The National Co.

For Mechanical & Electrical Works

Method Statement for Flushing and Cleaning

the Chilled Water and Hot Water Pipes

The American University in Cairo

New Campus Development

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The National Co.
For Mechanical & Electrical Works

Contents

1. PREAMBLE

2. INTRODUCTION

3. HEALTH AND SAFETY

4. SPECIFICATIONS CLAUSES

5. DELIVERY, STORAGE AND HANDLING

6. SYSTEM PREPARATION AND PRE-CLEANING/CHECKING

7. CHILLED AND HOT WATER CLEANING PROCEDURE

8. CHEMICAL ANALYSIS OF RAW WATER SUPPLYING.

9. PRODUCT INFORMATION SHEETS

10. RECOMMENDED DOSAGE RATE

11. SITE ANALYSIS

12. CHEMICAL TEST LIMITS

13. CONTRACT FOR WATER TREATMENT CONSULTING SERVICES

14. ORGANIZATION CHART

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The National Co.
For Mechanical & Electrical Works

1.Preamble:

- The introductive explanation of the proposed method statement for the

flushing and cleaning of the HVAC chilled and hot water pipes would briefly be our
understanding of the services to be provided for the AUC New Campus Development
Project. Site conditions and logistics thereto stages of construction, to be adopted in
our work and shall comply with the general condition and specifications of the
contract. However the following aspects to be considered while planning for this
operation:

 Importance of safety to this project.

 Importance of meeting project milestone dates.

 Importance of final product quality.

- The following points will outline our proposed procedures for HVAC work in
this project

2.Introduction:

- System technique will forward all information's about Chemical required for
our scope to parcel# 60 (plant room) contractor for coordination.

- Obtain PMCM permit to work, witness and approval.

- Construct a safe access to the areas that cleaning work to be done.

- Start of work.

- Allow trade constructors to commence their portion of the work.

3.Health & Safety:

- This section is covered in our proposed safety program (HSE) and safety
program (SOP) submitted among contract requirements. However, the following
points are to be noted:

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The National Co.
For Mechanical & Electrical Works
- All relevant personnel protection equipment (PPE) shall be provided to all
personnel involved in the work and wearing of PPE shall be enforced by the team as
whole all site personnel shall wear the following at all times.

- Safety boots.

- Safety helmets.

- Safety glasses with side shields.

- Other utilities shall be clearly marked and identified. Signboards identifying

the type of utilities shall be displayed at the relevant locations indicating limits of the
works.

- Public is strictly not allowed to enter the site only authorized persons are
permitted into the work zone. Any accident shall be promptly reported to the safety
department for further investigations and action.

 Emergency drill should be arranged how to secure injured persons.

 Proper ventilates should be supply in the localized working areas in addition to

suitable test area Lighting.

4.Specifications Clauses:

- Specification sections:

- Div. 15189 HVAC water treatment & chemical cleaning system.

- Div. 15411 HVAC pipes and fittings.

5.Delivery. Storage And Handling:

- Material delivery to the site shall be in such intervals to ensure uninterrupted

progress of work and with quantities proportional to HVAC net works (chilled /hot).

- Materials shall be stored to permit easy access for inspection and

identification. Packaged materials shall be protected.

- Protect from direct sunlight exposure.

- Material inspection requests (MlR's) shall be submitted upon material

receiving in store.

6.System Preparation and Pre-Cleaning/Checking:

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The National Co.
For Mechanical & Electrical Works

- System preparation & pre cleaning checking.

- Checking the temporary strainers, all portable pumps and equipment in

cleaning path.

- A suitable number of staff must be available for cleaning the strainer (also
suitable tools, accessories must be available). Normally, all pumps must be in manual
operation when undergoing strain cleaning plus checking the availability of strainer
gaskets.
- Checking the Air Vent availability and working mechanisms.

- Checking drain valves.

- Recording the pressure gauge reading in the network showing the pressure in
the discharge side of the main circulation pumps.

