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

Building Engineering Services AssociationInstallation and testing of: AcknowledgmentsPART THREE Members of the drafting panel whoHIGH compiled this guide. BESA wishes to record its sincereTEMPERATURE thanks to the following members of the TR/20 draftingHOT WATER Sub-Committee, without whose direct input of knowledge,HEATING 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 0-903783-42-8 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 THREE TR/20 is published against a background of significantHIGH change within the building services engineering sectorTEMPERATURE over recent years. Of particular note has been theHOT WATER industry wide campaign to raise standards andHEATING 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 Three – High Temperature Hot Water HeatingCONTENTSSection 1 INTRODUCTION Page1.01.1 FOREWORD 61.2 OBJECTIVE 61.3 STANDARD OF WORKMANSHIP 61.4 QUALITY ASSURANCE 71.5 SCOPE 71.6 PUBLICATION AND REVIEW 71.7 OPERATING CONDITION 7 DESCRIPTION OF SERVICE 7Section 2 MATERIALS AND JOINTING METHODS 82.1 82.2 PIPING MATERIALS 82.3 SELECTION TABLE “A” 8 STEEL PIPE JOINTING 8 2.3.1 Threaded 9 2.3.2 Welded 2.3.3 Flanged 10 10Section 3 STEEL PIPEWORK CONSTRUCTION AND ASSEMBLY 103.1 103.2 PIPING MATERIAL DETAILS 10 3.1.1 Pipe Finish 103.3 THREADED ASSEMBLY 10 3.2.1 Threaded Joints 113.4 3.2.2 Bends and Fittings 113.5 WELDED ASSEMBLY 113.6 3.3.1 Welding Methods 12 3.3.2 Welding Fitting 12 FLANGED ASSEMBLY 12 SUPPORT AND FIXINGS 13 EXPANSION AND CONTRACTION 13 3.6.1 Natural Flexibility 3.6.2 Expansion Devices 13 3.6.3 Anchors and Guides 13 3.6.4 Cold Draw 13 13Section 4 STAINLESS PIPEWORK CONSTRUCTION AND ASSEMBLY 144.1 144.2 PIPING MATERIAL DETAILS 14 THREADED ASSEMBLY 154.3 4.2.1 Threaded Joints 15 4.2.2 Bends and Fittings 154.4 WELDED ASSEMBLY 154.5 4.3.1 Welding Methods 154.6 4.3.2 Welding Fitting 15 FLANGED ASSEMBLY 15 SUPPORT AND FIXINGS EXPANSION AND CONTRACTION 16 4.6.1 Natural Flexibility 16 4.6.2 Expansion Devices 16 4.6.3 Anchors and Guides 16 4.6.4 Cold DrawSection 5 GENERAL REQUIREMENTS5.15.2 MAIN EQUIPOTENTIAL BONDING5.3 DRAINING5.4 VENTING EXPANSION AND CONTRACTION4

Installation and Testing of Pipework Systems Part Three – High Temperature Hot Water5.5 PROTECTION Page 5.5.1 Physical 5.5.2 Corrosion 16 165.6 CONNECTIONS TO EQUIPMENT 16 5.6.1 Connections to Existing Equipment 16 5.6.2 Connections for Future Use 17 175.7 EXTERNAL FABRIC PENETRATIONS 175.8 CONSTRUCTION AND ASSEMBLY PROCEDURES 17 17 5.8.1 Cleanliness 17 5.8.2 Pipe Sleeves 17 5.8.3 Alignment 18 5.8.4 Spacing and Clearance 18Section 6 ACCESSORIES AND PIPELINE ANCILLARIES 186.1 186.2 GENERAL REQUIREMENTS 196.3 VALVE LOCATIONS AND FUNCTION 19 6.2.1 Isolating Valves 196.4 6.2.2 Regulating valves 19 PIPELINE ANCILLARIES 19 6.3.1 Safety Valves 19 6.3.2 Ball Float Valves 20 6.3.3 Non-return Valves 20 6.3.4 Strainers 20 6.3.5 Instrumentation and Test Points 20 6.3.6 Pressure Gauges 20 6.3.7 Thermometers 20 IDENTIFICATION 6.4.1 Pipeline 21 6.4.2 Valves and Plant 21Section 7 TESTING 21 22Section 8 THERMAL INSULATION 228.1 22 APPLICATION 238.2 8.1.1 Installation Considerations 23 8.1.2 Workmanship 23 TRACE HEATING 8.2.1 Pre-Installation Guidelines 24 8.2.2 Installation Guidelines 24 8.2.3 Heating Cable Connections 24 8.2.4 Heating Cable Testing 24 24Section 9 FLUSHING, CLEANING AND WATER TREATMENT 249.1 249.2 APPLICATION 25 SYSTEM CLEANLINESS 259.3 9.2.1 Introduction 259.4 9.2.2 Delivery and Storage9.5 9.2.3 During Installation 26 9.2.4 During Testing 27 9.2.5 Dynamic Flushing 28 FILLING THE SYSTEM CHEMICAL CLEANING WATER TREATMENTSection 10 BIBLIOGRAPHY AND SOURCES10.1 REFERENCES10.2 MISCELLANEOUS PUBLICATIONS10.3 ABBREVIATIONS 5