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Building Engineering Services Association Installation and testing of:PART SEVENCONDENSERAND COOLINGWATER TR/20 www.theBESA.com

Building Engineering Services AssociationInstallation and testing of: AcknowledgmentsPART SEVEN Members of the drafting panel who compiled this guide BESA wishes to record its sincere thanksCONDENSER to the following members of the TR/20 draftingAND COOLING Sub-Committee, without whose direct input of knowledge,WATER time and experience this publication would not have been produced. TR/20 John StClair Eric Innes Cliff Toft Geoffrey Robinson Alan Keating – Secretary Frank J Ferris - Consultant BESA also wishes to acknowledge the input from BSRIA, CIBSE, IoP, IGEM, OFTEC, plus the remaining members of the Technical Committee for their time, input and vetting. ISBN 0-903783-46-0 First published 2003 ©2003 BESA BESA Publications Old Mansion House Eamont Bridge Penrith CA10 2BX 01768 860405 [email protected]. www.theBESA.com

Building Engineering Services AssociationInstallation and testing of: ForewordPART SEVEN TR/20 is published against a background of significant change within the building services engineering sectorCONDENSER over recent years. Of particular note has been theAND COOLING industry wide campaign to raise standards andWATER performance through the Construction Best Practice Programme. Much effort has been and continues to be TR/20 made to raise the productivity, performance and competence standards of our sector. To support this programme BESA has undertaken to provide a number of measures designed to demonstrate and achieve positive differentiation of their members. One such measure has been to undertake a fundamental review of TR/10, the previous BESA standard for Installation work ‘Heating Hot and Cold Water Supply’. As a result of this review TR/20 replaces TR/10 and emerges as a new standard for ‘The Installation and Testing of Pipework Services’ for the building services engi- neering sector. It embraces a comprehensive range of pipework services and is structured as a set of 10 ‘stand alone’ sectionalised specifications. The objective of TR/20 is to provide a pipework installation specification that will ensure compliance with accepted good practice. It is intended that this standard specification will be used generally as a means of measurement and assessment of a contractor’s performance and, specifically, to demonstrate compliance and competence under the BESA Inspection and Assessment arrangements. It is envisaged that TR/20 be used either in the absence of a client specification or by specific reference as an integral part of such a specification. It is also proposed that TR/20 be used as a quality benchmark whereby any shortfall identified within an alternative specification is drawn to the client’s attention. Unlike its forerunner, TR/20 does not address design or commissioning requirements. These are considered to be very ably addressed by other industry documents already in place published by CIBSE, BSRIA, OFTEC and others, for which appropriate references are provided. TR/20 also excludes equipment incorporated within or connected to the pipework installation. The specification and selection of equipment is considered to be a responsibility of the system designer who should ensure that where appropriate the selection is compliant with the client’s brief. Additionally, it is not the policy of BESA to promote any particular product or manufacturer. During the review and drafting process the drafting Sub-committee has consulted widely with individuals and external organisations to ensure that the new standard fully reflects the industry’s current good practice. The resulting publication will, I believe, serve as a recognised benchmark for our industry sector and BESA members in particular. I take this opportunity to thank all who have contributed to its production and in particular the members of the TR/20 Sub-committee for their tireless efforts and collective contribution of invaluable knowledge and experience. John Hunt Former Chairman, BRSA Technical Committee www.theBESA.com

Installation and Testing of Pipework Systems Part Seven – Condenser and Cooling WaterCONTENTSSection 1 INTRODUCTION Page1.0 FOREWORD1.1 OBJECTIVE 71.2 STANDARD OF QUALITY 71.3 QUALITY ASSURANCE 71.4 SCOPE 81.5 PUBLICATION AND REVIEW 81.6 OPERATING CONDITION 81.7 DESCRIPTION OF SERVICE 8 1.7.1 Open circuit systems 8 1.7.2 Closed circuit systems 8 8Section 2 MATERIALS AND JOINTING METHODS2.1 92.2 PIPING MATERIALS 92.3 SELECTION TABLE “A” 92.4 THREADING - Steel 102.5 WELDING - Steel 102.6 FLANGES 112.7 GROOVED JOINTS 112.8 PRESSED FIT 11 COMPRESSION, CAPILLARY, BRAZED JOINTS OR PUSH FIT 112.9 2.8.1 Compression Joints 11 2.8.2 Capillary Joints 11 2.8.3 Brazed Joints 11 2.8.4 Push Fit 11 PROPRIETARY SYSTEMS 12Section 3 STEEL PIPEWORK CONSTRUCTION AND ASSEMBLY 123.1 123.2 PIPING MATERIALS 12 3.1.1 Pipe Finish 123.3 THREADED ASSEMBLY 12 3.2.1 Threaded Joints 123.4 3.2.2 Bends and Fittings 133.5 WELDED ASSEMBLY 13 3.3.1 Welding Methods 133.6 3.3.2 Welding Fittings 133.7 FLANGED ASSEMBLY 133.8 GROOVED ASSEMBLY 14 3.5.1 Joints 143.9 3.5.2 Fittings 14 PRESS FIT ASSEMBLY 15 SUPPORT AND FIXINGS 15 EXPANSION AND CONTRACTION 15 3.8.1 Natural Flexibility 15 3.8.2 Expansion Devices 16 3.8.3 Anchors and Guides 16 3.8.4 Cold Draw 16 CONSTRUCTION AND ASSEMBLY 16 3.9.1 Cleanliness 16 3.9.2 Pipe Sleeves 3.9.3 Alignment 17 3.9.4 Spacing and Clearance 17 17Section 4 COPPER PIPEWORK CONSTRUCTION AND ASSEMBLY 174.1 PIPING MATERIALS 4.1.1 Grades and Types4.2 4.1.2 Finish JOINTING METHODS4