The above mention steps shall be applied after the hydraulic pressure test for all
:Note
.the system

7.Chilled And Hot Water Cleaning Procedure:

- Static Flushing.

 The paperwork distribution system shall be separated into isolations of high to low
points. Each section shall generally include a drain valve at it's lowest point with
access to drain.

 A static flushing schedule shall be devised and the section to be flushed clearly
indicated on a schematic diagram of the system.

 The system flushing shall be achieved using separate portable pumps with 3m/S
cleaning flow rate as per codes.

 Open all isolating, regulating and gate valves on the section to fully open. (except
the A.H.U and F.C.U) must be avoided.

 Sensitive equipment on the section shall be bypassed, isolated or completely

removed and replaced with a spool piece to ensure system flow .

 Disconnect the section of pipework immediately upstream of all portable pumps

and inspect for any contaminants which could damage the impeller. Remove any
such contaminants and refit the pipework section.

 Fill the system utilizing water from the main tank via a hose from the cold water
booster pumps.

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The National Co.
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 Leave the system charged for 48 hours to soften the inclusions.

 Drain the entire system and clean out all dirt pockets and strainers.

 If required, refill and drain the system twice more checking dirt pocking and
strainers each time.

 If the system is to be left for a period of more than 48 hours before

commencement of dynamic flushing, the system should be re-filled with inhibitor
dosed water.

 All future branches & non connected Branches to be bypassed during dynamic
flushing.

- Degreasing & Removal of Surface Oxides.

 The Chemical cleaning and dosing shall be performed by "system technique"

utilizing the EN labor under PMCM supervision after the system has been
thoroughly clean water flushed to the satisfaction of the "system technique /
PMCM.

 Chemical Cleaning must be carried out within 24 hours of the pre-flush.

 With the system filled and vented with clean water, run the primary pumps, and System
Technique are to introduce the correct amount of "Ferroquest 5236" into the system.

 The system is then to be circulated for 24 hours with 3m/S.

 System Technique will then perform their analysis of the water in the system.

 The system water is then to be disposed of via the foul water drains.

 Fill and Vent the system again, circulate for a further 24 hours, drain and fill
again.

 Analysis of the water will be carried out by System Technique to check for traces
of the Ferroquest. If traces of this cleaning agent are found, then the above step
2.3.7 is to be repeated until the properties of the drain water equal those of the fill
water.

- Passivation / Corrosion Inhibitor Dosing.

 If the system is not to be put into operation for more than one week, then the
system should be regularly monitored and circulated, and if necessary further
dosed until the system is handed over and put into operation.

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The National Co.
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- Pant Data.

 Water volume: ………………cubic meter approx.

 Operation ……….……....hr./day
……………….days/year
 Initial application 10kg/m³ of system capacity subsequent routine testing
should achieve 1000 ppm concentration of additive.
 pH adjustment No pH adjustment
 Dosing Corrisheild NT4293 will be injected into the system using
existing pressurized liquid feeder.

8.Chemical Analysis of Raw Water Supplied.

Substance/or Characteristic Intern. Units Feed Water

Color Hazen 1
Turbidity NTU 1
Odour …… Nil
pH-value ……. 6.8-8.0
Conductivity µ mhos 360
TDS mg/L 240
Calcium ion (Ca) mg/L 80
Chloride (Cl) mg/L 30
Bicarbonate (HCO3) mg/L Nil
Carbonate (CO) mg/L 110
Hydroxide (OH) mg/L Nil
Silica (SiO2) mg/L <30
Iron (Fe) soluble mg/L <0.3
Total hardness mg/L 120
Free chlorine mg/L <0.3

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The National Co.
For Mechanical & Electrical Works

9.Product Information Sheets.

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The National Co.
For Mechanical & Electrical Works

10.Recommended Dosage Rate.

- The Chilled Water System.

 An initial dosage of 3.75 kilogram of Corrisheild NT 4292 per one cubic meter of
system water capacity should be applied to the system and subsequent routine
testing should achieve an operating concentration of 1000 ppm.

