Employer Doc. No.

NSRP Contractor Doc. No.

Complex Project Nghi Son Refinery and Petrochemical S-000-1710-0110V
Limited Liability Company
Nghi Son, Vietnam Rev. 1 Page 1 of 13

Employer Contract No.: Contractor JOB Code: 0-6495-20 Date: 18/JAN/16

General Pre-commissioning Procedure for Water Flushing

Unit No.: Not Applicable

Unit Abbreviation: Not Applicable

Document Class: Z

Issue Purpose For Construction

Rev Date Page Description Prep'd Chk'd App'd

2, 3, 7, Added General
1 18/JAN/16 K.T R.G M.T
8-13 SWMS
Follow Employer’s
0 27/OCT/14 1,5,6,7 A.S R.G M.T
Comment
A 22/APR/14 All First issue A.S M.T M.T

Operation Centre JOB Code: Operation Centre Doc. No.:

Responsible Company Prepared by Checked by Approved by
JVD K.Tani Rabin G. M.Tonosaki

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 Employer Doc. No.
NSRP Complex Project Rev. 1

Title: General Pre-commissioning Procedure for Water Contractor Doc. No.

Page 2 of 13
Flushing S-000-1710-0110V

CONTENTS

1 INTRODUCTION ...................................................................................................................................3
2 REFERENCE DOCUMENTS ................................................................................................................3
3 ABBREVIATION AND DEFINITION .....................................................................................................3
4 SCOPE OF APPLICATION...................................................................................................................3
5 HSE .......................................................................................................................................................4
6 METHOD ...............................................................................................................................................4
6.1 Gravity Flow Flushing Method ...........................................................................................................4
6.2 Power Flushing Method ......................................................................................................................4
7 PRECAUTION .......................................................................................................................................4
8 DETAILS FOR IMPLEMENTATION .....................................................................................................5
8.1 Planning ................................................................................................................................................5
8.2 Preparation/Execution.........................................................................................................................6
9 ACCEPTANCE CRITERIA ....................................................................................................................7
10 POST WORK.........................................................................................................................................7
11 ATTACHMENT......................................................................................................................................7
Attachment-1: General Safe Work Method Statement (SWMS) for Water Flushing………………8-13

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Title: General Pre-commissioning Procedure for Water Contractor Doc. No.

Page 3 of 13
Flushing S-000-1710-0110V

1 INTRODUCTION
This document describes the general requirements for carrying out water flushing applied to pipes of the
plant constructed in NSRP Project.
Detailed procedures for implementation of water flushing will be prepared as required on a system basis,
based on the philosophies described in this procedure.
Detailed procedures together with the General Safe Work Method Statement (SWMS) and Job Safety
Analysis (JSA) shall be utilized implementation of water flushing as per Project HSSE requirement.

2 REFERENCE DOCUMENTS
S-000-1710-0001V Pre-commissioning and Commissioning Execution Plan
S-000-1710-0100V Pipe Cleaning Guide

3 ABBREVIATION AND DEFINITION

The following terms are defined in Project Coordination Procedure (S-000-1140-0001V)
 Employer
Nghi Son Refinery and Petrochemical Limited Liability Company
 Contractor
A Joint Venture formed by JGC Corporation, Chiyoda Corporation, GS Engineering &
Construction Corporation, SK Engineering & Construction Co., Ltd., Technip France and
Technip Geoproduction (M) Sdn. Bhd.
 JVD
Contractor's Joint Venture Directorate

4 SCOPE OF APPLICATION
This method is widely used in pipe cleaning and is usually applied to pipes where liquid flow during
normal operation. Kinetic energy generated by pump or obtained by gravity with pre-filled water with
proper volume is used to flush foreign materials from pipes or collect them in filters/strainers for removal.
Water must be air blown out of system to avoid damage to pipe or contamination of process.
Water flushing utilizes the above principle to expel foreign materials, and improve the cleanness of the
pipe, by having a break in the pipe at the flushing boundary limits, where the water flow is discharged or
to remove foreign materials by installing a temporary strainer/filter in the closed circulation loop.
For water flushing, the high velocity in the pipelines is achieved by being connected to a pump, which is
operated on water.
It is important that the water being used for line flushing is low enough in contaminants in relation to
water quality to ensure that the required flushing specification can be achieved in the water flushing. The
flushing medium shall be in general fresh water. When flushing stainless steel lines, the chloride content
shall be less than 50 ppm.

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Title: General Pre-commissioning Procedure for Water Contractor Doc. No.

