PROJECT PROCEDURE

WATER FLUSHING
PROJ. 2171
DOC. NO. : IONE-AA00-PE-CM-0018
KARBALA REFINERY PROJECT Rev. A Page 1/21
Ref. FEED DOC. NO. : 2342-AA00-JSM-901

WATER FLUSHING PROCEDURE

PROJECT : KARBALA REFINERY PROJECT

LOCATION : KARBALA, IRAQ

EMPLOYER : STATE COMPANY FOR OIL PROJECTS (SCOP)

A 30 MAR 19 ISSUED FOR REVIEW J.S.HEO J.K.KWON Y.S.KIM Y.B.LIM H.S.HWANG

REVD REVD APPRD CONFD

REV. DATE DESCRIPTION PRPD CHKD
(PQM) (PM) (PD) (SCOP)

Joint Venture of Hyundai Engineering & Construction Co., Ltd., GS Engineering & Construction Co., Ltd., SK
Engineering & Construction Co., Ltd., and Hyundai Engineering Co., Ltd.,

Note :
a) Revision bar(vertical line) shall be placed in the right hand margin to indicate where the changes has been made
b) PRPD = Prepared by, CHKD = Checked by, REVD = Reviewed by, APPRD = Approved by, CONFD = Confirmed by
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TABLE OF CONTENTS

1. INTORDUCTION.................................................................................................................... 3
1.1 Scope .............................................................................................................................3

1.2 Purpose ......................................................................................................................... 3

1.3 Application .................................................................................................................... 3

2. DEFINITIONS ......................................................................................................................... 3

3. REFERENCE .........................................................................................................................6

4. WORK FLOW ........................................................................................................................7

5. HSE .........................................................................................................................................8

6. PLANNING .............................................................................................................................8
6.1 Package Preparation.....................................................................................................8

6.2 Notification of Inspection .............................................................................................9

6.3 Preparation of Tools, Measuring Devices and Supplies .............................................9

7. EXECUTION......................................................................................................................... 10
7.1 Pre-Work of Water Flushing .......................................................................................10

7.2 Execution of Water Flushing ...................................................................................... 11

7.2.1 Continuous Flushing ...................................................................................................... 12

7.2.2 Water Filling and Dumping Out ....................................................................................... 12

7.3 Acceptance Criteria ....................................................................................................13

7.4 Post Work of Water Flushing .....................................................................................13

8. DOCUMENTATION AND REPORTING ........................................................................... 13

9. ATTACHMENT .................................................................................................................... 14
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1. INTORDUCTION

1.1 Scope

This Procedure provides necessary information, general requirements and guidelines for
Water Flushing method of water pipelines installed for Karbala Refinery Project.

Detailed Water Flushing method shall be included on the marked up P&ID with water In /
Out points and valve Open / Close status etc.

1.2 Purpose

The purpose of Water Flushing is to remove loose foreign materials from the inside of
utility, oil and gas pipelines (such as welding rods, sand, pebbles, nuts and bolts, tools,
rags, etc.) in order to avoid line blockage and damage to sensitive instrument components
such as orifice plates, thermocouples, control valve and rotating equipment and so on.

1.3 Application

Water Flushing is one of the pipe cleaning method utilizing water kinetic energy and is
carried out either cleaning by circulation of water or filling and dumping water.

Attention has to be given to the potential corrosiveness of water and special water quality
may be necessary.

Specific cleaning medium for each service line is shown on the attachment #4.

2. DEFINITIONS
Contract means the Contract Agreement, the Conditions, the Employ’s requirements,
the Tender, and the further documents (if any) which are listed in the Contract
Agreement.

Party means the Employer or the Contractor, as the context requires.

Employer means the person named as Employer in the Contract Agreement and the
legal successors in title to this person. The “Employer” and reference to “Engineer”
means the Director General of SCOP or any person authorized by him.
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Contractor means the person(s) named as contractor in the contract Agreement and
the legal successors in title to this person(s).

Employer’s Personnel means the Employer’s Representative, the assistants referred

to in Sub-Clause 3.2 [Other Employer’s Personnel] and all other staff, labor and other
employees of the Employer and of the Employer’s Representative; and any other
personnel notified to the Contractor, by the Employer or the Employer’s Representative,
as Employer’s Personnel.

Contractor’s Personnel means the Contractor’s Representative and all personnel

whom the Contractor utilizes on Site, who may include the staff, labor and other
employees of the Contractor and of each Subcontractor; and any other personnel
assisting the Contractor in the execution of the Works.

