Document No: 2352-MS-2022

Method of Statement for Chilled Water Chemical Revision: 00

Flushing Dated: DECEMBER 07, 2022
Page 1 of 12

CLIENT M/s. DUBAI SOUTH

PROJECT NAME RFP 061C/AD/21 - BALANCE SCOPE OF

WORKS OF AEROSPACE SUPPLY
CHAIN FACILITY PHASE -03 AT PLOT
NO. AC6-18 AT THE AVIATION
DISTRICT OF DUBAI

CONSULTANT M/s. AL WASL AL JADEED

CONSULTANTS
MAIN CONTRACTOR M/s. AL TURATH ALASEEL
CONTRACTING L.L.C
 Document No: 2352-MS-2022
Method of Statement for Chilled Water Chemical Revision: 00
Flushing Dated: DECEMBER 07, 2022
Page 2 of 12

Contents

1.0 Purpose
2.0 Safety of Equipment’s
3.0 Planning and Management

3.1 Fresh Water & Wastewater disposal arrangement

3.2 Flow requirement
3.3 Pump Calculations

4.0 Resources
5.0 Preparation
6.0 Typical stages of Pre-Commission Cleaning of Pipe work systems

6.1 Static Flushing

6.2 Hydraulic Flushing
6.3 Dynamic Flushing
6.4 Chemical Cleaning
6.5 Effluent Disposal / Chemical Removal
6.6 Passivation
6.6.1 Back flushing of Fan Coil Units (FCUs)
6.4.2 Back flushing of Air Handling Units (AHUs)
6.5 Corrosion Inhibitor and biocide dosing

7.0 Water Quality at different stages

7.1 Dynamic Flushing - Water quality before addition of Cleaning chemical

7.2 Cleaning Stage - Water quality after addition of Cleaning chemical
7.3 Post Cleaning Stage
7.4 Passivation Stage (Water quality after Passivation)
7.5 Corrosion Inhibitor and Biocide Dosing (Water quality before adding
final chemicals)

8.0 Sampling Points

9.0 Recommendations after Cleaning & Passivation
 Document No: 2352-MS-2022
Method of Statement for Chilled Water Chemical Revision: 00
Flushing Dated: DECEMBER 07, 2022
Page 3 of 12

1.0 Purpose

This document describes the methodology and procedure for flushing of chilled water system and to ensure
that all concerned persons are familiar with the sequence of activities, utilization of resources, and execution of
the works in compliance with applicable Safety and Quality Procedures, and Project Documents and
Specification.

2.0 Safety of Equipment’s

Corodex team will take necessary measures for the safety of the temporary equipment’s and other works

3.0 Planning & Management:

• Ensure Hydro-testing is completed before start the flushing works (Hydro test Report)
• Inspection of the system and identifying ideal positions for the flushing points
• Establishing how the flushing velocities are to be achieved i.e. pumping requirements
• Flushing the system with water at high velocity
• Adding a chemical cleaner to the system water to remove oil, grease, corrosion deposits and to
mobilize any suspended solids present & Passivation to form protective layer on metal surface
• Testing the water for the presence of iron and suspended solids etc.
• Addition of a corrosion inhibitor and Biocide for long term protection

3.1 Fresh Water and WW Disposal arrangements:

Job Description Items Planning & Management

Temporary Temporary collection tank should be available at site to
Collection Tank collect Fresh water
Temporary
Temporary Make-up water pump require to transfer Fresh
Make-up water
water in the system
Fresh Water pump
Hoses to transfer Fresh Water
Source Water to be arranged via Tankers if not available at site
Timings It is important to check and confirm the timings of tanker
Restrictions movement in particular area to avoid delays
Temporary Temporary collection tank should be available at site to
Collection Tank collect Fresh water
Hoses to transfer Wastewater
To maintain water quality as per DM guidelines, minimize
WW Disposal Filtration
water consumption, and particles removal
WW disposal need to be done as per DM regulations,
Permits
arranging DM permits for disposal
Disposal to be arranged via Tankers - To be disposed
Source
through tankers at designated areas by Sharjah Municipality
 Document No: 2352-MS-2022
Method of Statement for Chilled Water Chemical Revision: 00
Flushing Dated: DECEMBER 07, 2022
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3.2 Flow requirement:

