondary sub-circuits should be fully opened to flow, so that the resistance at the pumps is
as low as possible. During the flush, a flow measurement should be taken at the flow measurement device
in the main return to the secondary pumps. The value obtained should be witnessed by the witnessing
authority and recorded.

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The secondary system water should normally be flushed back into the primary pipework header, and from
there direct to drain. It may sometimes be preferable not to flush contaminated secondary water back into
the clean primary pipework. The flushing water should then be drained at the base of the secondary
circuit take-offs (valve 6), or at the base of the risers (valve 8). This would certainly be the case when the
main plant and primary circuit is installed in a rooftop plant room, and it is deemed impractical to flush
particles back up a vertical return pipe.

For the purpose of the following example procedure, it is assumed that the main proportion of the
flushing water will be deposited to the drain.

Example procedure
1. Ensure that the valves isolating the secondary circuit connections to the primary ring main are still
closed (valves 3 and 4).
2. Ensure that individual terminal units remain isolated and bypassed.
3. Ensure that all valves on the horizontal mains are fully open.
4. Remove or bypass constant flow regulators, DPCVs or PICVs (including those in end of line
bypasses).
5. Ensure that the three-port mixing valve before the secondary pump is in the full-flow non-mixing
position.
6. Establish a flow through the primary by operating all primary pumps simultaneously and (if flushing
from the primary) create a balanced flushing flow into and out of the system as described in the
preceding Section.
7. Open valves 3 and 4.
8. Turn on the secondary pump. If necessary, gradually adjust drain valve 1 (Figure 12). Simultaneously
monitor the secondary pump motor current to ensure that the full load current is not exceeded.
9. Monitor the pressure drop across the secondary pump strainer to ensure that the manufacturer’s
recommended maximum pressure drop is not exceeded, and pump cavitation problems are avoided.
10. Measure the flow rate in the secondary mains to ensure that the specified flushing velocity is being
achieved. Ask the witnessing authority to witness the flow rate achieved and record the value (if the
required flushing velocity cannot be achieved, turn on the standby secondary pump and allow both
pumps to operate in parallel).
11. Run the pumps until the drain water is clear of contaminants.
12. Turn off the secondary pumps. Turn off the primary pumps. Close the flushing drain and fill points
(drain valve 1 followed by flushing supply valve 5).
13. Close valves 3 and 4.
14. Close all valves on the horizontal mains to each floor (valves 9 to 17).
15. Isolate and clean the primary and secondary pump strainers.
16. Isolate and clean the dirt pockets at the base of each riser (valves 7 and 8).

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Figure 12: First flush through horizontal mains

Typical air handling unit circuits

Top of riser
automatic air
vent

16

15 17
Typical radiator circuits

13

12 14
Typical fan coil circuits

10

9 11

7 8
Dosing pot
PRV

Mixing
Low 3
bypass
loss
header
Buffer/thermal
store

Primary
circuit Sidestream
filters

2 4
6
5 1

Pressurisation
unit

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5.2.5 Dynamic flushing of horizontal mains to each floor

The flushing procedure should be tailored to the design of the system by the cleaning specialist. In
general, flushing should start from the top floor and work down the building through intermediate levels
to the ground or lowest floor. In order to achieve the specified minimum flushing velocity along the full
length of the horizontal mains, it will probably be necessary to open the flushing bypasses to the terminal
units in batches, starting from the end terminal and working back towards the riser. This is to prevent the
water short circuiting the downstream pipe sections. (For reverse return systems, the units should be
opened commencing with the unit closest in the direction of flow.)

A sufficiently large batch of terminal unit bypasses must be opened to ensure that the required flushing
velocity is achieved in the main pipe serving the batch. This essentially means opening a sufficient
number of terminal unit bypasses, such that the total bypass pipe area is equivalent to the area of the main
pipe local to the batch under flush.

An example of “batch flushing” would be as follows:

Start with one open bypass at the furthest unit from the branch mains. For example, given the
arrangement of terminals shown in Figure 13, the flush might start with only one bypass to terminal T6
open. When this flush is complete, the bypass to terminal T5 would be opened. When this flush is
complete the bypass to terminal T4 is opened and terminal T6 might be closed (depending on the velocity
achieved). As each batch flush is completed (assessed by monitoring the water quality from a drain cock
located on the return pipe to the riser) the flush is moved on by opening one further terminal unit bypass
and closing another as appropriate. As the batch moves along the horizontal pipe the entire pipework
length is flushed to achieve the necessary minimum flushing velocity.

Figure 13: Staged flush of terminal unit bypasses

T1 T2 T3 T4 T5 T6

When the batch flushing process is complete, all terminal unit bypasses should be opened in sequence
back to the furthest terminal unit.

It should be remembered that as the batches roll from the furthest terminal unit towards the main floor
valve, the pipework sizes may increase, which in turn may require the batch size (i.e. the number of
simultaneously open bypasses) to increase to maintain the flushing velocity for the adjacent mains
pipework size.

When undertaking batch work flushing of a reverse return circuit, consideration must be given to the
pipework size changes that take place at the centre of the pipe run. A reverse return circuit will
incorporate large-bore pipework on the flow and small-bore pipework on the return at the connection

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point to the first terminal unit and conversely a small-bore flow and large-bore return at the connection
point to the last terminal unit. Dynamic flushing batch work needs to be modified to take this into
account when flushing these circuits.

It is important that between each batch flush, water quality is monitored, ensuring the water is visually
clear and free of debris before moving to the next batch. This is important when undertaking fit-out
cleaning via a temporary pump, where recirculation of mobilised debris is highly likely due to the short
circuit lengths in use and restricted water to drain volume relative to the recirculating water volume. If a
batch is moved on prematurely and debris-free water is not verified, debris fall out is possible at the “just
closed” terminal unit bypass.

For large systems the batch work flushing process may take a number of days. The cleaning specialist
should advise and, if necessary, take measures to protect the pipes during this period, possibly by adding a
holding charge of corrosion inhibitor at the end of each day to reduce overnight corrosion.

Due to the difficulty of setting the system into the correct batch arrangement for retrospective witnessing,
witnessing and recording of flushing velocities should ideally be undertaken during the process itself.

