HYDROSAFE

AKSEM KİMYA

METHOD STATEMENT FOR

FULL FLUSHING PROCESS
[Static – dynamic - chemical flushing]

This method statement was prepared according to BSRIA AG 1/2001 standart.

1. Definition / Scope

This document consists of the flushing process application in closed

loop systems, its purpose-scope-justification, methods, requirements
and monitoring principles.

2. Objectives / Rationale

Please see pages between 2-6 in BSRIA AG 1/2001 about these items.

2.1. Steel pipes are coated during manifacturing with protective oily
materials in order to minimize the corrosive effects of oxygen and
moisture.

2.2. The protective oily materials coated in the inner surface of the steel
pipes causes corrosion of carbon and through water flow some
undesirable materials such as sludge and mud within a short frame of
time in closed circuit systems.

2.3. Depending on the Mechanical structure of the system and chemical

composition of water varying with time converts sludge layer into
deposit formation.

2.4. Iron deposits which constitute during manifacturing process of

steel, inorganic dust and particles from the media also accumulate in
the system.

2.5. These particles give damage in the pumps, heat exchangers , coils,
valves,fittings and other devices, during the circulation of water.
 2.6. Solid phase layer and deposits accelerate the occurence of various
types of corrosion,loss of heat transfer efficiency and change flow
regime adversely [→ turbulance laminar, vortex, pressure fluctuation
etc.]

2.7. With the respect of these results, the efficiencies of mechanical

equipment and devices in the system are affected through decreased
heat transfer and useful life.

2.8. Consequently, besides the loss in comfort and energy [fuel,

electricity], the estimated depreciation and maintenance [labor,
materials] costs increase by increasing total operating costs.

3. Information about Flushing Process

Please see pages between 2-6 in BSRIA AG 1/2001 about these items.

3.1. The adhesive impurities formed inner side of the pipes via Physical,
Chemical and Physico-chemical bounds could not be removed by water
alone.

3.2. Flushing with just water can only remove some of the particles from
the surface physically. oil layer can not to be washed off.This types of
implementations lead to faulty measurements in terms of ΣFe and other
parameters and this measurement could be misleading.

3.3. Impurities are accumulated via physico-chemical bounds to the

system, therefore the devices and equipment should be cleaned up
without any damage through the proper application and selection of the
chemical products.

3.4. Chemical effect coefficient of the product and the effect on the
corrosion of oxygen in the water limits the application time of the
flushing process.

3.5. After flushing process, inner side of the pipes and equipments will
be cleaned up ,so the system is subjected to the maximum corrosion
risk of oxygen, which is taken through addition of make-up water into
the system. After rinsing ,chemical protection program should be started
immediately.

3.6. Starting Protection Chemical Program without making the flushing

process, will accelerate the sludge formation and the corrosion
depending on the water properties and impurities increasingly.
4. Conditions

4.1. Chemical products

4.1.1. Suitable chemicals for the use of closed circuit cleaning should
be oil, dirt, welding deposits, iron deposits and rust, dust and inorganic
particles, cleaning attributes must be provided.

4.1.2. The chemicals used for flushing process must be in neutral pH

and organic based.

4.1.3. Physical and chemical properties of the chemical should be

documented and shold not give any damage to devices, equipments
and pipes.

4.1.4. Chemical products could be accepted by registered

organizations.

4.1.5. The chemicals can be drained into waste water piping

system/drainage. (see page 27 in BSRIA AG1/2001)

4.2. Mechanical installation

4.2.1. Watermeters should be installed to the make up lines in order to
record the quantity of make up water

4.2.2. Make up water line must be connected to return collector to avoid

cold water entering to the boiler.

4.2.3. Make up water must be fed by a pressure-sensitive valve into the

system to compensate sudden losses or leaks. A 1 inch valve outlet
must be connected to each independent circuit [zone] on both of
departure and return collectors, either adding chemicals or sampling.

4.2.4. Drainage points of the system should allow to be monitored.

4.2.5. FCU, AHU and chillers, thermoelectric devices, should be

installed in connection with the bypass line.

4.2.6. Pumping and return lines must be connected to a by pass line.

4.2.7. Circulation of water should be checked if it provides water for the

whole system.

4.2.8. Drainage valves should be connected to the column end lines.

 4.2.9. For making good circulation the air must be released from the
system.(see page 8 in BSRIA AG 1/2001)

4.2.10. Air-conditioning, air-cooling systems, boiler, heat exchangers

must be by passed, depending on the approval of the responsible of
manufacturers. (see page 46 in BSRIA AG 1/2001)

4.2.11. Electrical connections of all pumps must be ready before

cleaning.