Subcontractor means any person named in the Contract as a subcontractor, or any

person appointed as a subcontractor, for a part of the Works; and the legal successors
in title to each of these persons.

Commencement Date means the date of notification to the Contractor’s bank of the
opening of the activated L/C referred to in clause 14.16.1, unless otherwise defined in
the Contract Agreement (date upon which Letter of Credit is opened). “Contract
Effective date” means the date of signature of the Contract.

Materials means things of all kinds (other than Plant) intended to form or forming part of
the Permanent Works, including the supply-only materials (if any) to be supplied by the
Contractor under the Contract.

Plant means the apparatus, machinery and vehicles intended to form or forming part of
the Permanent Works.

Temporary Works means all temporary works of every kind (other than Contractor’s
Equipment) required on Site for the execution and completion of the Permanent Works
and the remedying of any defects.
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Works means the Permanent Works and the Temporary Works, or either of them as
appropriate.

Contractor’s Documents means the calculations, computer programs and other

software, drawings, manuals, models and other documents of a technical nature
supplied by the Contractor under the Contract; as described In Sub-Clause 5.2
(Contractor’s Documents).

Country means the Republic of Iraq.

Site means the places where the Permanent Works are to be executed, including
storage and working areas, and to which Plant and Materials are to be delivered, and
any other places as may be specified in the Contract as forming part of the Site.

Variation means any change to the Employer’s Requirements or the Works, which is
instructed or approved as a variation under Clause 13 [Variation and Adjustment].

“Pre-commissioning or PRECOMMISSIONING” means all checks, cleaning and

testing of Plant and its implementation without introducing hydrocarbons or permanently
energizing or pressure said Plant. Pre-commissioning includes all activities
implemented between the completion of construction activities and Ready for
Commissioning.

“Commissioning or COMMISSIONING” means all activities associated with preparing

or testing functionalities of the Plant or part thereof prior to initial START-UP up to the
condition of Plant “ready for START-UP”. When the COMMISSIONING activities are
completed, the condition of Plant “ready for START-UP” is achieved, a “Plant ready for
START-UP” certificate is issued.

“START-UP” means introduction of feedstocks into process Plant with the express
purpose of producing a product for the first time; this is often referred to as “oil in”. This
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activity will be carried out by the Operation personnel of the CONTRACTOR.

“Black Start-up” is the start-up process of plant without relying on the external electric
power supply.

3. REFERENCE

l Pre-commissioning & Commissioning execution plan_rev.0

(IONE-AA00-PE-CM-001)

l Checklist for plant completion pre-commissioning, commissioning and start-up

(2342-AA00-JSM-903_0)
l Pre-commissioning & Commissioning execution Plan (2342-AA00-JSM-901_0)
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4. WORK FLOW

Water flushing will be conducted in accordance with the work flow chart as show as
below Picture-1.

Contractor Company

Preparation of Water Flushing

PLANNING

Package

Issue
Preparation of Notification For Information

Perform Pre-work Activities

EXECUTION

Execution of Water Flushing Participation & Witness

(As requested)

Perform post-work Activities

REPORTING

Recording & Sign Sign to Record Sheet

Register to UNICCS

[Picture-1]
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5. HSE

The following particular precautions shall be taken for safe Water Flushing operation.

a) All unauthorized personnel are excluded from water exit area prior to starting
flushing.

b) All personnel carrying out the Water Flushing operation shall be fully understood
their tasks and ensured by suitable protective equipment: i.e. ear protection, gloves,
and goggles as a minimum.

c) Hold toolbox meeting in the field involving all concerned personnel to remind again
the safety measures and objective of the activities.
d) Notify Water Flushing location, route and time of flushing in advance to related
disciplines working in associated area.

e) The area of the water exit should be roped off and clearly marked with warning
notices and kept free of personnel.

f) Particles with water exiting the piping could be injured people and damage nearby
equipment. Adequate protection has to be installed and every attempt should be
made to have the area abandoned prior to Water Flushing.

g) Ensure an effective communication system connected between those responsible

for the operation and safety personnel. The suitable communication exists between
the water supply point operators and dumped out area operator.

6. PLANNING

Water Flushing plan shall be properly prepared according to the site condition, such as
the availability of facilities on site and the configuration of the pipelines, etc.

6.1 Package Preparation

Water Flushing package shall be prepared by including followings

a) Water Flushing Package will consist of Marked-up P&ID and Record Sheet.

b) Marked-up P&ID will be shown as below.