Example Procedure
1. Set up the flushing condition by following the same basic procedure as described in Section 5.2.4
(stages 1 to 9), but with only isolating valves 15 and 16 serving the top horizontal mains open to flow,
and valves 9, 10, 12 and 13 closed (Figure 14).
2. Close a sufficient number of terminal unit bypasses, such that the bypass pipe area is equivalent to the
pipe area onto the floor.
3. Measure the flow rate in the pipework onto the floor to ensure that the specified flushing velocity is
being achieved. Ask the witnessing authority to witness the flow rate achieved and record the value. (If
the required flushing velocity cannot be achieved, turn on the standby secondary pump and allow both
pumps to operate in parallel).
4. Work back along the system, closing and opening terminal bypasses until all sections of the pipework
run have been flushed at the required velocity.
5. Continue the process until the drain water is free from contaminants.
6. Close valves 15 and 16 on the top floor and simultaneously open valves 12 and 13 to allow the water
to flush through the horizontal mains on the next floor down (Figure 15). Note: in the absence of
bypasses the flush involves a simple flush through the end of run bypass.
7. Close valves 12 and 13 on the middle floor and simultaneously open valves 9 and 10 to allow the
water to flush through the horizontal mains on the next floor down. Repeat stages 2 to 5 until the
cleaning process is complete.
8. Check the pressure drop across the primary and secondary pump strainers. (If necessary, turn off the
pumps and clean the strainer baskets and dirt pockets.)
9. Turn off the secondary pump. Turn off the primary pump. Close drain valve 1 followed by flushing
supply valve 5.
10. Isolate and clean the primary and secondary pump strainers.
11. Isolate and clean the dirt pockets at the base of each riser (valves 7 and 8).
12. Repeat the flushing procedure for each of the secondary circuits fed from the primary circuit header.

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Figure 14: Forward flush through horizontal mains on top floor

Typical air handling unit circuits

Top of riser
automatic air
vent
16

15 17

Typical radiator circuits

13

12 14
Typical fan coil circuits

10

9 11

7 8
Dosing pot
PRV

Mixing
Low 3 bypass
loss
header
Buffer/thermal
store

Primary
circuit Sidestream
filters

2 4
6
5 1

Pressurisation
unit

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Figure 15: Forward flush through horizontal mains on intermediate floors

Typical air handling unit circuits

Top of riser
automatic air
vent
16

15 17

Typical radiator circuits

13

12 14
Typical fan coil circuits

10

9 11

7 8
Dosing pot
PRV

Mixing
Low 3 bypass
loss
header
Buffer/thermal
store

Primary
circuit Sidestream
filters

2 4
6
5 1

Pressurisation
unit

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5.2.6 Final full system flush

If individual circuits or sections of pipe are left isolated for a period of time after flushing, the dissolved
iron level in the water will increase. To bring all parts of the system back within the guidelines defined in
Section 3, the entire system should be flushed again simultaneously following the approach illustrated in
Figure 12. The aim is to dilute and replenish the system water; there is no need to measure flushing flow
rates.

5.2.7 Reconnection of terminal units and main plant items

Only after the primary and secondary circuits have been flushed, chemically cleaned (as described in
Section 7), and finally dosed with biocide and inhibitor should system water be permitted to enter
terminal units and plant items.

All terminal units and plant items should have been isolated and bypassed during the preceding flushing
and chemical cleaning stages. Those that were not isolated should have been cleaned at the same time as
the adjoining pipework.

To flush these components, the bypasses should be closed and each unit should be flushed as shown in
Figure 16. For plant items and terminal branches protected by in-line strainers, the strainer baskets should
be initially be left in place to catch large solids but then removed to maximise the flushing flow rate.

The purpose of flushing is to remove any loose debris which might have entered during manufacture of
these components. Although the amount of debris likely to be found in any one terminal unit is not great,
if allowed to enter the system, the accumulated deposits may cause unacceptable levels of suspended
solids in circulation.

Figure 16: Two-stage flush through terminal unit

Stage 1 Stage 2

Terminal units can be flushed, using the inhibitor and biocide-dosed system water, into a temporary
vessel such as a bucket.

The flushing of specified terminal units should be witnessed by the witnessing authority. Any units
blocked or partially blocked should be reported back to the installing contractor.

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6 CLOSED-LOOP PRE-TREATMENT CLEANING (CPC)

Closed-loop pre-treatment cleaning (CPC) is a method for cleaning installations by filling with chemically
dosed pre-treated water and dynamically circulating the water through deep-bed filter media housings to
remove contaminants. The fill water may also be pre-treated with non-chemical methods such as ultra-
violet or other bacteriological removal equipment. CPC is undertaken without the need for a chemical
cleaning procedure of the type described in section 7.

CPC can reduce water consumption, providing either an effluent-free or reduced-effluent process with
potential environmental benefits. Only sufficient water to fill the system (plus temporary cleaning
equipment) is usually required to undertake this method. CPC may therefore be advantageous where:

• water supplies are limited;

• demineralised or softened fill water is used;
• system draining is impractical.

Depending on the project circumstances, the CPC process may also offer programme advantages as fewer
stages may be involved. The process may offer a more flexible and adaptable approach on large projects
with multiple stages involving phased completion.

As water is not exchanged during the cleaning process, system trending using a corrosion monitoring
service may commence as soon as the system has been filled.

6.1 CPC SYSTEM FILLING

CPC filling is undertaken by pre-treating the initial system fill water (i.e. the water used to fill the system
for the first time). Chemicals to assist in mobilising system contaminants and provide corrosion and
microbiological protection are introduced via specialised pre-treatment equipment, directly in proportion
to the volume of fill water. This pre-treated water is then used to clean the system by circulating it
through filter media to remove solids with minimal flushing to drain.

The pre-treatment equipment and associated filling process should aim to provide optimum corrosion
and microbiological protection to installations at the point of filling. A purpose-built pre-treatment rig
(CPC filling unit) should be used for this purpose which would ideally incorporate the following, as
appropriate:
• adjustable proportional dosing equipment for the introduction of corrosion and microbiological
control chemicals
• microbiological reduction and or removal apparatus
• failsafe mechanisms to prevent the introduction of untreated or under-treated make-up water
• volumetric water meter
• incoming and outgoing water testing points
• hygienic connection hoses.

During, and on completion of filling, tests should be undertaken on the fill water to ensure that the pre-
treatment equipment is functioning correctly and that acceptable chemical and microbiological parameters
are being achieved. Standard on-site test kits may be used for determining key chemical properties, and an
ATP site test kit can be used to indicate and monitor microbiological levels. These methods may be
supported by laboratory analysis, as appropriate. If microbiological removal or reduction apparatus is
incorporated, laboratory sampling of system water may commence seven days after completion of the
final bulk fill.

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Installations should ideally be filled from the lowest point. During filling, thorough venting procedures
should be undertaken using installed facilities. The CPC filling unit should then remain connected to the
system during the dynamic circulation process and be used for system make-up water.

6.2 CPC DYNAMIC FLUSH

For the purpose of flushing the system, temporary CPC conditioning units (or filter units) should be
fitted on a common system return circulation point to remove contaminants, as shown in Figure 17.

Figure 17: Inclusion of CPC conditioning units

Low loss
header

Buffer/thermal
store

Primary
circuit

Pressurisation
unit

CPC conditioning unit

incorporating filtration and
deaeration apparatus

The conditioning unit should be connected to the system using appropriately pressure and temperature-
rated hoses or pipework taking account of system operating pressure at the point of connection. The unit
should be fitted with a flow measurement device to enable measurement of cleaning rates and as a way of
indicating the condition of filter media.

