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

Building Engineering Services AssociationInstallation and testing of: AcknowledgmentsPART TEN Members of the drafting panel who compiled this guide BESA wishes to record its sincere thanksOIL to the following members of the TR/20 drafting Sub-Committee, without whose direct input of knowledge, TR/20 time and experience this publication would not have been 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 0-903783-49-5 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 TEN TR/20 is published against a background of significant change within the building services engineering sectorOIL over recent years. Of particular note has been the industry wide campaign to raise standards and TR/20 performance through the Construction Best Practice 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 Ten – OilCONTENTSSection 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 Conventional Gravity Feed from a Storage Vessel. 8 1.7.2 Oil Transfer Systems 8 1.7.3 Pumped Circulation Systems. 8 8Section 2 MATERIALS AND JOINTING METHODS2.1 92.2 PIPING MATERIALS 92.3 SELECTION (TABLE “A”) 10 STEEL PIPE JOINTING 102.4 2.3.1 Threaded 10 2.3.2 Welded 102.5 2.3.3 Flanged 102.6 COPPER PIPE JOINTING 11 2.4.1 Compression 11 2.4.2 Capillary 11 2.4.3 Flanged 11 2.4.4 Flared 11 2.4.5 Brazed 11 PLASTIC PIPE JOINTING 11 PROPRIETARY SYSTEMS 12Section 3 STEEL PIPEWORK CONSTRUCTION AND ASSEMBLY 123.1 123.2 PIPING MATERIAL DETAILS 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 133.6 3.3.1 Welding Methods (TABLE “B”) 13 3.3.2 Welding Fittings 14 FLANGED ASSEMBLY 14 SUPPORT AND FIXINGS 14 3.5.1 Pipework Support Centres (TABLE “C”) 14 EXPANSION AND CONTRACTION 14 3.6.1 Natural Flexibility 15 3.6.2 Expansion Devices 3.6.3 Anchors and Guides 15 3.6.4 Cold Draw 15 15Section 4 COPPER PIPEWORK CONSTRUCTION AND ASSEMBLY 154.1 16 PIPING MATERIAL DETAILS 164.2 4.1.1 Grades and Types 164.3 4.1.2 Pipe Finish 16 COPPER PIPE JOINTING METHODS 164.4 COMPRESSION JOINT AND FITTING ASSEMBLY 4.3.1 Compression Method 4.3.2 Compression Fittings CAPILLARY JOINT AND FITTING ASSEMBLY 4.4.1 Capillary Method of Assembly4

Installation and Testing of Pipework Systems Part Ten – Oil4.5 4.4.2 Capillary Fittings Page4.6 FLANGED JOINT AND FITTING ASSEMBLY 164.7 FLARED JOINT AND FITTING ASSEMBLY 16 BRAZED JOINT AND FITTING ASSEMBLY 164.8 4.7.1 Brazing Method 164.9 4.7.2 Brazing Fittings 16 PULLED BENDS 174.10 SUPPORT AND FIXINGS 17 4.9.1 Pipework Support Centres (TABLE “D”) 17 EXPANSION AND CONTRACTION 17 4.10.1 Expansion Devices 17 4.10.2 Anchors and Guides 17 4.10.3 Cold Draw 18 18Section 5 STAINLESS STEEL PIPEWORK CONSTRUCTION AND ASSEMBLY 18Section 6 PLASTIC PIPEWORK CONSTRUCTION AND ASSEMBLY 196.1 196.2 INTRODUCTION 196.3 APPLICATION SELECTION TABLE 19 JOINTING METHODS SELECTION 196.4 6.3.1 Flanged 196.5 6.3.2 Crimped 196.6 6.3.3 Electrofusion 196.7 ELECTRICAL CONDUCTIVITY 206.8 EXPANSION AND CONTRACTION 206.9 ULTRA-VIOLET LIGHT 206.10 MIXING OF PIPES AND FITTINGS 206.11 PRESSURE FLUCTUATION 206.12 HANDLING 20 BURIED PIPEWORK 20 PRESSURE AND TEMPERATURE RELATIONSHIP IDENTIFICATION OF MATERIAL 21 21Section 7 GENERAL INSTALLATION REQUIREMENTS 217.1 217.2 MAIN EQUIPOTENTIAL BONDING 217.3 DRAINING 217.4 VENTING 217.5 EXPANSION AND CONTRACTION 21 PROTECTION 227.6 7.5.1 Physical 22 7.5.2 Corrosion 227.7 CONNECTIONS TO EQUIPMENT 227.8 7.6.1 Connections to Existing 22 7.6.2 Connections for Future Use 227.9 BUILDING FABRIC PENETRATIONS 22 CONSTRUCTION AND ASSEMBLY PROCEDURES 227.10 7.8.1 Cleanliness 23 7.8.2 Pipe Sleeves 23 7.8.3 Pipe in Pipe 23 7.8.4 Spacing and Clearance 23 7.8.5 Alignment 23 LOCATION RECORDING 23 7.9.1 Marker Tape 23 7.9.2 Line Diagram 23 HIDDEN PIPEWORK 23 7.10.1 Buried Pipework 7.10.2 Minimum Depth at Cover 7.10.3 Minimum Distance from Building 7.10.4 Ground Ducts 5

Installation and Testing of Pipework Systems Part Ten – OilSection 8 ACCESSORIES AND PIPELINE ANCILLARIES Page8.18.2 GENERAL REQUIREMENTS 24 VALVE LOCATIONS AND FUNCTION 248.3 8.2.1 Isolating Valves 24 8.2.2 Pressure Regulating Valves 248.4 8.2.3 Pressure Relief Valves 24 8.2.4 Gauge Cocks 24 8.2.5 Drain Cocks 24 8.2.6 None Return Valve 24 PIPELINE ANCILLARIES 24 8.3.1 Fire Valves 24 8.3.2 Float Valves 25 8.3.3 Strainers 25 8.3.4 Oil Filter 25 8.3.5 Instrumentation and Test Points 25 8.3.6 Pressure Gauges 25 8.3.7 Thermometers 25 8.3.8 Pump Sets 25 8.3.9 Line Heaters 25 8.3.10 Outflow Heaters 25 IDENTIFICATION 25 8.4.1 Pipelines 25 8.4.2 Valves and Plant 25 26Section 9 TESTING 27Section 10 THERMAL INSULATION 27 2710.1 APPLICATION 28 28 10.1.1 Installation Considerations 28 10.1.2 Workmanship 29 TRACE HEATING 2910.2 29 10.2.1 Pre-installation Guidelines 29 10.2.2 Installation 29 10.2.3 Heating Cable Connection 29 10.2.4 Heating Cable Testing 30 10.2.5 Steam Trace Heating 30Section 11 FLUSHING AND CLEANING 30 3111.1 SYSTEM CLEANLINESS 32 11.1.1 Delivery and Storage 11.1.2 During Installation 11.1.3 During Testing FILLING AND VENTING11.2Section 12 BIBLIOGRAPHY AND SOURCES12.1 REFERENCES12.2 ABBREVIATIONS12.3 MISCELLANEOUS6