Pressure Test - Flushing - Pickling - Passivation Hyd-Cw-Gr
Pressure Test - Flushing - Pickling - Passivation Hyd-Cw-Gr
Pressure Test - Flushing - Pickling - Passivation Hyd-Cw-Gr
6.5.1 General
The order how to make these operations it will be as follow:
• Initial flushing just to remove the bigger parts from the system
• Pressure test during this operation possible leakage can be discovered and must
be removed (reweld some parts or opening flange to change gasket,
etc.)
• Flushing to remove all dirty, scale, chippings, etc.
• Pickling where required (according to the kind of fluid)
• Passivation where required (according to the kind of fluid)
Circuit preparation
The circuit where the activities are performed is modified compared to the intended circuit design in
order to concentrate the activities on individual circuit parts.
The changes are made through the application of tubular pipe connection constructed ad hoc or
hoses in order to bypass the machines and then directly connect the delivery and return piping.
During the above operation all sensible equipments / instruments (orifice plates, flow meter
elements, control valves and safety valves, etc.) shall be removed and replaced with mock-ups
(plugs) or by pass until the end of these operations.
On the contrary, if the equipments / instruments are provided with insulating valves, it will be
enough to shut-off those manual valves upstream and downstream the equipments / instruments in
order to avoid any damages to the equipments / instruments themselves.
A list shall be prepared and be part of the flush & test procedure.
This procedure specifies the method of cleaning and passivation of internal surface of carbon steel
piping based on use of chemical components to be added in water, prior to taking in service for the
first time after installation / fabrication.
Certain equipment and piping must be chemically cleaned to remove mill scale, dirt, greases used
as rust preventatives, and other foreign materials that could result in operating and maintenance
problems, excessive wear and damage to reciprocating of equipments and corrosion due to the
reaction of scale with the process environment.
Chemical cleaning will generally be done after completion of unit construction. If connection is
flanged the cleaning is done prior to completion of construction and the cleaned equipment must
be protected from atmospheric exposure and entry of any outside debris or dirt otherwise the
cleaning shall be done after completion of unit construction.
6.5.3 Flushing
All pipes before commissioning must be flushed. There are many flushing methods. Below we
report the most common that can be easily applied on site:
The water used for flushing shall therefore be drained and just replaced by the water of the quality
specified by the cleaning (pickling) & passivation process, and the lime must then be
commissioned.
In case of water seal, these shall be inspected and if necessary cleaned before to put water inside.
6.5.3.4 Requirements
• Fresh water for filling and flushing for circuits should be done until water qualities within the
acceptable limits.
• Manpower to:
- Remove all manometers on pumping station and main line
- Remove flow transmitter on pipe lines
- Remove basket filters
- Isolate the automatic make up valves installed on the main headers: close the interception
valves and open the by-pass valves.
• Install all necessary temporarily loops and bypass piping for flushing / draining.
• Install blinds and suitably sized drain where necessary especially at the lowest part.
• Checklist to facilitate valve line-ups as required for each major flush path.
General for flushing the following shall be excluded or removed from the circuits by closing the
valve:
• All manometers on pumping station and main line
• Flow transmitter on pipe lines (only if orifices are used)
• Basket filters: remove the baskets.
• Automatic make up valves installed on the main headers: close the interception valves and
open the by-pass valves.
Objective
• To reduce the interference caused by dirt, grit and sand (debris) in the subsequent process of
removal of foul and mill scale.
• To limit the demand of cleaning chemicals this would otherwise be lost through adsorption on
the fouling deposits and other contaminants.
• To curtail the time required to achieve desired water quality at the end of the pre-cleaning
process, i.e. oil, grease and mill scale removal.
6.6.2 Requirements
• All Necessary Chemicals
• Forklift for shifting the chemicals
• Manpower for shifting, handling and adding of chemicals.
• Ensure that adequate supply of good make up water is available during the cleaning
passivation period.
• Pit / tank where to discharge the cleaning solution should be ready to accept the cleaning
solution once the Iron level has been stabilized
6.6.3 Procedure
Stage 1
The cleaning process mentioned will be carried out merely adding the recommended level dosage
of Hydrex – 5208 cleaning chemicals based on Organic acid, with dispersant and re-circulated
the water minimum period of 24 hours. This period may be extended depends on the stabilization
of total iron level in the re-circulating water. During this cleaning the pH, turbidity, total iron cleaner
residual will be monitored at intervals of every hour.