Temporary deaeration equipment should also be connected to the system or conditioning unit during
flushing to help stifle corrosion during the process itself. The deaeration equipment should be connected
at a common circulation point in the system and deaeration should normally be undertaken on a side-
stream basis. The deaeration equipment must have a working pressure rating greater than the system head
pressure, at the point of connection. Due to system pressures, it may be necessary to locate the
deaeration equipment remotely from the conditioning unit.

After filling, the system is subjected to dynamic flushing velocities, as described in sections 5.2.3 for
primary circuits and 5.2.4 for secondary circuits. The main difference in the procedure is that instead of

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opening valves to allow flushing water to enter and drain from the system, flushing water is directed
through the conditioning unit so that debris is removed by the filter media.

The cleaning can be undertaken on either a side-stream or a full-flow basis, but ideally it should be full-
flow as this has the advantage of preventing the recirculation of contaminants. As all, or a proportion of,
the recirculating water is passed through the filter, the duration of the clean will depend on the method
chosen.

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7 CHEMICAL CLEANING PROCEDURE

7.1 INTRODUCTION

Chemical cleaning is the responsibility of the cleaning specialist. However, in order to ensure that the
chemical clean is successful, the installing contractor should be prepared to commit resources to assist
with the process. In particular, the installer will need to be aware of system conditions that should be
maintained during the clean.

The cleaning specialist should verify that all proposed cleaning and water treatment chemicals are
compatible with system materials (particularly metals, metal alloys and rubber seals).

7.1.1 The importance of pre-flushing

Properly executed clean water flushing as described in Section 5 is an essential prerequisite to the
chemical cleaning programme.

Chemical cleaning should not be attempted unless the system has been thoroughly flushed to the
satisfaction of the cleaning specialist.

If a system contains significant amounts of loose installation or corrosion debris and flushing is not
carried out before the chemical clean, then the result will be high consumption of chemicals, while the
cleaning effect will be minimal.

If there has been a delay between pressure testing and pre-commission cleaning then a biocide wash may
help to improve the effectiveness of the pre-flush and chemical cleaning by disrupting accumulated
biofilm.

Chemical cleaning should be carried out immediately after the preceding dynamic flush.

7.1.2 The importance of flow

Proper circulation in all parts of the system is essential to effect thorough cleaning within a predictable
timescale. Proper system flow ensures that:
• fresh cleaning agents are continually presented to the deposits, helping to speed up their
dissolution
• the penetration of deposits by the chemicals is assisted by the mechanical action of the fluid flow
• the temperature of cleaning agents (and metal) are kept even around the system
• insoluble material is kept in suspension and does not redeposit in the pipework
• accurate quality control is possible due to uniform sample availability
• any gases produced due to the cleaning agent are carried to vent in the flow stream.

7.1.3 The importance of temperature

Pre-commission cleaning is generally carried out cold as boilers may not yet have been commissioned.
However, very cold weather may result in extended contact periods. The cleaning specialist should advise
the project manager on the minimum acceptable temperature for the proposed cleaning methodology and
contingency measures in case this temperature cannot be achieved without heating.

If heat is available, either from the boiler plant or a temporary heat source, then it may be possible to
reduce the period of exposure to the cleaning chemicals and achieve a more effective clean. Heating to
40C may provide a useful increase in cleaning effectiveness without introducing additional safety issues.

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This may also be achievable in a chilled water system subject to isolation of temperature-sensitive plant
and equipment.

Cycling the circulation temperature may also help to dislodge corrosion deposits in difficult-to-clean
situations through thermal expansion and contraction of the pipework.

7.1.4 Duration of chemical circulation within the system

The required chemical circulation time for a successful clean is usually between 12 and 72 hours, run
either continuously or intermittently (in eight-hour periods for example). The circulation period is specific
to the chemical being employed and will be dependent on factors such as:
• the cleaning solution to be used
• the concentration of the cleaning solution
• the pH of the cleaning solution
• the temperature of the cleaning solution
• the type of iron oxide deposits present
• the types of non-iron-oxide constituents in the deposits
• the type and thickness of deposits
• the surface condition of deposits (hard or soft)
• the chemical compatibility with system materials.

The progress of the clean should be monitored as recommended by the chosen chemical manufacturing
company to ensure that the clean is effective and complete. Methods for monitoring the clean might
include:
• monitoring of dissolved iron levels until they plateau (i.e. do not increase) when more cleaning
chemical is added. This will confirm that the cleaning product is not saturated and the stabilisation of
dissolved iron levels is because there are no remaining iron oxides in the system.
• Inspection of accessible surfaces. Removeable pipe sections or corrosion coupons can be removed for
visual inspection to confirm the efficacy of the clean.

A record of the clean should be kept including measured dissolved iron levels after each addition and
circulation of cleaning chemical. The cleaning process should be described in advance as part of the
proposed cleaning method statement.

7.1.5 Disposal of chemicals

It is sometimes possible to discharge diluted chemicals into foul water drains. Under no circumstances
should chemicals be discharged into surface water drains.

Before any water containing chemicals can be discharged into the public drains, permission must be
obtained from the sewerage undertaker. Application must be made and details given of the chemicals to
be discharged, the maximum quantity, the maximum rate of discharge, the temperature, and the proposed
date on which the discharge will take place.

Permission to allow the discharge will depend primarily on the nature of the chemicals. The discharge
must comply with legal requirements, including the Control of Pollution Act 1974 (as amended), The
Trade Effluents (Prescribed Processes and Substances) Regulations 1989 (as amended) and The Trade
Effluents (Prescribed Processes and Substances) Regulations 1992.

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Based on these acts and regulations, the sewerage undertaker can specify the limits for temperature, pH
and concentrations of substances which may be permitted for discharge. Effluents which do not meet
these criteria will not be permitted.

In addition to an assessment of the substances in the effluent, the sewerage undertaker will also take into
account the size and condition of the local sewers and sewage works, together with the degree of
downstream usage for the local rivers into which the treated effluent will eventually be deposited. As
there is considerable reusage of river water in the London area, this imposes greater restrictions on the
quantities of chemicals permitted for discharge.

7.2 CLEANING OPTIONS

A typical chemical cleaning programme is likely to include some or all of the following procedures:
• dynamic flushing
• biocide wash (for systems at risk from bacteria)
• removal of surface oxides (for systems with mild steel components)
• effluent disposal/final flushing
• neutralisation (for inhibited acid cleans only)
• passivation
• addition of inhibitor holding charges to minimise corrosion during the final flush stage
• final corrosion inhibitor and biocide dosing.

Dynamic flushing, as described in section 5 of this guide, is an essential prerequisite to any system
chemical clean.

Note that dynamic flushing may need to be carried out several times, between different stages of the
cleaning programme, depending on the processes employed.

7.2.1 Biocide wash

In order to control bacteria and biofilms that may have become established inside pipework during the
installation process, it may be advisable to carry out a preliminary biocide wash as an initial stage of the
chemical cleaning procedure. This largely depends on the time elapsed between initial wetting of the
system and pre-commission cleaning and the results of bacteriological testing if carried out during the
intervening period.

A biocide wash may not always be necessary, and the advice of the cleaning specialist should be sought.