System pump Operational Flow = 60LPS – 2 pumps

Flow required = Operational flow + 10% Additional flow ( to be achived by operating the
third pump)

4.0 Resources

Description Scope of Work details

Items: Chemicals, Temporary pump, Flexible hoses,
Temporary Wastewater Collection Tank, Filtration Housing &
Corodex
Filters
Engineer & Technician: Corodex team for Cleaning,
Passivation, Water Analysis,
Manpower for 24 hours operation, loading/unloading, power
M/s Al Turath Alaseel
supply & operation of system pumps, Meters/gauges,
Contracting L.L.C provisions for hoses & looping, back flushing & strainers
cleaning ,fresh water supply, WW Disposal .

5.0 Preparation for the flushing the chilled water system circuit:

System Volume: 24 m3
 Document No: 2352-MS-2022
Method of Statement for Chilled Water Chemical Revision: 00
Flushing Dated: DECEMBER 07, 2022
Page 5 of 12

5.1 Typical stages of Pre-Commission Cleaning of Pipe work systems:

Static Dynamic Cleaning Post Passivation Biocide Wash+

Flush Flush Stage Cleaning Stage Inhibitor addition
(1) (2) (3) (4) (5) (6)

1. Check and ensure the system is hydrostatically pressure tested and verify test certificate.
2. Check the provision of air vents at location as per approved drawings.
3. Check and ensure sufficient quantities of chemicals are available as per requirement.
4. Place warning signs and warning tape as required.

6.0 Typical stages of Pre-Commission Cleaning of Pipe work systems:

Chemicals & Quantity to be

Section Stage
added
6.1 Static Flushing -

6.3 Dynamic Flushing -

Chemical Cleaning: Degreasing.
6.4 Removal of surface oxides & EC- CL 506 0.5-1.0 kg/m3
particulates
To be disposed through
6.5 Effluent Disposal / Chemical Removal
tankers at designated areas
EC-313 (Passivation)
6.6 Passivation
0.5 -1 kg /m3
EC-8539 (Wet lay up stagnant
system Corrosion Inhibitor)
3 kg/m3
6.7 Corrosion inhibitor and biocide
EC-401 (Non-Oxidizing
Biocide) 0.01 kg/m3
 Document No: 2352-MS-2022
Method of Statement for Chilled Water Chemical Revision: 00
Flushing Dated: DECEMBER 07, 2022
Page 6 of 12

Chemical Dosage

Chemicals Dosages (Kgs) & Quantity

EC- CL 506 0.5-1.5 Kg/m3
EC-313 0.5 - 1 Kg/m3
EC-8539 3 Kg/m3
EC-401 0.1 Kg/m3

6.1 Static Flushing: Main objective of this is to remove any debris and dirt accumulated in the
dirt pockets and strainers after the pressure testing.

Procedure:

i) At the end of pressure testing, leave the system with water for 12 - 24 hrs to soften any
inclusions.
ii) Open the air vents on top points and drain the entire system from the lowest drainage
point
iii) Refill the system and drain at least 1 more times (depends of water quality) checking the
strainers each time.
iv) Removing the strainers and manual cleaning has to be carried out to remove any pieces
of wood and metals. (Depending on the water quality )

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

i) Fill the system with clean water and check air vents
ii) Drain the water after 30 minutes.
iii) Refill the system with clean water and run the chilled water pump for 2 hours.
iv) Open the drain valves in the main lines and drain the water completely (drain
from lowest points).
v) Inspect and clean the strainers
vi) During the above flushing process the drain valves shall be kept open while the
pump is running, until the water appears clean. Close all the drain valves

Corodex Engineer will collect the samples from different points and test to confirm the
acceptable water quality for next stage (Cleaning stage)
 Document No: 2352-MS-2022
Method of Statement for Chilled Water Chemical Revision: 00
Flushing Dated: DECEMBER 07, 2022
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6.3 Chemical Cleaning: Cleaning stage is performed with cleaning agents, to remove dirt,
suspended solids, surface oxide deposits and grease with EC-CL 506 at the rate of 0.5 – 1.5
Kg/M3