Note: The stabilization of the iron level in the re-circulating water will be the indication of
completion of the cleaning process and will be the basis for the cutoff point.
Product Dosage ppm /Qty. Duration Control Frequency of Analysis
- pH, Every 1 Hr.
- Turbidity (FTU),
- TSS,
- Total Iron
- Treatment Reserve
200 ppm min
Provision of 2 days is being made for the Stage II cleaning process, however the cut off point for
this process is the stabilization of iron level in the re-circulating water.
Stage 2
Once the iron level has been stabilized in the in the re-circulating water its indication of completion
for the cleaning process stage 1, the system will start “balanced bleed (water is drained, ideally
from the lowest point in the system and simultaneously refilled by the make water while
recirculation continuous to be maintained) until the iron level reached at the point of less than 2.0
ppm while the pH at ideal level.
Then the system is ready to be drained completely and arrange to commence mechanical cleaning
for CW cooling water basin, clean all the strainers and open the loose leg areas for mechanical
cleaning as well. After the mechanical cleaning has been completed it is required to fill the system
immediately by good quality of make-up water for the preparation of passivation stage.
PROCEDURE PRESSURE Document n.:
Remarks:
All the by-pass line for the on line equipments and instrument can be removed, put in on line and
adjusts the water level as required.
Objective
The objective of the flushing process (Stage 2) is to flush the system off the Material/deposits
dislodged during the cleaning process (Stage II) and prepare the surface to receive the passivated
film in the subsequent process of passivation.
6.6.4 Passivation
Stage 3
Once water quality has been achieved in terms of turbidity at the end of stage 1, all bleed of points
will be shut and Stage II of the pre-cleaning process will be commenced. The next stage consist of
process as mentioned below
Product Dosage ppm Qty. (Kg) Duration Control Frequency of Analysis
2 - 5 days* - pH, Every Hr.
- Turbidity (FTU),
- TSS,
- Total Iron
- - -
Procedure:
In order to control the proliferation of bacteria in the re-circulating water and prevent it from
interfering with the passivation proves, a non-oxidizing biocide will be added based on the system
volume at the start up to the passivation process.
The pH, turbidity, iron and treatment reserve will be monitored during this stage to determine the
progress of the passivation process.
Notes:
• Passivation level of corrosion inhibitor will be maintained in the system until the treatment
reserve stabilizes. Any drop in the treatment reserve will be made up by fresh addition of
corrosion inhibitor.
• Most of the passivation is achieved in the first 3 – 4 hours after addition of the corrosion
inhibitor. However, in order to ensure the integrity and uniformity of the protective film
passivation level of the corrosion inhibitor will be maintained for the subsequent 2 - 5 days.
• There will be no deliberate discharge of the water from the system during and after this
passivation stage.
• Once the passivation is complete, lower treatment reserves as per the normal operation will be
maintained by allowing the treatment reserve to fall gradually. (This is not a necessity and will
be dictated by the system requirement of fresh make up water).
• It is ideal to maintain the circulation after passivation process is complete to ensure availability
of adequate level of corrosion inhibitor to maintain the uniformity and integrity of the
passivation film.
• There should be no interruption of the treatment programmed after completion of this stage in
order to maintain the passivation film layer.
PROCEDURE PRESSURE Document n.:
The objective of the passivation process is to promote the rapid formation of the protective and
passivation film on the metal surface.
6.1.2 Requirements
• All Necessary Chemicals
• Forklift for shifting the chemicals
• Manpower for shifting, handling and adding of chemicals.
• Ensure that adequate supply of good make up water is available during the cleaning
passivation period.
• Pit /tank where to discharge the cleaning solution should be ready to accept the cleaning
solution once the Iron level has been stabilized
6.1.3 Procedure
Stage 1
The cleaning process mentioned will be carried out merely adding the recommended level dosage
of Hydrex – 5208 cleaning chemicals based on Organic acid, with dispersant and re-circulated
the water minimum period of 24 hours. This period may be extended depends on the stabilization
of total iron level in the re-circulating water. During this cleaning the pH, turbidity, total iron cleaner
residual will be monitored at intervals of every hour.
Note: The stabilization of the iron level in the re-circulating water will be the indication of
completion of the cleaning process and will be the basis for the cutoff point.