7.2.2 Removal of surface oxides

There are a number of different chemical processes used for this activity:
• Inhibited acid cleaning
• Formulated products, such as polymers, chelants, and other formulated products.

Inhibited acid cleaning

Acid cleaning involves the circulation of citric acid or other organic acids at low concentration and can be
used for the removal of unwanted oxides and deposited scales from pipe surfaces.

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Ammoniated citric acid is recommended where austenitic steels or non-ferrous metals and alloys are
present. The monoammonium form of citric acid, neutralised to pH 3.5 to 4.0 has proved to be a useful
solvent for iron oxides.

In all uses of acids for cleaning there is a risk of both general and localised pitting corrosion of the metal,
once the removal of the oxide or scale has been achieved. Therefore, the action of the cleaning solution
should be controlled by the addition of a suitable acid inhibitor. The appropriate acid inhibitor will be
specific to the type of acid being used. The temperature may need to be kept within a set range to
minimise corrosion. Mixed with the acid before starting the clean, the acid inhibitor will not interfere in
the chemical reaction between the deposit and acid but will substantially minimise the reaction with good
metal.

Formulated products
Polymer cleaning: Polymer cleaners, otherwise known as dispersants, act by creating repellent forces
between individual particles in the solution. They are therefore able to break down the loose surface
deposits on the pipework and ensure that they stay in suspension until either flushed to drain or trapped
in a suitable filter. By installing a filtration unit in the main return pipe (or pipes) to remove dislodged
solids, dynamic flushing periods and flushing water consumptions can often be significantly reduced.

Polymer cleaners differ from acids and chelants in that they are not intended to dissolve the metal oxides.
Treatment of steel pipes with polymer cleaners will leave the original hard layer of impervious magnetite,
which may offer some degree of protection against further corrosion of the metal underneath.

Chelants and sequestrants: Oxides can be removed by application of chelant and sequestrant-based
formulated agents, otherwise known as complexing agents.

These agents can be used to remove iron oxide directly from steel, at pH 9.2. However, to achieve a
useful rate of dissolution of iron oxide, the process has to be carried out at an elevated temperature and
high pressure (typically 160°C and 5.5 bar) making it unsuitable for low temperature hot water heating
systems, chilled water systems and condenser water systems. More usually it is part of a formulated
product.

Under certain conditions, complexing agents can attack the underlying metal. A suitable inhibitor may
therefore be included in proprietary formulations.

Other formulated products: Neutral pH cleaners are proprietary formulations consisting of different
chemicals performing different functions. A single product might contain organic wetting agents and
detergents for degreasing, inorganic and/or organic corrosion inhibitors, reducing compounds and
organic iron oxide removers (chelants and sequestrants).

A particular feature of some formulated products is that they can promote a passive metal surface which
can be retained after the cleaning has been completed.

7.2.3 Effluent disposal / final flushing

The disposal of chemicals should be as agreed with the contractor in advance with due regard to the
limitations outlined in Section 7.1.5.

All chemicals should be removed by clean water rinsing and flushing at this stage, so decreasing their
corrosive effects by achieving neutral conditions, that is a pH value of approximately 7, depending on the
quality of the water used.

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The procedure for final flushing should be devised and agreed by the cleaning specialist. The final flush is
usually a dynamic flush of the system, taking particular care to ensure that no dead legs are left un-
flushed. The procedure used will be based on the principles described in Section 5 of this guide.
The use of flocculants or dispersants during the final flushing stages may further assist in mobilising any
loosely adherent particles.

7.2.4 Neutralisation

A neutralisation stage may be necessary if an inhibited acid cleaning agent is used. The final flushing will
have removed the majority of the cleaning chemical, but to ensure that any isolated pockets of chemical
are rendered harmless, an alkali solution may need to be introduced to the system. This may be a separate
stage in the process, or it may be achieved by introducing an alkali water treatment chemical. The same
chemical will then perform the functions of neutralising agent, passivating agent and corrosion inhibitor.

7.2.5 Passivation

After the system has been finally flushed, if a cleaning agent which is not also a surface passivator has
been employed, the pipework surfaces are left in an “active” state, therefore they are clean and exposed
and are particularly prone to further corrosion. Therefore, passivation of the exposed pipework surfaces
should take place immediately after the final flushing in order to render the active metal surfaces passive.
Passivation is achieved by introducing a passivating agent to the system. This may be a separate chemical
or it may be part of the function of the water treatment corrosion inhibitor chemicals.

7.2.6 Corrosion inhibitor / biocide dosing

On completion of the chemical clean, the system should be dosed with corrosion inhibitors and biocides
to help control the subsequent corrosion of the metal, and the possible development of microbiological
growth. One week after dosing, samples of the system water should be taken for testing and for record
purposes in accordance with Section 3.

Corrosion inhibitors
Although highly effective as a protection against corrosion in steel systems, nitrite-based corrosion
inhibitors can, in certain circumstances, exacerbate microbiological problems. Nitrite-reducing bacteria
(including some pseudomonas species) can use nitrite simultaneously encouraging their multiplication
while depleting inhibitor levels.

Many inhibitor formulations for heating and chilled water systems contain both nitrite and molybdate, the
latter of which is slower to take effect but is unaffected by biological degradation.

Inhibitor products also typically incorporate copper corrosion inhibitors such as azole chemicals. Azole-
based inhibitors for copper and copper alloys are also available.

Biocides
Biocides should be selected by the cleaning specialist to suit the system and the particular stage of system
cleaning. Biocides may be dosed into static systems to prevent bacteria multiplying when there is a delay
between pressure testing and the commencement of flushing and chemical cleaning (see Section 4.4.1).
They may also be used in conjunction with biodispersants to kill bacteria and remove biofilms during a
biocide wash. Finally, after the final fill of the system they will be used to provide ongoing protection for
the system against bacteria.

Note that all biocides selected for use must meet the requirements of the Biocidal Products Regulations
2001 (BPR). Written evidence from the chemical manufacturer should be provided confirming that the
active molecules in the biocide formulation are listed as participating on the European Chemicals Agency
(ECHA) Article 95 list.

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7.2.7 Treatment up to practical completion

The cleaning specialist or nominated water treatment contractor should continue to monitor and
maintain water quality until practical completion as described in section 3.3. The purpose of this
monitoring is to ensure that corrosion inhibitors are maintained at an effective concentration and to
establish whether the water quality is stable prior to practical completion.

During this period, water should be circulated and control valves exercised to ensure that treatment
chemicals are uniformly dispersed around the system.

7.3 ONGOING WATER TREATMENT

Water treatment is necessary throughout the operating life of the system to inhibit corrosion, control
bacteria and maintain system efficiency and life expectancy. Routine water treatment should follow the
advice of the water treatment specialist. Guidance is provided in BSRIA guide BG 50[4].

Regardless of the water treatment regime, it should be recognised that the corrosion of heating and
cooling systems is predominantly influenced by the level of dissolved oxygen in the circulating water.
Maintaining systems in a pressurised, water-tight condition is therefore essential. Excessive levels of
dissolved oxygen may cause incomplete passivation of surfaces and accelerated corrosion.