- Inhibitor Az 8104:

 More protection of system copper content will be carried out by inhibitor Az 8104.

 Recommended dose: 0.2kilos/1m³.

- Spectrus NX 1100:

 Spectrus NX 1100 is specified biocide for chilled water system as it gives an

excellent system disinfection against nitrifying bacteria which is commonly
existing in chilled system more over it is efficient against all other types of
bacteria.

 Recommended dose: 0.2kilos/1m³.

- Closed Recalculating Heating Water System.

 An initial dosage of 14 kilogram of Corrishield NT 4293 per one cubic meter of

system water capacity should be applied to the system and subsequent routine
testing should achieve an operating concentration of 1000 ppm.

11.Site Analysis.

- System Technique Will Carry out the Following Analysis.

 Mains water

oHardness.

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The National Co.
For Mechanical & Electrical Works
oAlkalinity.

oChlorides.

opH.

oConductivity.

oTotal dissolved solids.

oIron Fe.

oFree chlorine residual.

 Closed Hot Water System.

o pH.

oConductivity.

oTotal dissolved solids.

o Iron Fe.

oCorrosion Inhibitor level.

 Closed Chilled Water System.

opH.

oConductivity.

oTotal dissolved solids.

o Iron Fe.

o Corrosion Inhibitor level.

12.Chemical Test Limits.

- The Chilled Water System

PH 9-10.5
Sodium Nitrite(NaNo2) 1000ppm
Iron (Fe) <0.5

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The National Co.
For Mechanical & Electrical Works

- Closed Recalculating Heating Water System.

- PH 9-10.5
Sodium Nitrite(NaNo2) 1000ppm
Iron (Fe) <0.5

13.Contract For Water Treatment Consulting Services.

-One your guaranty offered via bid for water system technique or the approved equal
the with following activities.

 System technique engineers will visit the AUC campus twice per month to carry
out the chemical tests with the consultant engineers to check for the performance
and operating parameters.

oMains water.

oClosed hot water system.

oClosed chilled water system.

 Mains test are as following:

oHardness.

oAlkalinity.

oChlorides.

opH.

oConductivity.

oTotal dissolved solids.

oIron Fe.

oFree chlorine residual.

 Closed hot water system.

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The National Co.
For Mechanical & Electrical Works
opH.

oConductivity.

oTotal dissolved solids.

oIron Fe.

oCorrosion inhibitor level.

 Closed Chilled Water System.

opH.

oConductivity.

oTotal dissolved solids.

oIron Fe.

oCorrosion inhibitor level.

 System Technique will carry out once per month bacteriological tests on the
potable water to determine its suitability and conformity to the World Health
Organization (WHO) standards for human consumption.

 System Technique will supply chemical reagents and indicators at retail price to
enable AUC Campus own engineers to carry out on a daily basis the
recommended tests.

 System Technique will supply specially prepared log sheets which will be used by
AUC Campus own engineers to tabulate all the tests carried out by them.

The test and analysis carried by AUC campus own engineers are completely
:Note
.different from the test carried out by S.T

 Full details of tests carried out by System Technique are given in the consulting
report supplied by them.

 The Consulting Service Report (CSR) with the results of the Bacteriological tests
will be sent by fax and the original will be submitted to your engineer on our
monthly visit. The instructions and necessary actions recommended in these CSR
must be followed exactly.

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The National Co.
For Mechanical & Electrical Works

14.Organization Chart.

Eng. Ahmed Abd El Razek Project Manager

Eng. Mohamed Radwan Electromechanical Manager
Eng. Ramy Taher Service Engineer
Eng. Ahmed El Seweedy Service Engineer
Eng. Ahmed Saleh Service Engineer
Eng. Hossam El Touny Service Engineer
Mr. Ahmed Fouad Technician
Mr. Rabae Tawfik Technician
Mr. Khaled Abbas Technician
Mr. Mohamed Fathy Technician

-During each treatment one service engineer and two technician will be attended

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