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l Water Flushing PKG No.

l Temporary piping and fittings installation

l Location of isolation valve and blinds indicated Water Flushing limits

l Location of introduction and downstream water flushing point

l Equipment and instrument isolation status

c) Record sheet is mentioned on Attachment #3

6.2 Notification of Inspection

Notification of Water Flushing will consist of as below

l Inspection of Water Flushing PKG No.

l Unit / System / Sub-system No.

l Location

l Request date & Time of inspection

l Reference document as mentioned in paragraph 6.1

6.3 Preparation of Tools, Measuring Devices and Supplies

Tools, Measuring Devices and supplies can be required as below

l Temporary piping, Spool and spade, if any

l Pipe fitting and accessories to be removed

l Pipe wrench, valve wrench, cap, plug, elbow, reducer, etc.

l Radio or cell phone for communication

l Waring tape and sign board

l Personal protection equipment

l Whistle, Siren
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7. EXECUTION

7.1 Pre-Work of Water Flushing

a) Prior to Water Flushing, ensure that all the remaining works after pressure test have
been cleared.

b) In principal, the Water Flushing shall be carried out sequentially. i.e. first common
header then sub-header and finally branch lines.

c) Water shall flow from top to bottom if applicable.

d) Water Flushing sequence will be made according to construction progress or

geographical or functional criteria and also considering site requirements such as
availability of facilities, configuration of the lines or the devices to be removed etc.

e) All other lines connected to each unit not ready for Water Flushing shall be isolated
until release for ready to flush. Installation and removal of blinds will be controlled by
blind list.

f) Dead ends shall be cleaned separately. Remove end blind flanges and make hand
cleaning for the short dead ends.

g) Following Devices included in the flushing system shall be removed as follows.

l Control Valve

l Check valves (or internal).

l Orifice Plates or flowmeter elements

l In-line mixers/In-line strainers

l Spargers

l Spray Nozzles

l Thermowells

l Venturies

l Rotameters

l In-line flow totalizers

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l Nozzles of ejectors

l Traps

l Internals of filters and strainers

l Control valves except ball/gate type one

l Self-activated valves except ball/gate type one

l Emergency shut off valves except ball/gate type one

h) Following items shall be isolated

l Process impulse lines for instruments shall be isolated by block valve on the
impulse pipe itself and whenever possible, shall be disconnected.

l Rotating machines such as pumps and compressors by in/out isolation valves or

temporary blinds.

l Static equipment such as columns, drums which are contained internals are not
able to use air holding purpose. However no internals installed vessels, hold-up
vessels can be used for downstream lines cleaning after the upstream of the
equipment cleaning is completed.

l Special equipment such as desuperheaters, heating coils, etc.

i) Removal of ball/gate valves is normally not necessary since these valves do not
restrict the flush flow path. These valves should be kept in the full open position while
flushing.

j) Each flushing condition should be checked in advance. Any big remaining works that
will hinder the Water Flushing activity shall be coordinated to concerned discipline.

k) During Water Flushing operation, large quantity of water with sand, particles of rust,
etc. will be spread out near flush-off point. Therefore, equipment and devices shall be
protected properly nearby water flush-off point. These foreign materials might damage
or contaminate the devices or equipment.

l) In case of using permanent pumps, the suction line of the pumps should be cleaned
in advance and the suction strainer has to be installed.

7.2 Execution of Water Flushing

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Once all preparation work is completed, pre-commissioning supervisor shall inspect the
site and check that all protections are installed properly for water flushing.

Generally, Continuous circulation of water and filling and dumping water are applied to
flush the piping system in accordance with the site condition such as the availability of
water source, pipe configuration and size, flushing schedule etc.

7.2.1 Continuous Flushing

This type of flushing normally involves taking a section of piping and flushing is
from a “start-point” to an open end.

In general, the brief continuous flushing of water is as follows

a) The water to be connected from the source with temporary hose, pipe or
permanent line.

b) The water should be supplied continuously from its own flow or required
temporary pump.

c) Open the block valve located on water source to make the continuous flow or
operating the pump.

d) Downstream of water should be routed to disposal point.

e) Cooling water lines can be flushed by using permanent pumps. In this case,
the pump shall be operated by minimum by-pass line.

7.2.2 Water Filling and Dumping Out

Filling and dumping water flushing is often used for cleaning vessels and hook-up
piping attached to the vessels.

In general, the brief Water Filling and Dumping Out is as follows

a) The water to be connected from the source with temporary pipe, hose or
permanent line.

b) After water is ready, fill the water into vessel.

c) During fill the water into the vessels, dumping out point should be closed.

d) Dumping out point should be routed to disposal area.