Furthermore, if anodic type corrosion inhibitors such as nitrite-based and molybdate-based products are
used, it is important that the levels are maintained at those recommended by the product supplier. If
levels are permitted to fall, this may also lead to partial passivation of metal surfaces and an increased risk
of localised pitting corrosion.

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8 CONNECTIONS BETWEEN NEW AND EXISTING

SYSTEMS
To protect water quality in existing systems when they are extended or modified, newly installed pipes
should be cleaned and treated before being connected to an existing system. This situation is applicable to
shell and core projects where the base build system (after it has been in operation for more than three
months) may be viewed as an existing system, and tenant fit-out systems scheduled for connection would
be considered as new systems.

If systems are properly checked before connection, disputes concerning the origin of water quality
problems can be avoided.

Where there is no overriding need to provide direct connection between the new system and the existing
one, the designer should consider the possibility of indirect connection via plate heat exchangers. In that
case there is no possibility of cross contamination and cleaning of the new system can be considered in
isolation.

Note: This section is not applicable to small residential systems connected from indirect-fed heat interface
units i.e. units that incorporate a plate heat exchanger to maintain a separation between the water in the
residential system and the system providing the primary heat source.

8.1 SCOPE OF CLEAN REQUIRED

If the proposed new works are small relative to the size of the existing system, then the cleaning process
can be kept simple.

For example, where individual copper-fed terminal units are replaced or relocated and the works involve a
drain-down time of less than one working day, then the new or relocated terminals and copper pipes can
simply be flushed with existing treated system water following the guidance given in Section 5.2.7.

However, if the works involve draining mild steel pipes, then a full reclean may be required. A reclean is
recommended unless the drain-down lasts for less than 8 hours and the system is immediately refilled
with treated water and circulated. If the drained pipe sections are large relative to the overall size of the
system, it may still be advisable to reclean the drained pipework.

The above guidance applies to modifications to existing systems in a clean condition. Where
modifications are made to older systems, some assessment should be made of the pipework condition to
assess the levels of cleaning works required.

8.2 WATER SAMPLING

Whatever the extent of the new works, the condition of water in the existing system should be established
at the outset. Early sampling of water from the existing system will ensure that if the water quality is poor,
the maximum possible time is available to carry out remedial treatment on the existing system before the
new works are connected.

Before any new pipework is connected into the existing system, the quality of water in the new pipework
should also be demonstrated.

Water samples for both new and existing systems should be taken in sufficient numbers and appropriate
locations so as to obtain a proper indication of the overall system condition. Appropriate locations might
include drains around main plant items, system extremities, areas of low water velocity (such as terminal
branches), or areas that may have been temporarily isolated.

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An indication of the minimum number of samples can be taken from BS 8552[8] as summarised in
Appendix A, treating the new and existing systems as separate. The sampling procedure should comply
with BS 8552.

Acceptance will normally be based on one set of samples that complies with the guidelines in Table 4, or
as advised by the cleaning specialist.

8.3 SHELL AND CORE TYPE PROJECTS

Where it is known that a system will be extended at a future date, such as in shell and core type projects,
allowance should be made to facilitate connections between the main base-building system and future fit-
out works.

8.3.1 Provision for future extension

Figure 18 shows a typical pipe connection with allowance for future extension.

Figure 18: Branch connection showing provisions for future connection

2 5

Base building installation Fit-out installation

1 A permanent full-bore flushing bypass creates a low resistance path enabling the required flushing velocities to be
achieved in the base build pipework.

2 A temporary bypass between flow and return pipe connections prevents them from becoming dead legs where dirt
or bacteria could collect. If a drain cock is located in the temporary bypass, this will also allow water samples to be
taken.

3 The temporary bypass should contain a valve to enable a minimum flow rate to be set and maintained. In variable
flow systems, this is likely to be a PICV which will act to hold a fixed flow. The PICV may also be temperature
controlled so that it only opens when the temperature in the circuit reaches a set value.

4 The future works should be terminated with isolating valves to facilitate final connection of the cleaned and treated
system. When connected, the flow side isolating valve will act as downstream isolation for the strainer.

5 A visible air gap should be maintained at all times between existing and future works so that no confusion can arise
as to whether the two systems are connected or not. The gap will eventually be filled with a short section of pipe
(commonly referred to as a spool piece). To avoid the need for long and unwieldy spool pieces, the distance
between new and existing pipework should be kept as short as possible, while ensuring adequate space for the
required valve arrangement and the connection of pipework and hoses to a temporary pump. Suitable facilities
should be included with the spool piece to allow adequate venting at the time of fit-out/base build connection.

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8.3.2 Temporary pump sets

A temporary pump set will be needed to circulate chemicals and achieve flushing velocities in new circuits
that do not have their own pumps.

The temporary pump should be sized such that it can achieve the flushing velocity specified in Table 7,
(or the design velocity plus 10%, whichever is the greater). The system designer or installing contractor
should be able to provide values for the design flow rate and pressure loss through the new system.

Suitable locations for temporary pumps should be identified which are away from emergency exit routes
but within reach of electrical, water supply and drain facilities.
All temporary pumps should be:
• fitted with pressure control
• where necessary, located in bunds to retain water in the event of a leak
• connected to the building systems with hoses and components that are tested and rated to at least 1.5
times the maximum pump pressure.

Figure 19 shows typical provisions in a temporary pump set.

Rubber-lined hoses are susceptible to colonisation by bacteria and should be sterilised before use.

PRE-COMMISSION CLEANING OF PIPEWORK SYSTEMS 65

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 8 CONNECTIONS BETWEEN NEW AND EXISTING SYSTEMS

Figure 19: Temporary pump arrangement

2
1

3 4 8 9

7 6

1. Flexible pipe between the temporary pump and system is acceptable for short periods. However, if the temporary
pump is to be left in place for more than one month then connections should be hard piped. Flexible hoses used for
flushing purposes must be sterilised before use to avoid the risk of bacterial contamination.

2. All flexible hose connections should be screwed. Quick release couplings or jubilee clips could present a hazard if
they work loose or are released under pressure.

3. A regulating valve with flow measurement device is required on the return connection from the system to permit
measurement and regulation of the flushing velocity. For this application, a variable orifice regulating valve offers
greater flexibility since it can be used to measure a wider range of flow rates.

4. A strainer on the pump inlet is required to protect the pump against circulating debris.

5. The entire temporary pump set should be mounted in a tank or bund so that drips or spillages do not cause damage
to underfloor services, structure or finishes.

6. A water supply will be required to replenish dirty water drained from the system. The smaller the supply available
the longer it will take to clean the system. To facilitate the process, flushing connections should be provided in the
domestic cold water system by the base build team. An acceptable connection is a verifiable backflow preventer with
reduced pressure zone (commonly known as an RPZ).