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Flushing S-000-1710-0110V

5 HSE
The following HSE risks are inherent in water flushing:
 Potential for injury at water discharge area: The flushing discharge areas shall be cordoned
off with tape, warning notices posted, and patrolled by a commissioning team member to
ensure personnel safety.
 Appropriate personal protective equipment (PPE) shall be worn or used. The area will be
barricaded and unnecessary personnel will be asked to leave the affected area.
 Suitable back stop (e.g. net or tarpaulin etc.) will be used to capture all foreign materials.
 Clear path of water to a sewer.
 Build-up of water in low area if not drained.
 Erosion of gravel

6 METHOD
Water flushing will be conducted by any one of the following methods:

6.1 Gravity Flow Flushing Method

By discharging water from a pre-filled column/drum/vessel downstream pipes are water-flushed. Typical
example is the flushing of suction lines of pumps prior to pump operation for power flushing.

6.2 Power Flushing Method

Power flushing utilizes the kinetic energy fluid, enhanced by a pump which is installed in the plant. Fluids
possess kinetic energy when flowing through pipes, this is used to dislodge and carry with it foreign
materials such as sand, rust, weld slag and other debris that may be present inside pipe. These foreign
materials are collected in filters/strainer or ejected at open end. Never flush into a vessel or through
equipment.

7 PRECAUTION
The following precautions must be paid when water flushing is conducted.
 The execution of flushing works shall also include the necessary measures for safety, for
cleaning of area, and for disposal of waste water. During flushing operations, disposal of
flushing water to comply with the Effluent Discharge Norms as specified in the Environmental
Design Basis (S-000-1240-0111V).
 Take suitable measures to prevent flushing debris into equipment.
 Suitable back stop (e.g. net or tarpaulin etc.) will be used to capture all foreign materials.
 When columns/drums/vessels are used as water reservoir, their vent valves or appropriate
top opening shall be kept open until completion of water flushing to prevent pulling a vacuum
in system.
 If pumps will be used for water flushing then these must be safeguard from over current,
cavitation, etc. Vendor instruction and pump curve should be available. Process pumps
should not be used if not designed to pump water.

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Flushing S-000-1710-0110V

 When any operations data show abnormal pump performance related to vibration, noise,
electric current or temperature exceeds the normal value, stop running the pump at once.
CAUTION: Damage to the pump can occur due to abnormal pump performance.
 The line from the suction vessel to the pump shall be water flushed by gravity to the pump
suction. Do not flush through the pump.
 All equipment, piping, and component openings shall be provided with plastic pipe caps or
plastic bags to prevent contamination.
 Piping which is under construction shall be positively isolated until they are required.
 In order to avoid stress corrosion cracks, treated water shall be used for stainless steel pipes
and piping component which come into contact with water. Demineralized water, condensate
and BFW are preferable for stainless steel pipes. In addition, construction water from
temporary RO (Reverse Osmosis purifying) unit will meet the requirement of water quality for
stainless steel pipes.
 For all stainless pipes, flushing water shall be immediately drained and pipe shall be blown
dry upon completion of line to avoid chloride corrosion.

8 DETAILS FOR IMPLEMENTATION

8.1 Planning
 Normally utility line has a priority for flushing operations so that they are available for flushing
process equipment and piping.
 Main process, Offsite or Utility lines shall be flushed from upstream end after removing
flanges and fittings at the end of the line, and in some cases at intermediate points on the line.
Branches shall be flushed sequentially in the same manner.
 When flushing loop includes equipment such as, tube sides of heat exchangers, heater tubes,
tubes of air fin coolers, flushing-out points shall be assigned at inlet flanges of such
equipment. To prevent debris entering the equipment from its inlet flanges, the equipment
shall be either blinded or at a minimum “stood off”. After the above flushing is completed,
downstream flushing can be started through the equipment.
 Check procedures to determine which systems/lines should not be flushed using water.
Always use the appropriate flushing medium.
 When applicable, pump suction line is flushed out by gravity flow by filling suction drums with
water.
 Pumps used for flushing will be specifically stated to be used with the purpose in detailed
procedure and reviewed/approved by Employer. Process pumps should not be used if not
designed to pump water.
 Prior to filling column/drums/vessels or overhead piping system with water, check that they
and their foundations/supports are designed to withstand full water weight.
 Suction side of pump will be equipped with a strainer to catch foreign materials. For
temporary strainers, 20-40 mesh screens are typical, but refer to vendor instruction for
specific requirements.
 The velocity of water flushing is preferably 1.5-2.0 m/s.
 Detailed planning will be developed with marked up P&IDs and indicated the following points.