4.2.12. To avoid the effects of vacuum in the system, from top air
entrpoints must be provided. (see page 8 in BSRIA AG 1/2001)

4.3. Application process

4.3.1. Static and dynamic flushing

4.3.1.1. The system must be filled with fresh water. The filling
process must be done from the proper point of the system and filled
slowing to be enable the system to be vented correctly. (see page 31 in
BSRIA AG 1/2001)

4.3.1.2. After this the system should be drained. (see page 31

and page 32 in BSRIA AG 1/2001)

4.3.1.3. All dirt pockets and strainers must be cleaned out.(see

page 32 in BSRIA AG 1/2001)

4.3.1.4. This process will be repeated at least two times and/or

until the dirt pockets and strainers are cleaned. (see page 32 in BSRIA
AG 1/2001)

4.3.1.5. System must be filled with fresh water again and fresh
water should be observed by specialist.

4.3.1.6. System water pumps should be switched on and water

should circulate throughout the system except coils.at the same me
pressure should be kept at operational value. (see page 33,34,35,36 in
BSRIA AG 1/2001)

4.3.1.7. This water must be circulated for sufficient amount of

time. (see page 33,34,35,36 in BSRIA AG 1/2001)
 4.3.1.8. Water velocities in the system must be controlled for
flushing operation.(see page 33 in BSRIA AG 1/2001)

4.3.1.9. The steps between, 4.3.1.5 – 4.3.1.9 must be repeated

until system water seems equal to the fresh water.

4.3.2. Chemical flushing

4.3.2.1. Cleaning chemicals must be given to the system which
are defined in the offer of water treatment company.(see page 5
and page 27 in BSRIA AG 1/2001). Flushing chemical is
HYDROCLP CLEAN (see this documents).

4.3.2.2. Circulation must be provided for sufficient time.(see

page 48 in BSRIA AG 1/2001)

4.3.2.3. Flushing water quality must be measured by a specialist

and after he decides that the process is enough, water must be
fully drained.

4.3.2.4. After completely drain the circuit, device input and the
circulation pump in the whole system first made by the strainer
should be cleaned properly.

4.3.2.5. First rinse water should be subject to circulation for

sufficient amount of time and must be drained.

4.3.2.6. The entire process of monitoring water samples with the

chemical analysis should be done by taking the results and
recommendations of the report containing the application must
be delivered to the client representitive.

4.3.2.7. After chemical analysis if rinsing can not be done

properly, process will be repeated with circulation when systems
pumps are working until water treatment companies directives
are fully completed.(see page 23 and page 24 in BSRIA AG
1/2001)

5. Tracking - measurement - assessment

5.1. First measurement before giving protection chemical

(see page 23,24,25,27 in BSRIA AG 1/2001)
5.1.1. The measured rate of iron is the amount of free iron circulating in the
system.
 5.1.2. Free iron which is measured in the system comes from make up
water, and corrosion products from system. Doesn’t contain deposited
iron.

5.1.3. Measured pH, conductivity, and hardness as alkalinite are

important for additional water.

5.2. Measurements after flushing chemical given to the system

5.2.1. The existence condition of the circuit is given to the cleaning

chemicals, depending on the pH level is determined.

5.2.2. pH levels can be changed with water quality and use of the
chemical properties.

5.2.3. Rinsing and filling should be done without delay, for preventing
from water corrosive effect of the surface.

5.2.4. After the first rinsing the dirt filters must be cleaned, reduces the
number of rinse again.

5.2.5. When rinsing application, the iron level of the system will
decrease.

5.2.6. At the rate of iron reduction after the first rinse is inadequate
rinsing process is repeated again by water.

5.2.7. Rinsing application repeated until the system pH reaches  0.3 of

the pH of make up water.

5.2.8. During the rinsing application, ∑Fe concentrations are measured

in the system’s rinsing water. The rinsing applications are repeated
until the differance of the ∑Fe concentrations before and after rinsing
water measuring is almost stable. The differance value of the between
before and after ∑Fe measurings are admissible as a +15%.(also see
page 24 in BSRIA AG1/2001)

5.2.9. After rinsing process, system is filled fresh water and protective
chemical are given immediately (see page 47 in BSRIA AG 1/2001).