7. A drain connection will be required to remove dirty water. A purpose-made drain point should be installed in the
main foul drainage system at a convenient location for this purpose. An effluent permit will be required, and this may
need to include all chemicals proposed for use and those present in the system. Where a trapped waste connection
is provided solely for the purpose of facilitating the flushing process, this must be removed and capped after
completion.

8. A thermometer on the outlet from the pump will provide a check that circulating temperatures are below levels at
which bacteria could multiply.

9. A pressure gauge will demonstrate that the system is operating in a fully pressurised condition.

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 CONNECTIONS BETWEEN NEW AND EXISTING SYSTEMS 8
8.3.3 The cleaning process

With the appropriate temporary pumping facilities in place, flushing and cleaning of the new system
pipework can be carried out following the same basic procedures as described in Sections 5, 6 and 7 of
this guide. On completion of the cleaning process, the system should be dosed with corrosion inhibitor
and biocide chemicals as recommended in Section 7.2.6. Final dosage chemicals should be the same as
those in the base build system.

Seven days after dosing, samples should be taken to check for compliance with the criteria set down in
Table 4 (and the base build cleaning specialist’s sampling and analysis plan). If the results differ
significantly from the values set, appropriate remedial measures should be implemented.

8.3.4 Maintaining system cleanliness

The entire process of flushing, chemical cleaning and dosing the new system should be timed such that
connection to the existing system can take place as soon as possible after completion. Since time is
needed to prove adequate water quality, this is unlikely to be less than two weeks after completion of the
clean. Note that water quality should not be maintained by use of a temporary pump for longer than is
necessary.

During this period, the temporary pumps should be used to circulate the clean water and treatment
chemicals. The pumps should be run intermittently, at intervals recommended by the cleaning specialist,
making sure to avoid any increase in water temperature that might promote bacteria growth.
Furthermore, groups of terminals may need to be temporarily isolated in order to force treated water to
circulate around more remote branches rather those closest to the pump.

If the system is to be operated in this way for a prolonged period, the cleaning specialist should institute a
circulation and sampling regime to check water quality and undertake dosing as required. Where
temporary pumps are to be shared between different circuits, care should be taken not to spread bacteria
between circuits via the temporary pump.

8.3.5 Final connection

Final connection should be made only when satisfactory water analysis results have been obtained for the
newly installed pipework. It is a good idea to implement a certification system to confirm and record
system cleanliness prior to connection. An example form is shown in Appendix C.

The connection methodology should be agreed with the base build contractor/landlord at the earliest
opportunity.

Care should be taken to ensure that the spool piece is in a clean, treated condition before it is connected
into the system. If the spool piece shows signs of internal corrosion or contamination, it should be
cleaned using appropriate cleaning chemicals. Before installation, the spool piece should be immersed in
inhibitor and biocide chemicals overnight. To facilitate this operation, spool pieces should be kept as
small as possible.

Prior to installation, the spool piece should be visually inspected, and its condition witnessed by the
witnessing authority.

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 A APPENDIX – NUMBERS AND LOCATIONS OF SAMPLES

APPENDIX A – NUMBERS AND LOCATIONS OF SAMPLES

The information in the following tables is extracted from BS 8552[8] and represents the minimum number
of samples that should be taken from a typical building heating or cooling system that incorporates air
handling units, fan coils or radiators.

Note that the numbers of samples required are separately assessed for each individual system associated
with the building. Where a heating or cooling system is split into several hydraulically separated sub-
systems, for example, by means of plate heat exchangers, each sub-system counts as a separate system.

For other types of system or where the building is to be completed and commissioned in a number of
phases, the sampling programme should be discussed and agreed with the cleaning specialist.

The recommended frequency of sampling prior to pre-commission cleaning is every four weeks with
sample numbers and locations as shown in Table 8. Sample volume should be minimised to avoid system
de-pressurisation.

Table 8: Scope of sampling between filling/pressure testing and pre-commission cleaning (every four weeks)
for each system

System size Representative sample points

< 3000 litres and < 2 terminal units 1 sample location in main plant area
< 3000 litres and < 25 terminal units 1 sample location in main plant area +
1 remote location
≥ 3000 litres or ≥ 25 terminal units 1 sample location in main plant area +
1 remote location plus additional
sample locations to be agreed with
cleaning specialist

The recommended frequency of sampling between pre-commission cleaning and practical completion is
every two weeks with sample numbers and locations as shown in Table 9.

Table 9: Minimum scope of sampling immediately post clean and up to practical completion (every two
weeks) for each system

System size Representative sample points

Up to 3000 litres and < 2 terminal units 1 sample location in main plant area
Up to 3000 litres and < 25 terminal units 1 sample location in main plant area + 2 remote
locations
Up to 8000 litres or 25 to 80 terminal units 1 sample location in main plant area + 3 remote
locations
Up to 20,000 litres or 80 to 250 terminal 1 sample location in main plant area + 4 remote
units locations
Up to 40,000 litres or 250 to 500 terminal 1 sample location in main plant area + 5 remote
units locations
Over 40,000 litres or > 500 terminal units 1 sample location in main plant area + (Number of
terminal units / 500) x 5

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 EXAMPLE FRAMEWORK FOR RECORD KEEPING – APPENDIX B

APPENDIX B – EXAMPLE FRAMEWORK FOR RECORD

KEEPING
The following record sheets are provided as examples of the level of detail required and may be copied
without restriction and edited as required. Editable Excel versions are attached to the pdf of this guide,
and can be downloaded for free from www.bsria.com/goto/pcc.

Pre-commission cleaning system checks

Site name: Client job ref:

System: Contractor job ref:

Drawing ref: Page of

General checklist

Planned date of commencing works on this system

Planned date of completing works on this system
Cleaning specialist’s site supervisor (tel no)
Client’s responsible person (tel no)
Results of prior sampling available
Method statement submitted and accepted
Permits to work issued
Discharge permits valid
Sufficient chemicals available on site for cleaning and treatment
System under cleaning contractor’s control
All valves open
All sensitive equipment bypassed
Adequate water supply available
Protective measures in place
Free access to connection points
All pumps fixed and temporary operational
System water volume (litres)

Dynamic flushing

Balanced fill and flush set up

Primary fill point
Primary flush point

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 B APPENDIX – EXAMPLE FRAMEWORK FOR RECORD KEEPING

Schedule of flow rates

Site name: Client job ref:

System: Contractor job ref:

Drawing ref: Page of

Schedule of flow rates

Area/ Zone Pipe Valve Actual/ Flow Reqd BSRIA % BSRIA

Level Ref diam size Sig rate flow
Ref (mm) (mm) (kPa) (l/s) rate
(l/s)

Notes

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 EXAMPLE FRAMEWORK FOR RECORD KEEPING – APPENDIX B

Flushing velocity record sheet

Site name: Client job ref:

System: Contractor job ref:
Drawing ref: Page of
Comments
Witness
(initials)
Design
+10%
% of
Design +10%
flow rate
(l/s)
Measured
(l/s)
Measured
(kPa)
Valve
kv
(mm)
Valve
size
diameter
(mm)
Pipe
Section/
location
Date/
ref