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Flushing S-000-1710-0110V

 Water supply points

 Water Discharge Points
 Valve open/close
 Temporary piping, spools and blind, if any.
 Components to be removed from the line (such as valves, instrumentation etc.)
 Removal and reinstatement control list for temporary/permanent materials (e.g. blind, spool,
instrument, etc.) will be prepared.

8.2 Preparation/Execution
1. Remove or positively disconnect the following devices, and upon completion, reinstall those in the
correct position.
 Safety valves
 Check valves, if required
 Rupture disks
 Orifice plates or flow meter elements
 In-line mixers/In-line strainer
 Spargers
 Spray nozzles
 Control valves
 Self-actuated valves
 Soft seated valve which could be damaged by the ingress of water or dirt or restrict the water
flushing flow path
 Emergency shut off valves (only when they restrict the flush path)
 Thermo wells
 All other items which could be damaged by ingress of water or dirt or restrict the flush flow
path
2. 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 open position while flushing.
3. Install temporary piping spools and fitting requires for flushing
4. Prior to commencement of flushing, the route shall be checked at site.
5. Each flushing condition should be checked in advance. Any big remaining works that will hinder the
air blowing activity shall be coordinated to concerned discipline.
Pay attention particularly on the following:
 Piping and instrumentation works around flushing point
 Civil works
 Insulation works (if necessary)

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Flushing S-000-1710-0110V

6. Before proceeding to flushing, conduct job safety and environmental analysis on this procedure (and
other related topics) to all personnel who will be assigned in these activities. Items to be discussed
are the following:
 Safety ― risks, potential hazards, control measures/action, etc.
 Communication method (use of radio or hand signal or cell-phone, etc.)
 Each personnel responsibility
 Work method control (PTW, working at heights, barricades and etc.)
 Water Flushing procedure
7. Make line-up of the system in advance and put barricades around the area, if necessary.
8. Removed items should be kept in safe location and should be marked-up for identification. Upon
completion of water flushing, it must be reinstate back exactly to the same location and orientation.

9 ACCEPTANCE CRITERIA
The inspection criteria will be visual inspection of discharged water. When any foreign materials
interfering with actual plant operation are no longer visually checked in flushed water, water flushing shall
be deemed satisfactory completed. When Contractor is considering the system is clean, Employer shall
be invited for final test for witness and approval.

10 POST WORK
1. Ensure pipes are adequately drained and dried. If the system will not be in service immediately after
water flushing activity, dryness of the pipe internal shall be checked to assure free water is
completely drained and dried in order to avoid pipe internal corrosion and water contamination.
2. Pipes and devices removed during flushing shall be reinstalled. A reinstatement check against the
P&IDs will be conducted to ensure the reinstatement is completed and all equipment is correctly
oriented prior to putting a system into service.
3. Acceptance documentation with marked-up P&ID for water flushing activity shall be signed by
Contractor and Employer.

11 ATTACHMENT
Attachment-1: General Safe Work Method Statement (SWMS) for Water Flushing

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Contractor Doc No: S-000-1710-0110V_Rev'1
Attachment-1, General Safe Work Method Statement (SWMS) for Water Flushing
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CONTENTS

1 INTRODUCTION ...................................................................................................................................9
2 REFERENCE DOCUMENTS ................................................................................................................9
3 SCOPE ..................................................................................................................................................9
4 RESPONSIBILITIES .............................................................................................................................9
5 PROCEDURE......................................................................................................................................10
5.1 PREPARATION...................................................................................................................................10
5.2 EXECUTION........................................................................................................................................10
5.3 METHOD .............................................................................................................................................11
5.4 POST WORK .......................................................................................................................................11
6 EQUIPMENTS .....................................................................................................................................11
7 MATERIALS........................................................................................................................................11
8 LOCATION ..........................................................................................................................................12
9 SAFETY...............................................................................................................................................12

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Contractor Doc No: S-000-1710-0110V_Rev'1
Attachment-1, General Safe Work Method Statement (SWMS) for Water Flushing
Page 9 of 13