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e) Allow the water to enter the system to be cleaned by opening the block valves.

7.3 Acceptance Criteria

The acceptance criteria will be visual inspection of discharged water. When any foreign
materials interfering with actual plant operation are no longer visually detected at the
water discharging point, the water flushing shall be deemed satisfactory completed.

7.4 Post Work of Water Flushing

After the Water Flushing operations of the system, pipe, valves and fragile devices have
to be reassembled.

a) Fragile devices removed from Water Flushing operation as described in Paragraph

7.1 shall be reinstated.

b) Used temporary gasket must be replaced with permanent gaskets.

c) Threads is checked carefully and cleaned before reassembled.

d) A special attention is required during rotating equipment is reinstated to avoid

misalignment.

e) The orientation of check valves, globe valves, etc. shall be checked against the
direction of flow.

f) Specific In-line instruments shall be installed by instrument specialists according to

the relevant drawings.

g) Temporary blinds installed for Water Flushing shall be removed.

h) Temporary valves for Water Flushing are to be replaced by permanent valves and
spool.

8. DOCUMENTATION AND REPORTING

Work packages including Water Flushing procedures with supporting drawings such as
P&ID or sketches, all reports and results will be filled as part of the pre-commissioning
dossier. Each Water Flushing operation will be supported by Water Flushing record
sheet form as Attachment #3.
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9. ATTACHMENT

a) Attachment #1 Request For Inspection and Test

b) Attachment #2 Water Flushing Check List

c) Attachment #3 Cleaning Record Sheet

d) Attachment #4 Cleaning Medium for Each Service

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ATTACHMENT #1 REQUEST FOR INSPECTION & TEST

■ We Would Like to have your presence for inspection / test according to the following schedule. The under
noted work is completed
■ This is inform you that the following inspection / test will be carried out at the schedule time mentioned below;
Unit No. System No.
Sub-system No. Request Date

Package No. Location Date & Time

1
2
3
4
5
6

Attachment : Marked-up P&ID

Remark

CONTRACTOR (COMMISSIONING) EMPLOYER

Name

Position

Signature
Date / / / /
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ATTACHMENT #2 WATER FLUSHING CHECK LIST

Unit No.: System No.:

Sub-system No.: Location:
Package No.:

No CHECK LIST COMMENTS

Pre-Work
1 Pre-commissioning tasks completed YES □ NO □ N/A □

2 Check detailed marked-up P&ID available YES □ NO □ N/A □

Coordination with instrument group to remove / isolate fragile instrument

3 YES □ NO □ N/A □
devices from network to be cleaned
4 Water supply source is ready? YES □ NO □ N/A □

5 Support personnel (Pipe fitters, helpers) are available? YES □ NO □ N/A □

6 Access ladder or scaffolding available YES □ NO □ N/A □

7 Temporary blind installed (if any) YES □ NO □ N/A □

8 Hose and temporary pipe connection available YES □ NO □ N/A □

9 Pressure transmitter or local pressure gauge available YES □ NO □ N/A □

10 Safety Toolbox meeting completed YES □ NO □ N/A □

11 Line-up, particularly the flush-off point and ready for pressurization YES □ NO □ N/A □

Post Work
12 Removed pipes/equipment/device reinstated/re-connected YES □ NO □ N/A □

13 Hose disconnected YES □ NO □ N/A □

14 Blind removed (if any) YES □ NO □ N/A □

15 Test Reports signed and filed YES □ NO □ N/A □

Remarks:
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ATTACHMENT #3 CLEANING RECORD SHEET

Unit No.: System No.:

Sub-system No.: Package No.:

Cleaning Medium □ Air □ Water □ Others ( )

Cleaning Period (yyyy-mm-dd) : ~

Inspection Date (yyyy-mm-dd) :

Inspection Result : □ Accepted □ Failed □ Others

Comment :

CONTRACTOR (COMMISSIONING) EMPLOYER

Name

Position

Signature
Date / / / /
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ATTACHMENT #4 CLEANING MEDIUM FOR EACH SERVICE

No Category Service Description Cleaning Method Remark

1 AIR Air Air Blowing
2 ASW Sour Water Closed Drain Air Blowing
3 BDD Discharge to Blowdown Air Blowing
4 BFW Boiler Feed Water Air Blowing
5 CAU Caustic Soda Air Blowing
6 CDW Chilled Water Air Blowing
7 CLW Clarified Water Air Blowing
8 CND Clean Condensate Air Blowing
9 CSW Chemical Sewer Air Blowing
10 CWR Cooling Water Return Water Flushing