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 B APPENDIX – EXAMPLE FRAMEWORK FOR RECORD KEEPING

Coil back flush record sheet

Site name: Client job ref:

System: Contractor job ref:

Drawing ref: Page of

Complete a separate sheet for each system and day of activity

Area/ Coil Flushed Flushed F&R Bypass Comments Witness

Level Ref tick tick valves valve (initials)
Ref reset reset
tick tick

Remarks

Flushed by: Witnessed by (where initialled):

Date: Date:

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 EXAMPLE FRAMEWORK FOR RECORD KEEPING – APPENDIX B

Strainer / dirt pocket cleaning record sheet

Site name: Client job ref:

System: Contractor job ref:

Drawing ref: Page of

Date Area/ Strainer Stage Description of deposits Witness

Level Ref of op (initials)
Ref

Remarks:

Flushed by: Witnessed by (where initialled):

Date: Date:

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 B APPENDIX – EXAMPLE FRAMEWORK FOR RECORD KEEPING

Water sample progress schedule

Site name: Client job ref:

System: Contractor job ref:

Drawing ref: Page of

Date Area/ Sample Test Date Interim Date Comments

taken Level point spec results or final results
Ref Ref req’d received issued

74 PRE-COMMISSION CLEANING OF PIPEWORK SYSTEMS

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 EXAMPLE FRAMEWORK FOR RECORD KEEPING – APPENDIX B

Site analysis record sheet (Part 1 - Flushing)

Site name: Client job ref:

System: Contractor job ref:

Drawing ref: Page of

Flushing Post static Post Biocide wash Post

makeup flush dynamic balanced
water flush flush
Date

Area/Level

Sample
point
Conductivity
(µS/cm)
Total dissolved
solids (mg/l)
Dissolved
iron (mg/l)
Inhibitor
(mg/l)
Visual

pH

Biocide
(litres)
Cleaner
(litres)
Inhibitor
(litres)
Comments

Operative

Witness

Notes:
List of analytical methods and/or test kits for on-site tests to be included in method statement

PRE-COMMISSION CLEANING OF PIPEWORK SYSTEMS 75

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 B APPENDIX – EXAMPLE FRAMEWORK FOR RECORD KEEPING

Site analysis record sheet (Part 2 – Chemical clean and dosing)

Site name: Client job ref:

System: Contractor job ref:

Drawing ref: Page of

Chemical Chemical Post final Initial Post back Final

clean at clean at flush dosing flush dosing
start end
Date

Area/Level

Sample point

Conductivity
(µS/cm)
Total dissolved
solids (mg/l)
Dissolved iron
(mg/l)
Inhibitor
(mg/l)
Visual

pH

Biocide
(litres)
Cleaner
(litres)
Inhibitor 1
(litres)
Inhibitor 2
(litres)
Comments

Operative

Witness

Notes:
List of analytical methods and/or test kits for on-site tests to be included in method statement

76 PRE-COMMISSION CLEANING OF PIPEWORK SYSTEMS

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 EXAMPLE FRAMEWORK FOR RECORD KEEPING – APPENDIX B

Site analysis – Post cleaning to practical completion

Site name: Client job ref:

System: Contractor job ref:

Drawing ref: Page of

Week 1 Week 3 Week 5 Week 7 Week 9 Week 11

Date

Area/Level

Sample point

Conductivity
(µS/cm)
Total dissolved
solids (mg/l)
Dissolved
iron (mg/l)
Inhibitor
(mg/l)
Visual

pH

Biocide
(litres)
Inhibitor 1
(litres)
Inhibitor 2
(litres)
Comments

Operative

Witness

Notes:

PRE-COMMISSION CLEANING OF PIPEWORK SYSTEMS 77

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 B APPENDIX – EXAMPLE FRAMEWORK FOR RECORD KEEPING

System condition on completion of pre-commission cleaning

Site name: Client job ref:

System: Contractor job ref:

Drawing ref: Page of

Client company
Client representative (name)
Cleaning contractor
Cleaning supervisor (name)
Witness organisation
Witness (name)
Analytical laboratory
Date of fill
Date of flush
Date of initial chemical clean
Date of final chemical clean
Date of final inhibitor dosing
Biocide & dose rate
Inhibitor & dose rate
Other chemicals?

Reference sample
point
Date samples
taken
Witness initials
Specified Plant room Distant Terminal Other
range pipework units
(Note 1) (Note 2) (Note 2) (Note 3)
Total alkalinity
(mg/l CaCO3)
Chloride
(mg/l Cl)
Sulfate
(mg/l SO4)
Conductivity
(µS/cm)
Total dissolved
solids (mg/l)
Suspended solids
(mg/l)
Settled solids
(mg/l)

78 PRE-COMMISSION CLEANING OF PIPEWORK SYSTEMS

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 EXAMPLE FRAMEWORK FOR RECORD KEEPING – APPENDIX B

pH
Dissolved iron
(mg/l)
Total iron
(mg/l)
Dissolved
copper (mg/l)
Total
copper (mg/l)
Total aluminium
(mg/l) (if specified)
Zinc (mg/l)
(if specified )
Other chem
(if specified )
Chemical
inhibitor level
TVC @ 30°C
(cfu/ml)
Pseudomonads
@ 30°C (cfu/ml)
Sulfate-reducing
bacteria Pres/Abs)
Other micro
(if specified )

Notes:
1. The range should be taken from the client specification or agreed method statement and may vary from the
guidelines indicated in BSRIA guide BG 29/2020 Pre-commission Cleaning of Pipework Systems.
2. The results expressed in this table are calculated from the results of one or more individual samples as described in
BS 8552
3. One or more additional sets of sample points may be specified

Summary status Initials

The condition of the system complies with the specification or agreed method statement
The condition of the system is not fully compliant with the specification or agreed method
statement but is acceptable subject to the comments below
The condition of the system is not compliant with the specification or agreed method statement
and is not acceptable for the reasons given in the comments box

Comments:

Confirmed by the undersigned as a true record of the system condition

Signature On behalf of (company) Date
Cleaning supervisor
Witness

PRE-COMMISSION CLEANING OF PIPEWORK SYSTEMS 79

© BSRIA BG 29/2020
 C APPENDIX – EXAMPLE CERTIFICATE OF CONFORMITY

APPENDIX C – EXAMPLE CERTIFICATE OF CONFORMITY

An editable Excel version of this certificate is attached to the pdf of this guide, and can be downloaded
for free from www.bsria.com/goto/pcc. It may be used in accordance with the licence on the
acknowledgements page of this guide.

CERTIFICATE OF CONFORMITY FOR SYSTEM CLEANLINESS PRIOR TO SYSTEM

CONNECTION

Contract Name:

Contract No:

Certification of conformity with cleanliness levels requested for base build-fit-out

connection following assurances of acceptable water quality on both sides.