1 INTRODUCTION
Water flushing is widely applied for pipe cleaning especially when pipeline is for liquid service. The objective is
to maintain a water flow through the system at reasonable velocity for certain period of time. To achieve this
objective, the system is connected either with a water source at one end whereas water is discharged from
the other end. Repeated filling and draining is also carried out where continuous flow of adequate amount of
water is not possible. Where possible a closed loop is formed with a pump (permanent or temporary) that
operated on water including the piping system to be cleaned. Circulated dirty water is drained out as long as
the system does not achieve required level of cleanliness.
This document describes the general steps, resources and safety measures for carrying out water flushing
applied to pipes in a safely manner in accordance with the detail procedure prepared.
Before executing an activity this document shall be carefully assessed, amended as necessary based on the
site condition, work location and other special requirements if any stated in the detail procedure. JSA (Job
Safety Analysis) shall be carried out based on the content in this document and detail procedure and
mitigation measure shall be implemented before execution of the work

2 REFERENCE DOCUMENTS
S-000-1654-0100V Job Safety Analysis (JSA) and Safe Work Method Statement (SWMS)

3 SCOPE
This document is applicable for all water flushing activities carried out by JGCS Pre-commissioning,
Commissioning team within the NSRP Project and will be utilized in conjunction with the detail procedure
specific to a system or unit.

4 RESPONSIBILITIES
The organization composed on JGCS and Subcontracted personnel executes all work relating to water
flushing such as preparation, execution and post work. JGCS commissioning engineer, supervisor is
responsible for the necessary documentation and supervision work whereas subcontracted labour carries out
all field execution work under supervision of JGCS members.
Responsibilities of each member involved in water flushing activity is detailed below:
 Commissioning Section Leader
Commissioning Section Leader is responsible for approval PTW associated with water flushing. He / She
make sure the organization executes the work is competent, well trained to comply with the site HSSE
requirements.
 Commissioning Engineer / Commissioning Senior Supervisor
Commissioning Engineer is responsible for necessary planning and preparation for the work including
checking of PTW associated with water flushing. He / She makes sure site execution team prepares and
executes the work as per plan and procedure. He / She sometime attends TBT / START work to make sure
HSSE risk and mitigation plans are well known among the execution team and implemented well.
 Commissioning Supervisor
Commissioning Supervisor is the key role for site execution and is well experienced for the work. He / She
make sure all steps during site execution are carried out according to plan and procedure with observance of
site HSSE requirements. He / She carries out TBT / START before the activity to make whole group well

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Attachment-1, General Safe Work Method Statement (SWMS) for Water Flushing
Page 10 of 13

aligned of the work, risk and mitigation measures. During execution stage, he / she closely monitor all aspects
of work.
 Subcontracted Personnel
Subcontracted personnel forms the direct execution crew consisting of foreman, rigger, fitter and labour who
actually work under supervision of JGCS commissioning supervisor.
Foreman is the lead of the direct execution crew who is experienced with the similar work and executes the
work under JGCS supervisor or independently. The foreman is supported by the other team members in
preparation, execution and post work.

5 PROCEDURE
Water flushing generally involve preparation, execution and post work. Activities involved in each is detailed in
below subsections.

5.1 PREPARATION
Preparation step of water flushing includes following activities:
 Confirm completion of piping construction including availability of pipe supports
 Removal or positive disconnection of the piping components which are negatively affected by water
flushing
 Install temporary spool, blind plates/flanges, instruments as necessary
 Isolate the area of water flushing including the blow points. Install warning / caution signboards as
necessary
Note: warning / caution signboards must be prepared in dual language English and Vietnamese.
 Protection of nearby equipment, structures from the impact
 Arrange adequate drainage to prevent discharge water from causing water logging
 Arrange adequate means to prevent erosion of ground, soil by flushing water discharge and flow
 Preparation of an approved PTW
 Issue safety flash notice to inform all member about the activity, location and access control
 Notification to Employer is issued for witnessing the activity

5.2 EXECUTION
Execution step of water flushing includes following activities:
 Perform TBT (Tool Box Talk) /START (Start Task Analysis Risk Talk)
 Confirm line up as per detail procedure
 Confirm all barricades, warning/caution signboards are in place. No unauthorized personnel are
within or vicinity of the exclusion zone
 Set up water supply connection between water source and the subject to be water flushed
 Start water supply gradually, and increase to the required level. Check discharge water condition from
the flushing end. Continue the process until flushed water become clean

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Attachment-1, General Safe Work Method Statement (SWMS) for Water Flushing
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At the Initial stage of flushing the level of foreign material would be high which will come down with
time
 When closed loop is formed for flushing with permanent or temporary pump, fill the system first with
water and then start the pump. Gradually increase circulation flow to the maximum possible.
Check circulating water condition and start draining out from selected points. Make up fresh water
into the system to keep the system filled.
Monitor pump condition, clean the suction strainer when needed.
 For gravity flushing case, connect the system with water source such as tank and open the tank outlet
valve for flushing out the line. Alternatively fill up the system with water and drain out water quickly
from a manual operated valve suitably big to cause high flow through the system and located at the
lower point.
For this case, the filling-draining process should be repeated until drained water is clean.
 Perform flushing from all the points as in detail procedure
 Inform Employer to witness the line cleaning status