Installation and Testing of Pipework Systems Part Seven – Condenser and Cooling Water4.3 CAPILLARY JOINT AND FITTING ASSEMBLY Page 4.3.1 Capillary Method of Assembly 174.4 4.3.2 Capillary Fittings 17 COMPRESSION JOINT AND FITTING ASSEMBLY 174.5 4.4.1 Compression Method 184.6 4.4.2 Compression Fittings 18 FLANGED JOINTS 184.7 PUSH FIT ASSEMBLY 18 4.6.1 Push Fit Method 184.8 4.6.2 Push Fit Fittings 18 BRAZED ASSEMBLY 184.9 4.7.1 Brazing Method 184.10 4.7.2 Brazing Fittings 184.11 PRESS FIT ASSEMBLY 18 4.8.1 Method 184.12 4.8.2 Fitting 18 PULLED BENDS 19 SUPPORT AND FIXINGS 19 EXPANSION AND CONTRACTION 19 4.11.1 Pipework 19 4.11.2 Expansion Devices 19 4.11.3 Anchors and Guides 20 CONSTRUCTION AND ASSEMBLY 20 4.12.1 Cleanliness 20 4.12.2 Pipe Sleeves 20 4.12.3 Alignment 20 4.12.4 Spacing and Clearances 20 21Section 5 STAINLESS STEEL PIPEWORK CONSTRUCTION AND ASSEMBLY 21Section 6 PLASTIC PIPEWORK CONSTRUCTION AND ASSEMBLY 226.1 226.2 INTRODUCTION 22 APPLICATION SELECTION TABLE 236.3 6.2.1 Pressure and Temperature Relationship 23 JOINTING METHODS 236.4 6.3.1 Threaded 246.5 6.3.2 Solvent Welding 246.6 6.3.3 Flanges 246.7 6.3.4 Thermal Fusion 246.8 6.3.5 Butt Welding 246.9 6.3.6 Socket Welding 246.10 6.3.7 Electrofusion 256.11 6.3.8 Compression Fittings 256.12 6.3.9 Push-Fit 256.13 ELECTRIC CONDUCTIVITY 256.14 EXPANSION RATES 256.15 SUPPORTS 256.16 ULTRA-VIOLET LIGHT 266.17 MIXING OF PIPES AND FITTINGS 26 PRESSURE FLUCTUATION 26 HANDLING 26 THERMAL INSULATION AND TRACE HEATING 26 LOCATION OF PIPEWORK 26 CHEMICAL CLEANING 26 EXTERNAL INSULATION AND HIDDEN PIPEWORK 26 PLASTIC PIPEWORK AND COOLING SYSTEMS 27 IDENTIFICATION 27 CONSTRUCTION AND ASSEMBLY 27 6.17.1 Cleanliness 28 6.17.2 Pipe Sleeves 28 6.17.3 Alignment 6.17.4 Spacing and Clearances 5

Installation and Testing of Pipework Systems Part Seven – Condenser and Cooling WaterSection 7 GENERAL REQUIREMENTS Page7.1 MAIN EQUIPOTENTIAL BONDING 287.2 VENTING 287.3 DRAINING 287.4 EXPANSION 287.5 PROTECTION 28 7.5.1 Physical 287.6 7.5.2 Corrosion 28 CONNECTIONS TO EQUIPMENT 297.7 7.6.1 Connections to Existing 29 7.6.2 Connections for Future Use 29 EXTERNAL FABRIC PENETRATIONS 29 29Section 8 ACCESSORIES AND PIPELINE ANCILLARIES 298.1 GENERAL REQUIREMENTS 298.2 VALVE LOCATIONS AND FUNCTION 298.3 8.2.1 Isolating Valves 30 8.2.2 Regulating Valves 308.4 PIPELINE ANCILLARIES 30 8.3.1 Safety Valves 30 8.3.2 Ball Float Valves 30 8.3.3 Non-return Valves 30 8.3.4 Strainers 30 8.3.5 Instrumentation and Test Points 30 8.3.6 Pressure Gauges 30 8.3.7 Thermometers 31 8.3.8 Flow switches and indicators 31 IDENTIFICATION 31 8.4.1 Pipeline 31 8.4.2 Valves and Plant 32 32Section 9 TESTING 32 33Section 10 THERMAL INSULATION 33 3310.1 APPLICATION 33 34 10.1.1 Installation Considerations 34 10.1.2 Workmanship 34 TRACE HEATING 3410.2 34 34 10.2.1 Pre-installation Guidelines 35 10.2.2 Installation 35 10.2.3 Heating Cable Connection 35 10.2.4 Heating Cable Testing 35 36Section 11 FLUSHING, CLEANING AND WATER TREATMENT 36 3711.1 APPLICATION 3811.2 SYSTEM CLEANLINESS 11.2.1 Introduction 11.2.2 Delivery and Storage 11.2.3 During Installation 11.2.4 During Testing 11.2.5 Dynamic Flushing FILLING SYSTEM11.311.4 CHEMICAL CLEANING11.5 WATER TREATMENTSection 12 BIBLIOGRAPHY AND SOURCES12.1 REFERENCES12.2 ABBREVIATIONS12.3 MISCELLANEOUS6