System: .............................. Floor: ......................................... Area:

1. Has certificate of fit-out system cleanliness been produced,

Yes No
with cleaning records, indicating acceptable water quality and
bacteria levels? (ED)

2. Are the facilities team/base build contractor aware of the

connections and do they have an incumbent water treatment
specialist appointed? (ED)

3. Is the spool piece in a clean and acceptable condition? (ED)

4. If the answers to 1-3 above are “Yes” and the following signatures are in
place, connection / turn-on can take place.

Signed: ........................................ Date: ........................................ For:

Signed: ........................................ Date: ........................................ For:

Signed: ........................................ Date: ........................................ For:

Comments:

80 PRE-COMMISSION CLEANING OF PIPEWORK SYSTEMS

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 APPENDIX D – ACKNOWLEDGEMENTS D

APPENDIX D – ACKNOWLEDGEMENTS
BSRIA would like to thank the following contributors to previous editions of this guide:

AG 8/91 Steering Group

C. Parsloe (Chairman)
P. Barrett
J. Crombie
K. Sanders
P. Hill
A. Argent
K. Newman
R. Eycott
J. McLlellan
A. Elphick
J. Wilson
D. Coleman
J. Walker
E. Day
J. Knight
R. Triggs
R. Carter
R. Wilkins
J. Cooke
L. Stewart
H. Edwards
D. Carr
T. Hollis

AG 1/2001 Steering Group

C. Parsloe (Chairman)
E. Day
J. Wilson
K. Colgan
G. Nicholls
C. Toft
D. Corbett
M. Elliot
R. Eycott
I. Allan
R. Connew
J. Crombie
T. Quinlan
R. Watson
R. Wilkins
S. Abbott
J. Robinson
R. Carter
P. Worts
P. Neale
J. StClair
D. Garland
M. Brownhall

PRE-COMMISSION CLEANING OF PIPEWORK SYSTEMS 81

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 D APPENDIX – ACKNOWLEDGEMENTS

AG 1/2001.1 Review Group

C. Parsloe (Chairman)
N. Blundy
M. O'Mahony
L. Day
J. Hunt
G. Manly
P. Hadjioannou
R. Brown

BG 29/2011 Steering Group

R. Brown (Lead author)
R. Carlin
J. Bruce
E. Day
S. McGillivray
T. Dix
P. Barrett
J. Crombie
S. Wilton
C. Parsloe
P. Hancock

BG 29/2012 was an update to BG 29/2011, carried out by BSRIA staff without a steering group.

Acknowledgements for the 2020 edition can be found at the beginning of this guide.

82 PRE-COMMISSION CLEANING OF PIPEWORK SYSTEMS

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 GLOSSARY OF TERMS

GLOSSARY OF TERMS

Biocide A chemical agent which either kills or prevents the multiplication of

organisms in water systems.

Chelant An organic compound causing a substance which would normally be

(chelating agent) insoluble to be held in solution or to pass into solution.

Detergent A synthetic cleansing agent resembling soap in the ability to emulsify oil
and hold dirt, and containing one or more surfactants that do not
precipitate in hard water.

Dispersants Substances which create a repellent force between individual particles,

thereby encouraging them to remain in suspension during flushing.

Flocculant High molecular weight polymer that encourages particles to agglomerate.

(flocculating agent) Sometimes used as an aid for cleaning and flushing.

Inhibitor Also known as restrainer. Any compound that suppresses corrosion,

regardless of which electrochemical reaction it affects. The term inhibitor
applies to two distinctly different chemicals, commonly in use. Acid
inhibitors control the action of an acid solution used for cleaning;
corrosion inhibitors control the further corrosion of metallic surfaces in
water systems

Millscale A surface layer of iron oxides (mostly Fe3O4) formed during the
manufacture of mild steel pipes.

Passivator A compound that renders the “active” surface of metals “passive”,

meaning less prone to further corrosion. Every passivator is an inhibitor.

Practical completion The point of issuing a certificate of practical completion by the competent
authority to the effect that all works and tasks included in the contract
have been satisfactorily completed according to specification document
that forms part of the contract.

Pseudomonad Pseudomonas-like bacteria. Prior to the advent of DNA classification

methods, many bacteria were classified as Pseudomonas species on the basis of
appearance and growth characteristics. These are now recognised as
distinct species but are still relevant to pipework corrosion. The guideline
values included in this guide are therefore based on the enumeration of
pseudomonads.

Sequestrant A substance that removes a metal ion from a solution by forming a

(sequestering agent) complex ion that does not have the chemical reactions of the ion that is
removed. A sequestrant may be a chelating or complexing agent.

Surfactant A soluble compound that reduces the surface tension of liquids, or reduces
(surface-active agent) interfacial tension between two liquids or a liquid and a solid. Commonly
used during the de-greasing stage of the clean. Also used to increase the
effectiveness of inhibitor formulations (by improving contact) and may
themselves be inhibitors.

PRE-COMMISSION CLEANING OF PIPEWORK SYSTEMS 83

© BSRIA BG 29/2020
 REFERENCES

REFERENCES
1. VDI 2035 Part 1:2019-03 Draft Prevention of damage in water heating installations - Scale formation and water-
side corrosion and VDI 2035 Part 2:2009-08 Prevention of damage in water heating installations - Water-side
corrosion
Available to purchase from www.beuth.de.

2. HSE HSG 274 Legionnaires’ disease: Technical guidance Part 1 The control of legionella bacteria in evaporative
cooling systems
Available to download for free from www.hse.gov.uk.

3. BS EN ISO 9001:2015 Quality management systems. Requirements

Available from https://shop.bsigroup.com/

4. BSRIA BG 50/2013 Water Treatment for Closed Heating and Cooling Systems
Available from www.bsria.com, with free downloads for BSRIA members

5. BS 7593:2019 Code of practice for the preparation, commissioning and maintenance of domestic central heating and
cooling water systems
Available from https://shop.bsigroup.com/

6. BS EN 8554:2015 Code of practice for the sampling and monitoring of hot and cold water services in buildings
Available from https://shop.bsigroup.com/

7. PD 855468:2015 Guide to the flushing and disinfection of services supplying water for domestic use within buildings
and their curtilages
Available from https://shop.bsigroup.com/

8. BS 8552:2012 Sampling and monitoring of water from building services closed systems. Code of practice
Available from https://shop.bsigroup.com/

9. BS EN 10255:2004 Non-alloy steel tubes suitable for welding and threading. Technical delivery conditions
Available from https://shop.bsigroup.com/

10. CIBSE Commissioning Code W: 2010 Water Distribution Systems.

Available from www.cibse.org

11. WRAS Approved Installation Method 9-04-02 Solders & Fluxes

Available as a free download from www.wras.co.uk

12. BESA TR 6 Guide to Good Practice - Site Pressure Testing of Pipework

Available from www.thebesa.com

13. BS EN 10216-1:2013 Seamless steel tubes for pressure purposes. Technical delivery conditions. Non-alloy steel tubes
with specified room temperature properties
Available from https://shop.bsigroup.com/

84 PRE-COMMISSION CLEANING OF PIPEWORK SYSTEMS

© BSRIA BG 29/2020
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