11 CWS Cooling Water Supply Water Flushing

13 DWA Demineralized Water Air Blowing
14 FWA Fire Water (UG) Air Blowing
15 FWA Fire Water (AG) Air Blowing
16 UTILITY GAS Gas Air Blowing
17 HPC High Pressure condensate Air Blowing
18 HPN High Pressure Nitrogen Air Blowing
19 HPS High Pressure Steam Steam Blowing Except for steam tracing
20 HWR Hot Water Return Air Blowing
21 HWS Hot Water Supply Air Blowing
22 HWT Hot Water Air Blowing
23 INA Instrument Air Air Blowing
24 ING Inert Gas Air Blowing
25 LIN Liquid Nitrogen Air Blowing
26 LPC Low Pressure Condensate Air Blowing
27 LPS Low Pressure Steam Steam Blowing Except for steam tracing
28 MPC Medium Pressure Condensate Air Blowing
29 MPS Medium Pressure Steam Steam Blowing Except for steam tracing
30 NIT Nitrogen Air Blowing
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31 OWS Oily Water Sewer Air Blowing

32 OXY Oxygen Air Blowing
33 PCD Process condensate Air Blowing
34 PRA Process Air Air Blowing
35 PWA Drinking Water Air Blowing
36 QWA Quench Water Air Blowing
37 RNW Rain Water Air Blowing
38 RWA Raw Water Air Blowing
39 SPC Suspected Condensate Air Blowing
40 SRW Sour Water, Acid Water Air Blowing
41 SSW Sanitary Sewer Air Blowing
42 STW Stripped Sour Water Air Blowing
43 SWA Service Water Air Blowing
44 TWA Treated Water Air Blowing
45 UTA Plant, Service, Utility Air Air Blowing
46 WAT Wash Water Air Blowing
47 WSW White Sewer Air Blowing
48 WWT Waste Water Air Blowing
1 ACID Acid Air Blowing
2 AMN Amine Solution Air Blowing
3 AMS Ammonia Solution Air Blowing
4 AMW Amine Closed Drain Air Blowing
5 ASP Asphalt Air Blowing
6 ASW Sour Water Closed Drain Air Blowing
7 BUT Butane Air Blowing
PROCESS
8 CAH Calcium Hydroxide Air Blowing
9 CLD Closed Drain Header Air Blowing
10 CLG LPG Drain Air Blowing
11 CLO Chlorine Air Blowing
12 CRD Crude Air Blowing
13 DEA Diethanolamine Air Blowing
14 DGO Diesel Oil Air Blowing
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15 FLA Acid Flare Air Blowing

16 FLD Discharge to LP Flare Air Blowing
17 FLH Discharge HP Flare Air Blowing
18 FLO Flushing Oil Air Blowing
19 FLU Flue Gas Air Blowing
20 FUG Fuel Gas Air Blowing
21 FUH Heavy Fuel Oil Air Blowing
22 FUL Light Fuel Oil Air Blowing
23 FUO Fuel Oil Air Blowing
24 GSL Gasoline Air Blowing
25 HGO Heavy Gas Oil Air Blowing
26 HOR Hot Oil Return Air Blowing
27 HOS Hot Oil Supply Air Blowing
29 HYD Hydrogen Air Blowing
30 HYP Hypochlorite Air Blowing
31 KER Kerosene Air Blowing
32 KOH Potassium Hydroxide Air Blowing
33 LBL Lube Oil Lube Oil Flushing
34 LPG LPG Air Blowing
35 NTG Natural Gas Air Blowing
36 PCB Potassium Carbonate Air Blowing
37 PHA Phosphoric Acid Air Blowing
38 PRO Process Air Blowing
39 PRP Propane Air Blowing
40 QHO Quench Oil Air Blowing
41 REG Regeneration Gas Air Blowing
42 RFD Refrigerant Fluid Air Blowing
43 SLL Seal Oil Air Blowing
44 SOL Solvent Air Blowing
45 VTG Vent Gas Air Blowing
1 ALF Alum. (Flocculants) Air Blowing
OTHERS
2 ATF Antifoaming Air Blowing
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3 BRN Brine Air Blowing

4 CAT Catalyst Air Blowing
5 CHP Chemical Product Air Blowing
6 FOM Foam Air Blowing
7 GLY Glycol Air Blowing
8 INH Inhibitor Air Blowing
9 SLD Sludge Air Blowing
10 SLP Slop Air Blowing
11 SLY Slurry Air Blowing
12 SOC Sodium Carbonate Air Blowing