Procedure:

i) Refill the system with clean water and add cleaning chemicals in required
quantities
ii) Samples shall be collected from various parts of the system to ensure the
chemical solution has reached all parts of the system.
iii) Run the pump and circulate the water (with chemicals added) for a minimum
period of 6 to 12 hours (depends on water quality)
iv) Circulation to be more effective the flow can be restricted to one particular
Branch at a time for 2 to 3 hours
v) Samples to be tested

6.4.1 Effluent Disposal / Chemical Removal: Removal of Mill scale, Installation debris,
corrosion products, after cleaning stage

Procedure:

i) After the cleaning process is completed as described above the cleaning

solution shall be flushed out. Or minimize concentration of particulates via
Filtration
ii) Check and clean the strainers

Iron content at this stage should be <5 ppm

6.5 Passivation: Stage require to develop protective layer on metal surface with EC-313 at the
rate of 0.5 -1 Kg/m3 that inhibit metal corrosion
Procedure:
i) Close all drain points before addition of EC-313 and add the chemical in system
water
ii) Circulate water for 12 – 24 hours at low velocity to allow formation of passivation
layer on metal surface
iii) Circulation to be more effective the flow can be restricted to one particular
Branch at a time for 2 to 3 hours
iv) Open all FCUs, AHUs, etc. by closing the bypass valves for back flushing

7.0 Back flushing of Fan Coil Units (FCUs)

➢ Close bypass valve A

➢ Connect the drain hose and have a bucket near strainer Y
➢ Open strainer Y & valve B to drain all the water from strainer into the bucket
➢ Continue the flushing till water is clear from strainer Y
 Document No: 2352-MS-2022
Method of Statement for Chilled Water Chemical Revision: 00
Flushing Dated: DECEMBER 07, 2022
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➢ Once the water is clear from strainer, close the strainer & valve B
➢ Connect the drain hose and have a bucket near DC
➢ Open valve B and drain all the water from DC into the bucket
Continue the flushing till water is clear from DC
➢ Once the water is clear from DC, close valve B
➢ Have a bucket near FC-1
➢ Remove FC-1
➢ Open valve B and drain all the water from FC-1 into the bucket
➢ Continue the flushing till water from FC-1
➢ Once the water is clear from FC-1 close valve B
➢ Reconnect FC-1 with FCU
➢ Connect the drain hose and have a bucket near FC-2
➢ Remove FC-2 & open valve B
➢ Drain the water from FC-2 & open valve B
➢ Drain the water from FC-2 till the water is clear
➢ Once the water is clear close valve C
➢ Remove the spool pieces & install the PICV and reconnect FC-2 with FCU
➢ Put the FCU in operation

6.5. Back flushing of Air Handling Units (AHUs)

➢ Close bypass valve A

➢ Connect the drain hose and have a bucket near strainer Y
➢ Open strainer Y & valve B to drain all the water from strainer into the bucket
➢ Continue the flushing till water is clear from strainer Y
➢ Once the water is clear from strainer, close the strainer & valve B
➢ Connect the drain hose and have a bucket near DC
➢ Open valve B and from DC into the bucket
 Document No: 2352-MS-2022
Method of Statement for Chilled Water Chemical Revision: 00
Flushing Dated: DECEMBER 07, 2022
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➢ Continue the flushing till water is clear from DC

➢ Once the water is clear from DC, close valve B
➢ Connect the drain hose and have a bucket near FC-1
➢ Remove FC-1 and open valve B
➢ Drain from FC-1 till the water is clear
➢ Close valve V
➢ Connect the drain hose and have a bucket near FC-2
➢ Remove FC-2 & open valve B
➢ Drain the water from FC-2 & open valve B
➢ Drain the water from FC-2 till the water is clear
➢ Once the water is clear close valve C
➢ Remove the spool pieces & install the PICV and reconnect FC-2 with FCU
➢ Put the AHU in operation

6.6 Corrosion inhibitor and biocide dosing

i) Ensure clean water in the system and add EC-8539 (Corrosion Inhibitor) at the
rate of 3 Kg/M3 and circulate water for 2 – 3 hours then add EC-401 (Non-
oxidizing Biocide) at the rate of 0.1 Kg/M3 to kill microbiological growth
ii) Circulation to be more effective the flow can be restricted to one particular
Branch at a time for 2 to 3 hours
iii) Collect sample after 2-3 Hours for analysis to ensure water quality
 Document No: 2352-MS-2022
Method of Statement for Chilled Water Chemical Revision: 00
Flushing Dated: DECEMBER 07, 2022
Page 10 of 12