Dosage ppm
Product Duration Control Frequency of Analysis
/Qty.
- pH, Every 1 Hr.
- Turbidity (FTU),
- TSS,
- Total Iron
- Treatment
Reserve 200 ppm
min
Provision of 2 days is being made for the Stage II cleaning process, however the cut off point for
this process is the stabilization of iron level in the re-circulating water.
PROCEDURE PRESSURE Document n.:
Objective
The objective of this process is to render the metal surface free of scale, foulants and other
deposits and thus the rapid formation of the uniform passivating film of corrosion inhibitor in the
subsequent process of passivation.
Stage 2
Once the iron level has been stabilized in the re-circulating water its indication of completion for the
cleaning process stage III, the system will start “balanced bleed until the iron level reached at the
point of less than 1.0 ppm and the pH at ideal level prior to drain closed loop (QW) tank and
commence mechanical cleaning accordingly and refill immediately for preparation of the
next stage.
Remarks:
All the by-pass line for the on line equipments and instrument can be removed, put in on line and
adjusts the water level as required.
Objective
The objective of the flushing process (Stage 2) is to flush the system off the material/deposits
disludged during the cleaning process (Stage 1) and prepare the surface to receive the passivating
film in the subsequent process of passivation.
6.1.4 Passivation
Stage 3
Once water quality has been achieved in terms of the iron Level at least < 1.0ppm passivation is
ready to add as per the dosage rate of 5000 ppm of Hydrex - 2510. Then after an hour circulation
Hydrex – 7310 at dosage rate of 100ppm should be added.
Product Dosage ppm Qty. (Kg) Duration Control Frequency of Analysis
2 - 5 days - pH, Every Hr.
- Turbidity (FTU),
- TSS,
- Total Iron
- - -
Procedure:
In order to control the proliferation of bacteria in closed re-circulating water and prevent it from
interfering with the passivation proves, a non-oxidising biocide will be added based on the system
volume at the start up to the passivation process.
The pH, turbidity, iron and treatment reserve will be monitored during this stage to
determine the progress of the passivation process.
Objective:
The objective of the passivation process is to promote the rapid formation of the protective and
passivation film on the metal surface.
PROCEDURE PRESSURE Document n.:
Contractor must supply a flushing pump; system pumps are not to be used. Pump flow must be
high enough to create turbulent flow in every part of circuit during the cleaning phase. This level is
to be determined by the following formula, assuming Reynolds Number (Re) to be greater than
10.000 (minimum fluid velocity, 4,5 m/sec):
Q
where: Re= ( v) 21·300
Q = flow (lpm) D
d = pipe ID (mm)
ν = kinematics viscosity of the fluid (cSt)
The pump will most likely not be able to maintain the turbulent flow during the fluid flush phase.
Flow can be maximized by circuit isolation during this phase.
Sampling ports must be provided to permit samples to be taken ahead of filters when flushing in
either direction (fluid sampling containers according to ISO 3722).
Because of danger and flaking, no rubber hoses are to be used for bypass during flushing.
Where flushing all piping in series is not practical because of pressure drop, temporary manifolds
may be installed with isolation valves to form parallel circuits. However, the turbulent flow velocity
discussed in item 5, above, must be maintained.
Filters must be provided with means to detect “dirty” conditions; these filters must not have bypass
valves inside them.
Isolation valves must be provided so that filters can be changed without disturbing flow.
To facilitate the choice of the flushing pumps to use, we list the capacity referring to the various
internal diameters of pipes assuming the Re > 10.000, fluid velocity > 4,5 m/sec and fluid viscosity
= 30 cSt.
Though vibrators may be used on low spots where dirt tends to accumulate, hammering is
preferred. In addition, starting and stopping flow by sudden opening and closing of valves is a good
assist.
Reverse flow is required during pickling, passivation and flushing phases, when the hammering is
to be repeated in direction of flow.
The particles removed by the flushing should be caught with a filter with a high “β ratio”. We
consider fundamental that filters of major companies makers are employed and also we do not
recommend the use of low finesse filters followed by high finesse filters, as this is not economically
convenient.
During flushing, contractor is to inspect lines frequently and to stop flushing immediately if a leak
occurs. Flushing fluid must be kept out of customer’s sewers.
After system has been drained of all fluids, system is to be purged whit dry nitrogen.