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

Building Engineering Services AssociationInstallation and testing of: AcknowledgmentsPART EIGHT Members of the drafting panel who compiled this guide BESA wishes to record its sincere thanksSTEAM AND to the following members of the TR/20 draftingCONDENSATE Sub-Committee, without whose direct input of knowledge, time and experience this publication would not have been TR/20 produced. 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 0-903783-47-9 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 EIGHT TR/20 is published against a background of significant change within the building services engineering sectorSTEAM AND over recent years. Of particular note has been theCONDENSATE industry wide campaign to raise standards and performance through the Construction Best Practice TR/20 Programme. Much effort has been and continues to be 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 Eight – Steam and CondensateCONTENTSSection 1 INTRODUCTION Page1.0 FOREWORD 71.1 OBJECTIVE 71.2 STANDARD OF WORKMANSHIP 71.3 QUALITY ASSURANCE 71.4 SCOPE 81.5 PUBLICATION AND REVIEW 81.6 OPERATING CONDITIONS 81.7 DESCRIPTION OF SERVICE 8 9Section 2 MATERIALS AND JOINTING METHODS 92.1 PIPING MATERIAL 102.2 SELECTION TABLE.“A” 102.3 STEEL PIPE JOINTING 10 2.3.1 Threaded 102.4 2.3.2 Welded 10 2.3.3 Flanged 102.5 COPPER PIPE JOINTING 102.6 2.4.1 Compression Joints 10 2.4.2 Capillary Joints 10 2.4.3 Brazed Joints 11 PRESS FIT JOINTS 11 PROPRIETARY SYSTEMS 11 11Section 3 STEEL PIPEWORK CONSTRUCTION AND ASSEMBLY 113.1 PIPING MATERIALS 123.2 3.1.1 Pipe Finish. 12 THREADED ASSEMBLY 123.3 3.2.1 Threaded Joints 12 3.2.2 Bends and Fittings 133.4 WELDED ASSEMBLY. 133.5 3.3.1 Welding Methods 143.6 3.3.2 Welding Fittings 14 FLANGED ASSEMBLY 14 SUPPORT AND FIXINGS 14 EXPANSION AND CONTRACTION 14 3.6.1 Natural Flexibility 3.6.2 Expansion Devices 15 3.6.3 Anchors and Guides 15 3.6.4 Cold Draw 15 15Section 4 COPPER PIPEWORK 154.1 CONSTRUCTION AND ASSEMBLY 15 PIPING MATERIALS 154.2 4.1.1 Grades and Types 154.3 4.1.2 Finish 15 JOINTING METHODS 154.4 CAPILLARY ASSEMBLY 15 4.3.1 Capillary Method of Assembly 164.5 4.3.2 Capillary Fittings 164.6 COMPRESSION ASSEMBLY 16 4.4.1 Compression Method of Assembly 4.4.2 Compression Fittings FLANGED ASSEMBLY BRAZED ASSEMBLY 4.6.1 Brazing Method of Assembly 4.6.2 Brazing Fittings4

Installation and Testing of Pipework Systems Part Eight – Steam and Condensate4.7 PRESS FIT ASSEMBLY Page 4.7.1 Press Fit Method of Assembly 164.8 4.7.2 Press Fit Fittings 164.9 PULLED BENDS 164.10 SUPPORT AND FIXINGS 16 EXPANSION AND CONTRACTION 16 4.10.1 Expansion of Copper Pipework (up to 35mm nominal bore) 17 4.10.2 Expansion Devices 17 4.10.3 Anchors and Guides 17 4.10.4 Cold Draw 17 18Section 5 STAINLESS STEEL PIPEWORK CONSTRUCTION AND ASSEMBLY 18Section 6 GENERAL REQUIREMENTS 196.1 196.2 MAIN EQUIPOTENTIAL BONDING (Cross Bonding) 19 TRAPPING AND VENTING 196.3 6.2.1 Traps and Vents 196.4 6.2.2 Steam Separators 19 6.2.3 Condensate Pumps 206.5 6.2.4 Condensate and Flash Steam Pipework 20 EXPANSION 206.6 PROTECTION 206.7 6.4.1 Physical 20 6.4.2 Corrosion 20 CONNECTIONS TO EQUIPMENT 20 6.5.1 Connections to Existing 20 6.5.2 Connections for Future Extensions 20 EXTERNAL FABRIC PENETRATIONS 20 CONSTRUCTION AND ASSEMBLY 20 6.7.1 Cleanliness 21 6.7.2 Pipe Sleeves 21 6.7.3 Alignment 6.7.4 Spacing and Clearance 21 21Section 7 ACCESSORIES AND PIPELINE ANCILLARIES 217.1 227.2 GENERAL REQUIREMENTS 227.3 VALVE LOCATIONS AND FUNCTION 22 7.2.1 Isolating Valves 227.4 7.2.2 Pressure Reducing Valves 22 PIPELINE ANCILLARIES 22 7.3.1 Safety Valves 22 7.3.2 Non-return Valves 22 7.3.3 Isolating Valves 23 7.3.4 Strainers 23 7.3.5 Instrumentation and Test Points 23 7.3.6 Pressure Gauges 23 7.3.7 Thermometers 23 IDENTIFICATION 7.4.1 Pipelines 24 7.4.2 Valves and Plant 24 24Section 8 TESTING 25 25Section 9 THERMAL INSULATION 259.1 APPLICATION 9.1.1 Installation Considerations9.2 9.1.2 Workmanship TRACE HEATING 9.2.1 Pre-installation Guidelines 9.2.2 Installation Guidelines 5

Installation and Testing of Pipework Systems Part Eight – Steam and Condensate 9.2.3 Heating Cable Connections 26 9.2.4 Heating Cable Testing 26 26Section 10 FLUSHING, CLEANING AND WATER TREATMENT 26 2610.1 APPLICATION 26 2610.2 SYSTEM CLEANLINESS 27 27 10.2.1 Introduction 27 10.2.2 Delivery and Storage 27 10.2.3 During Installation 29 10.2.4 During Testing 29 10.2.5 Dynamic Flushing 10.2.6 Water TreatmentSection 11 BIBLIOGRAPHY AND SOURCES11.1 REFERENCES11.2 MISCELLANEOUS PUBLICATIONS11.3 ABBREVIATIONS6