7.0 WATER QUALITY ANALYSIS AT DIFFERENT STAGES

7.1 Dynamic Flushing (Water quality before addition of Cleaning chemical EC-CL 506)
Parameter Unit Supply Water After Dynamic
Flushing
pH - 7.5 – 9.0 7.5 – 9.5
TDS ppm <250 <800
Total Iron ppm <0.1 <5.0
Total Suspended solids ppm <5 <50
(TSS)
Appearance - Clear -

7.2 Cleaning Stage (Water quality after addition of Cleaning chemical EC-CL 506)
Parameter Unit Supply Water Cleaning Stage
pH - 7.5 – 9.0 6.5 – 7.5
TDS ppm <250 <2000
Total Iron ppm <0.1 -
Total Suspended solids ppm <5 -
(TSS)
Appearance - Clear As per system
condition
Note: Iron & TSS content depends on system condition

7.3 Post Cleaning Stage (Before adding passivation stage)

Parameter Unit Supply Water Cleaning Stage

pH - 7.5 – 9.0 7.5 – 10.0
TDS ppm <250 <700
Total Iron ppm <0.1 <5.0
Total Suspended solids ppm <5 <30
(TSS)
Appearance - Clear As per system
condition

7.4 Passivation Stage (Water quality after adding EC-313 Passivation chemical)
Parameter Unit Supply Water Cleaning Stage
pH - 7.5 – 9.0 7.5 – 10.5
TDS ppm <250 <1500
Total Iron ppm <0.1 <2.0
Total Suspended solids ppm <5 <30
(TSS)
Appearance - Clear Clear
 Document No: 2352-MS-2022
Method of Statement for Chilled Water Chemical Revision: 00
Flushing Dated: DECEMBER 07, 2022
Page 11 of 12

7.5 Corrosion Inhibitor and Biocide Dosing (Water quality after adding final
chemicals)

Parameter Unit Supply Water Cleaning Stage

pH - 7.5 – 9.0 >8.5
TDS ppm <250 < 2500
Inhibitor as NO2 ppm - > 600 ppm
Total Iron ppm <0.1 <1.0
Total Suspended solids ppm <5 <30
(TSS)
Appearance - Clear _

8.0 Sampling Points:

Circulation pump return

Lowest Drain points at different locations (Valve chamber )
Ref: BSRIA BG29/2012 page# 87

10.0 Chemical Dosage Calculations:

System Volume = 24 m3

• EC-506 ( Cleaning Chemical )

Quantity of Chemical in Kg = Volume ( m3 ) / 1000 * Dosage in ppm (mg/l)

= 24 m3 / 1000 * 1000 ppm
= 24 Kg

• EC-313 ( Passivation Chemical )

Quantity of Chemical in Kg = Volume ( m3 ) / 1000 * Dosage in ppm (mg/l)

= 24 m3 / 1000 * 1000 ppm
= 24 Kg
 Document No: 2352-MS-2022
Method of Statement for Chilled Water Chemical Revision: 00
Flushing Dated: DECEMBER 07, 2022
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• EC-8539 ( Corrosion inhibition Chemical )

Quantity of Chemical in Kg = Volume ( m3 ) / 1000 * Dosage in ppm (mg/l)

= 24 m3 / 1000 * 3000 ppm
= 72 Kg
• EC-401 ( Microbiocide )

Quantity of Chemical in Kg = Volume ( m3 ) / 1000 * Dosage in ppm (mg/l)

= 24 m3 / 1000 * 100 ppm
= 2.4 Kg

11.0 Recommendations after Cleaning & Passivation:

➢ Pressure to be maintained in the system after connecting the system pumps.

➢ Chemicals level to be maintained to ensure protection of metal
➢ Monitor water quality
➢ New circuits not to be added without water analysis (to ensure acceptable parameters)
➢ Addition of Biocide, Once in 3 months (Quarterly) to avoid microbiological growth.