5.3 METHOD
There are several methods applied for water flushing such as gravity flow and power flushing; power flushing
may be carried out either by connecting with a water source or forming a closed loop with a pump. Detail
procedure shall indicate the method will be adopted for a work and describe in detail the steps for execution.
Common risk and mitigation measures associated with each method is covered in the safety section.

5.4 POST WORK

Post work after water flushing includes following activities:
 Drain out water well from the system. Where possible supply compressed air into the system to
confirm no free water is drained from lowest drain points
 Remove all the temporary spool, blind, gaskets from the system (unless otherwise necessary)
 Protect pipe ends with permanent or temporary cover till reinstatement work is done
 Remove all barricade and warning/caution notice displayed for the work
 Remove all other protection devices mobilized for the work for the protection of surrounding
equipment, structures.

6 EQUIPMENTS
Following equipment are utilized for all components of work associated with water flushing:
 Water source (Tank, vessel, tower etc)
 Pump (permanent or temporary)
 Lifting crane (as necessary)

7 MATERIALS
Following materials are required for all components of work associated with water flushing:

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Attachment-1, General Safe Work Method Statement (SWMS) for Water Flushing
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 Barricading tape
 Warning, caution sign
 Air horn or whistle
 Walky-talky
 Hand tools
 Scaffolding materials
 Temporary pipe spools, blinds, gaskets, instruments
 PPEs
 Water supply hose with anti-whip fitting
 Back stop material (tarpaulin, net or wooden board etc)

8 LOCATION
Detail procedure will indicate the exact location of the work in the form of P&ID mark-up.
Before water flushing safety flash notice will be issued across the project to make people aware of the
work, risk and mitigation measures to be implemented.

9 SAFETY
Below mentioned are potential hazards for all components of work associated with water flushing and
mitigation measures. JSA shall identify the risk and mitigation measures in further details.
Risk Mitigation measures
Improper lifting (tools, equipment, method  Project approved tools, equipment, method and
and manpower) manpower shall be utilized
 Only experienced, trained and authorized personnel
shall be allowed to work
Fall from height, falling objects  All personnel shall have undergone work at height
training and authorized to work at height
 100% compliance with PPE and other fall protection
measures are mandatory
Entangled by rotating parts  When pump is utilized for water flushing, all rotating
parts shall be well covered
 The surrounding area shall be cordoned off with tape,
warning notices posted, and patrolled by a
commissioning team member to ensure personnel
safety.
 Only competent persons shall be allowed in the vicinity
and to operate rotating machines
 Approved LOTO procedure shall be utilized in case of
activities such as strainer cleaning
Electrical shock  Only competent persons shall be allowed to operate

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Attachment-1, General Safe Work Method Statement (SWMS) for Water Flushing
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Risk Mitigation measures

electrical facilities and substations
 All equipment shall be tested and approved by
competent personnel before use
Rupture of equipment, piping by  All equipment and piping to be water flushed to be
overpressure assessed to have design pressure or hydro test
pressure higher than that of water flushing or water
source
 Otherwise temporary protection device such as
pressure safety valve shall be utilized.
 Systems that are adjacent to the system being water
flushed, must also be protected against inadvertent
pressurization. Suitable isolations, vents and drains
should be verified before water flushing occurs.
Trip, slip, fall; erosion of soil, ground  Water discharge and flow path should be well prepared
for draining out discharged water and prevent water
logging, slippery ground
 The water discharge areas shall be cordoned off with
tape, warning notices posted, and patrolled by a
commissioning team member to ensure personnel
safety.
 Whistle / Horn shall be used to notify workers in the
surrounding area
Damage of surrounding facilities being hit  Suitable back stop (e.g. tarpaulin, wooden board or
by high energy of discharge water metal plate etc.) will be used to prevent water flow
hitting to surrounding objects
 Confirm piping, equipment to be water flushed in well
supported, have completed construction work
Damage, disturbance in adjacent systems  Adjacent piping which is under construction shall be
positively isolated.
 Systems that are adjacent to the system being water
flushed, must also be protected against inadvertent
pressurization. Suitable isolations, vents and drains
should be verified before water flushing occurs.

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